Generac 1647-0 Owner’s Manual

WATTS

Portable Generator Owner's Manual

Call: Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT

Web: www.generac-portables.com or www.briggsandstratton.com 0 9

Model No. 1647-0 (8,000 Watt AC Generator) Manual No. 189065GS Revision 4 (08/08/2003)

Questions? Help is just a moment away! I!!!!! !!![1[11

TABLE OF CONTENTS

SafetyRules.................................. 2-4

Know Your Generator ........................... 5

Assembly.................................... 6-7

Operation .................................. 8-I1

Maintenance.................................. 12

Storage...................................... 13

Troubleshooting ............................... 14

Notes ....................................... 15

Schematic/Wiring Diagram .................... 16-17

Replacement Parts........................... 18-22

Warranty .................................... 23

EQUIPMENT

DESCRIPTION

_Read this manual carefully and become familiar

with your generator. Know its applications,its

limitations and any hazards involved.

This generator is an engine-driven, revolving field, alternating current (AC) generator. It was designedto supply electrical power for operating compatible electrical lighting, appliances,tools and motor loads.Thegenerator's

revolving field is driven at about 3,600 rpm by the engine.

SAFETY RULES

This is the safety alert symbol. It is used to

alert you to potential personal injury hazards.

Obey all safety messages that follow this

symbol to avoid possible injury or death.

The safety alert symbol (_.) isused with a signalword (DANGER, CAUTION,WARNING), a pictorial and/or a

safety messageto alert you to hazards.DANGER indicates a hazard which, if not avoided,will result in death or

serious injury. WARNING indicatesahazardwhich, if not avoided,could result in death or serious injury.

CAUTION indicatesa hazardwhich, if not avoided,might result in minor or moderate injury. CAUTION, when used

without the alert symbol, indicatesa situation that could result in equipment damage.Follow safetymessagesto

avoid or reduce the risk of injury or death.

WARNING

The engine exhaust from this product contains I chemicals known to the State of California to cause

cancer, b rth defects, or other reproduct ve harm.

CAUTION! DO NOT exceed the generator's wattage/amperagecapacity.See"Don't Overload

Generator" on page I I.

Every effort has been made to ensure that informationin

this manualis accurate andcurrent. However, we reserve the right to change,alter or otherwise improve the product

and this document at anytime without prior notice. The Emission Control System for this generator is

warranted for standards set by the Environmental

Protection Agency.For warranty information refer to the

engine owner's manual.

In the Stateof California a spark arrester is required by lawJ

(Section 4442 of the California PublicResourcesCode). Other states may havesimilar laws.Federallawsapply on federal lands.If you equip the muffler with a spark arrester,

it must be maintained in effective working order.

Hazard Symbols and Meanings

Electrocution Electrical Shock Electrical Shock

Toxic Fumes

Explosive Pressure

Explosion Fire

Chemical Burn Hot Surface

DANGER

, WARNING

Operate generator ONLY outdoors.

Keepat least 2 feet of clearance on all sides of generator for

adequate ventilation.

DO NOT operategenerator insideanybuildingor enclosure, includingthegenerator compartmentof arecreationalvehicle(RV).

DANGER

When usinggenerator for backup power, notify utility

company.Use approved transfer equipment to isolate generator from electric utility.

Use a ground fault circuit interrupter (GFCi) in anydamp or highly conductive area,such as metal decking or steel work.

DO NOT touch bare wires or receptacles. DO NOT use generator with electrical cords which are worn

frayed,bare or otherwise damaged.

DO NOT operate generator in the rain. DO NOT handle generator or electrical cords while standing

inwater, while barefoot, or while handsor feet are wet. DO NOT allow unqualified persons or children to operate or

service generator.

WHEN ADDING FUEL

Turngenerator OFF and let it cool at least 2 minutes before

removing gas cap.Loosen cap slowly to relieve pressure in tanlc Fill fuel tank outdoors.

DO NOT overfill tank.Allow spacefor fuel expansion. Keep fuel awayfrom sparks,open flames, pilot lights, heat, and

other ignition sources. DO NOT light acigarette or smoke.

eVHEN OPERATING EQUIPMENT

DO NOT tip engine or equipment at angle which causesfuel to spill.

Thisgenerator isnot for use in mobile equipment or marine applications.

