Generac 1654-0 User Manual

Owner’s Manual / Manual del Propietario

Questions? Help is just a moment away!

Preguntas? La ayuda es justa un momento lejos!

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

Llamada: Generador Helpline De Generac - 1-800-270-1408 M-F 8-5 CT

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

Model No. 1654-0 (5,500 Watt AC Generator) Manual No. 189828GS Revision 1 (02/05/2002)

Safety Rules / Reglas De Seguridad . . . . . . . . . . . . 2-3 / 20-21

Assembly / Ensamblaje . . . . . . . . . . . . . . . . . . . . . 4-5 / 22-23

Know Your Generator / Conozca Su Generador. . . . . . 6 / 24

Operation / Funcionamiento . . . . . . . . . . . . . . . . . 7-9 / 25-27

Product Specifications / Especificaciones Del Producto 10 / 28

Maintenance / Mantenimiento . . . . . . . . . . . . . . . . . . . 10 / 28

Storage / Almacenamiento. . . . . . . . . . . . . . . . . . . . . . 11 / 29

Troubleshooting / Diagnosticos De Averías . . . . . . . . . 12 / 30

Schematic / Esquemático . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Wiring Diagram / Digrama Eléctrico. . . . . . . . . . . . . . . . . . 15

Replacement Parts / Piezas De Recambio . . . . . . . . . . . 16-19

Notes / Notas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Garantia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page

• Generator / Generador

• Wheel Kit / Juego de Llantas

• Locking 30 Amp Plug / Tapone de Fijación

• Engine Oil / Aceite para Motor

• Owner's Manual / Manual del Propietario

• Engine Manual / Manual del Motor *If any parts are missing or damaged, call 1-800-270-1408. *Si alguna de las partes no está presente o está dañada, llame

1-800-270-1408.

Parts Included* / Piezas Incluidas*

Table of Contents / Tabla de Contenidos

5500 Watt Heavy Duty Generator

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 designed to supply electrical power for operating compatible electrical lighting, appliances, tools and motor loads.The generator’s revolving field is driven at about 3,600 rpm by a single-cylinder engine.

CAUTION! Do Not exceed the generator’s

wattage/amperage capacity. See “Don’t Overload the Generator” on page 9.

Every effort has been made to ensure that information in this manual is accurate and current. However, Generac reserves the right to change, alter or otherwise improve the product and this document at any time 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.

SAFETY RULES

The safety alert symbol ( ) is used with a signal word (DANGER, CAUTION,WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. CAUTION, when used without the alert symbol, indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING

• Operate generator ONLY outdoors.

• Keep at least 2 feet of clearance on all sides of generator for adaquate ventilation.

• Do not operate generator inside any building or enclosure, including the generator compartment of a recreational vehicle (RV).

Running generator gives off carbon monoxide, an ordorless, colorless, poison gas.

Breathing carbon monoxide will cause nausea, fainting or death.

DANGER

WHEN ADDING FUEL

• Turn generator OFF and let it cool at least 2 minutes before removing gas cap.Loosen cap slowly to relieve pressure in tank.

• Fill fuel tank outdoors.

• Do not overfill tank.Allow space for fuel expansion.

• Keep gasoline away from sparks, open flames, pilot lights, heat, and other ignition sources.

• Do not light a cigarette or smoke.

WHEN OPERATING EQUIPMENT

• Do not tip engine or equipment at angle