'HEN TRANSPORTING OR REPAIRING EQUIPMENT Transportlrepair with fuel tank EMPTY or with fuel shutoff

valve OFE Disconnect spark plugwire.

_HEN STORING FUEL OR EQUIPMENT WITH FUEL

IN TANK

Store awayfrom furnaces, stoves, water heaters, clothes dryers or other appliancesthat havepilot light or other ignition source becausethey can ignite fuel vapors.

DANGER

DO NOT allow any open flame,spark, heat,or lit cigarette

during andfor several minutes after charging a battery. Wear protective goggles,rubber apron, and rubber gloves.

, WARNING

Thisgenerator does not meet U. S.Coast Guard Regulation 33CFR-183 and should not be used on marine applications.

Failure to use the appropriate U. S.Coast Guard approved generator could result in bodily iniury and/or property damage.

mm_mm

WARNING

;ENERATOR

Disconnect the spark plug wire from the spark plug and place

the wire where it cannot contact spark plug.

, WARNING

CAUTION

See"Don't Overload Generator" on page I I. Start generator and let engine stabilize before connecting

electrical loads. Connect electrical loads in OFF position, then turn ON for

operation.

Turn electrical loads OFF and disconnect from generator before stopping generator.

CAUTION

DO NOT touch hot surfaces.

Allow equipment to cool before touching.

CAUTION

DO NOT tamper with governed speed.Generator supplies correct rated frequency and voltage when running at governed speed.

DO NOT modify generator in any way.

Use generator only for intended uses. tf you have questions about intended use,ask dealer or call

1-800-270-1408.

Operate generator only on levelsurfaces. DO NOT expose generator to excessive moisture, dust, dirt,

or corrosive vapors. DO NOT insert any objects through cooling slots.

tf connected devices overheat, turn them off and disconnect them from generatoc

Shut off generator if.'

-electrical output is lost;

-equipment sparks,smokes,or emits flames;

-unit vibrates excessively.

KNOWYOUR GENERATOR

Read this owner's manual and safety rules before operating your generator. Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and

adjustments. Save this manual for future reference.

Fuel Tank Choke Lever

Circuit Breakers (AC)

Recoil Starter

OnlOff Switch

120/240 Volt AC,

30Am

Receptacle

Grounding Fastener

120Volt AC, 20 Amp

Duplex Receptacle

120 Volt AC, 20 Amp, Duplex Receptacle -- May be

used to supply electrical power for the operation of

120Volt AC, 20 Amp, single phase, 60 Hz electrical lighting,

appliance, tool and motor loads.

120 Volt AC, 30 Amp Locking Receptacle -- May be

used to supply electrical power for the operation of

120Volt AC, 30 Amp, single phase, 60 Hz electrical lighting,

appliance, tool and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle -- May

be used to supply electrical power for the operation of

120 andlor 240 Volt AC, 30 Amp, single phase, 60 Hz

electrical lighting, appliance, tool and motor loads.

1201240 Volt AC, 50 Amp Receptacle -- May be used to supply electrical power for the operation of 1201240Volt AC, 50 Amp, single phase, 60 Hz electrical loads.

.'leaner

SparkArrester Muffler

120/240Volt AC,

50 Amp Receptacle

Air Cleaner -- Uses a dry type filter element and foam pre-cteaner to limit the amount of dirt and dust sucked into the engine.

Choke Lever -- Usedwhen starting a cold engine. Circuit Breakers (AC) -- Eachreceptacle is provided

with a "push to reset" circuit breaker to protect the generator againstelectrical overload.

FuelTank -- Capacity of seven (7) U.S.galtons. Grounding Fastener -- If required, pleaseconsult a

qualified electrician, electrical inspector, or the local agency havingjurisdiction.

On/Off Switch -- Set this switch to "On" before starting unit. Set switch to "Off' to shut clown the engine.

Recoil starter -- Used to start the engine. Spark Arrester Muffler -- Exhaust muffler lowers

engine noise andis equipped with a spark arrester screen.

ASSEMBLY

Your generator requires some assemblyand is ready for use after it has been properly serviced with the

recommended oil and fuel.

If you have any problems with the assembly of your generator, please call the generator helpline at

1-800-270-1408.

Remove Generator From Carton

• Set the palteted carton on a rigid flat surface.

• Carefully cut bandsaround the shipping carton.

• Lift carton off the generator.

• Remove all packing material, carton fillers, etc.

• Remove the generator from the shipping pallet.

Carton Contents

Check all contents. Ifany parts are missingor damaged,call the generator helpline at 1-800-270-1408.

The generator Electric start battery cables

Generator and engineowner's manuals Locking 30Amp plugs

Battery mounting bracket/hardware 2 bottles engine oil

Wheel kit

INSTALL WHEEL KIT

NOTE: Wheel kit is not intendedfor over-the-road use.

To installyour wheel kit, you needthe following toot:

• Socket wrench with I/2" or 13mm sockets.

• Neddle-nose pliers InstallWheel Kit as follows: (SeeFigure I)

I. Placegenerator on a hard flat surface.

2. Standat control panel end of generator and gently tilt generator up,high enough to placewooden blocks

beneath cradle.This will allow you to add wheels.

3. Slide axle through holes in brackets provided on generator cradle.

4. Slide a wheel spacer,wheel and flat washer on one end

of axle. Make sure air inflationvalve isoutward. Place e-ring onto groove in axle.

5. Placeone end of needle nose pliers on bottom of axle

and other end of pliers on top of e-ring.Seat e-ring by pressing pliers closed.

6. Slideaxlethrough until wheel istight againstbracket.

7. Install e-ring on other side in same manner as steps4

& 5. Removewooden blocks.

8. Attach vibration mounts to support leg with a 30mm

capscrew and lock nut.

Wheels

Locknut

,_port Leg

Flatwasher

/ Vibration

_ Mount --

E-Ring

_-- Flatwasher

__ Lockwasher

30mm _ 20mm

-Capscrew Capscrew

9. Withwheelson,securesupportlegassemblytocradle with20mmlongcapscrews,flatwashers,andlock

washers.

10.Checkeachfastenertoensureitissecureandtires areinflatedbetween15-40PSI.

INSTALLING BATTERY

NOTE: The generator can be started manually.If you

choose not to use the electric start feature of this generator, you do not need to install the battery.

_ AUTION! If battery is not installed, DO NOT

operate engine without insulatingthe red positive battery cable with electrical tape, or it could blow a fuse and causesparks.

We recommend you purchase and install a Briggs & Stratton 12Volt DC battery (Group U I;Type GT-X).The

battery should be serviced with electrolyte fluid and fully charged prior to installation.

Install the battery as follows:

I. Find battery fasteners shipped loose in carton.

2. Set battery onto tray.

3. Retainbattery to tray with one battery hold down bracket,two Jbolts,two fiat washersandtwo hex nuts (Figure2).

4. Connect red battery cablefrom engine starter switch to positive (+) terminal on battery with bolt, washer and nut (Figure 2).

5. Connect black battery cable to negative (-) terminal on battery with bolt, washer and nut (Figure 2).

6. Double check all connections to ensure they are in

correct locations and secure.

BEFORE STARTING THE

ENGINE

Add Engine Oil and Fuel

• Place generator on a level surface.

• Refer to engine owner's manualand follow oil and fuel

recommendations and instructions.

CAUTION

• Refer to engine manualfor oil andfuel fill information.

• Damage to equipment resulting from failure to follow this

instructionwill void warranty.

NOTE: Check oil often during engine break-in. Refer to

engine owner's manualfor recommendations. NOTE: The generator assembly rotates on a pretubricated

and sealed ball bearing that requires no additional lubricationfor the lifeof the bearing.

USING THE GENERATOR

System Ground

The generator hasa systemground that connects the generator frame components to the ground terminals on the AC output receptacles.The systemground is connected to theAC neutral wire (the neutral is bonded to the generator frame).

Special Requirements

There may be Federalor State Occupational Safety and

Health Administration (OSHA) regulations,localcodes,or

ordinances that apply to the intendeduse of the generator.

Pleaseconsult a qualified electrician, electrical inspector,or

the localagencyhavingjurisdiction.

• In some areas,generators are required to be registered with localutilitycompanies.

• If the generator is used at a construction site, there may be additional regulations which must be observed.

Connecting to a Building's Electrical

System

Connections for standby power to a buitding's electrical system must be made by a qualified electrician.The connection must isolate the generator power from utility power, and must comply with all applicable lawsand

electrical codes.

OPERATING THE

G EN ERATO R

CAUTION

See"Don't Overload Generator" on page I I. Start generator and let engine stabilize before connecting

electrical loads. Connect electrical loads in OFF position, then turn ON for

operation. Turn electrical loads OFF and disconnect from generator

before stopping generator.

Starting the Engine

Disconnect altelectrical loadsfrom the generator. Use the following start instruction steps by numerical order:

I. Make sure unit is on a levelsurface.

IMPORTANT: Failureto start and operate unit on a level surface will causethe unit not to start or shut down during operation.

2. Turn the fuel valve to the "On" position (Figure 3).

DANGER

When usinggenerator for backup power, notifyutility company.Use approved transfer equipment to isolate

generator from electric utility.

Use a ground fault circuit interrupter (GFCI) in anydamp or highly conductive area,such as metal decking or steel work.

DO NOT touch bare wires or receptacles. DO NOT use generator with electrical cords which are worn

frayed,bare or otherwise damaged.

DO NOT operate generator in the rain. DO NOT handle generator or electrical cords while standing

inwater, while barefoot, or while handsor feet are wet. DO NOT allow unqualified persons or children to operate or

service generator.

Fuel Valve is shown in the On position

3. Follow start instructions given in engine owner's manual.

NOTE: If engine starts after 3 pulls but fails to run, or if unit shuts down during operation, make sure unit is on a level surface and check for proper oil level in crankcase. This unit may be equipped with a low oil protection device. See engine manual.

Connecting Electrical Loads

• Let enginestabilize and warm upfor a few minutes after

starting.

• Plug in and turn on desired 120 and/or 240VottAC,

singlephase,60 Hz electrical loads.

• DO NOT connect 240Volt loads to 120Volt receptacles.

• DO NOT connect 3-phase loads to generator.

• DO NOT connect 50 Hz loads to generator.

• DO NOT OVERLOADTHE GENERATOR. See "Don't Overload Generator" on page 1I.

Stopping the Engine

I. Unplug all electrical loads from generator panel

receptacles.NEVER start or stop enginewith electrical

devices plugged in and turned ON.

2. Let engine run at no-load for several minutes to

stabilize internal temperatures of engine and generator.

3. Turn engine off according to instructions given in the

engine owner's manual.

4. Movefuel valveto "Off" position.

_, DANGER

Operate generator ONLY outdoors. Keep at least 2 feet of clearance on all sides of generator for

adequate ventilation. DO NOT operate generator inside any building or enclosure,

including the generator compartment of a recreational vehicle (RV). Remove generator from shelter when temperature is above

40°F [4°C].

RECEPTACLES

_, CAUTION

COLD WEATH ER

OPERATION

Under certain weather conditions (temperatures below 40°F [4°C] and a high clew point), your generator may experience icing of the carburetor and/or the crankcase breather system.

Build a structure that will enclose three sides and the top

of the generator:

I. Make sure entire muffler-side of generator is exposed.

Note that your generator mayappear different from

that shown in Figure 4.

NEVER attempt to power a device requiring more amperagethan generator or receptacle can supply.

DO NOT overload the generator. See"Don't Overload Generator".

120/240 Volt AC, 50 Amp Receptacle

Use a NEMA 14-50 plugwith this receptacle (Figure5). Connect a 4-wire cord set rated for 250Volt AC loads at

50 Amps to the plug.

_240 Volts AC

rame Ground

Y (Hot)

X (Hot)

2. Ensurea minimum of two feet clearance between open

side of box and nearest object.

3. Faceexposed end away from wind and elements.

4. Enclosureshould hold enough heat created by

generator to prevent problems.

W (Neutral)

NEMA 14-50

Usethisreceptacletooperate240VoltAC,60Hz,single phaseloadsrequiringupto8,000watts(8.0kW)ofpower. Theoutletisprotectedbya35Amppush-to-resetcircuit

breaker.

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a NEMA LI4-30 plug with this receptacle.Connect a 4-wire cord set rated for 250Volt AC loads at 30 Amps (or greater) (Figure 6).You can use the same4-wire cord if you

)lanto run a 120Volt load.

_ire Cord Set NEMA L5-30

Neutral

120V

Hot

4-Wire Cord Set

(Neutral)

Y (Hot) | X (Hot)

NEMA L14-30 /_ Ground(Green)

This receptacle powers 1201240Volt AC, 60 Hz,single

phase loads requiring up to 3,600 watts of power at

30 Amps for 120Volts;7,200 watts of power (7.2 kW) at 30 Amps for 240Volts.The outlet is protected by a 30 Amp

push-to-reset circuit breaker.

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire cord set rated for 125Volt AC loads at 30Amps to the plug (Figure 7).

Ground (Green)

Usethis receptacle to operate 120VoltAC, 60 Hz, single phaseloads requiring up to 3,600 watts (3.6 kW) of power at 30Amps.The outlet is protected by a 30Amp push-to-reset circuit breaker.

120 Volt AC, 20 Amp, Duplex

Receptacle

Eachreceptacle (Figure 8) is protected against overload by a 20 Amp push-to-reset circuit breaker.

Use each receptacle to operate 120Volt AC, single-phase, 60 Hz electrical loads requiring up to 2,400 watts (2.4 kW) at 20Amps of current. Use cord sets that are rated for

125Volt AC loads at 20Amps (or greater).

DON'T OVERLOAD

G EN ERATO R

Capacity

You must make sure your generator cansupply enough

rated (running) and surge (starting) watts for the itemsyou

will power at the sametime. Follow these simple steps:

I. Select the itemsyou wilt power at the same time.

2. Total the rated (running) watts of these items.Thisis

the amount of power your generator must produce to keep your itemsrunning. SeeFigure 9.

3. Estimatehow many surge (starting) watts you wilt

need.Surge wattage isthe short burst of power needed to start electric motor-driven tools or

appliancessuch asa circular saw or refrigerator.

Becausenot all motors start at the sametime, total

surge watts can be estimated by addingonly the item(s)with the highest additional surge watts to the total rated watts from step 2.

Example:

Tool or Appliance

Window Air Conditioner

Refrigerator Deep Freezer

Television Light (75 Watts)

Total Rated (Running)Watts = 3075

Highest Additional SurgeWatts = 1800

Total Generator Output Required = 4875

Rated (Running)

Watts

1200

800 500 500

3075 Total

Running Watts

Power Management

To prolong the lifeof your generator and attached devices, it is important to take care when addingelectrical loadsto

your generator.There should be nothing connected to the generator outlets before starting its engine.The correct and safeway to managegenerator power is to sequentially

add loadsas follows:

I. With nothingconnected to the generator, start the

engine asdescribed in this manual.

2. Plugin and turn on the first load,preferably the largest

loadyou have.

3. Permit the generator output to stabilize (engine runs

smoothly and attached device operates properly.

Additional Surge

(Starting)Watts

1800

1600 500

1800 Highest SurgeWatts

4. Plug in and turn on the next load.

5. Again,permit the generator to stabilize.

6. Repeat steps 4 and 5 for each additional load. NEVER add more loadsthan the generator capacity.Take

specialcare to consider surgeloads in generator capacity, asdescribed above.

Additional

(Starting)

Watts

Tool or Appliance

Essentials LightBulb - 75 watt

Deep Freezer SumpPump

Refrigerator/Freezer - 18Cu. Ft.

Water Well Pump- I/3 HP

Heatin_Coolin_

Window AC - 10,000 BTU Window Fan

FurnaceFanBlower - I/2 HP Kitchen

Microwave Oven - 1000Watt Coffee Maker

Electric Stove - SingleElement Hot Plate

Family Room DVD/CD Player

VCR

Stereo Receiver Color Television - 27"

Personal Computer w/I 7" monitor Other

SecuritySystem

AM/FM Clock Radio

GarageDoor Opener - I/2 HP Electric Water Heater - 40 Gallon

DIY/Job Site

Quartz Halogen Work Light

Airless Sprayer - I/3 HP

Reciprocating Saw Electric Drill - I/2 HP

Circular Saw - 7 I/4"

Miter Saw- I0" Table Planer - 6" Table Saw/RadialArm Saw- I0"

Air Compressor - I-I/2 HP

Rated*

(Running) Surge

Watts

500 500 800 1200 800 1600

1000 2000

1200 1800

300 600 800 1300

1000 1500 1500

2500

100

100 450 500 8O0

180 300 480 520

40O0

1000

600 1200 960 960

1000 1000 1500 1500

1800 1800 1800 1800

2000 2000 2500 2500

*Wattages listedare approximate only.Check toot or appliancefor actual wattage.

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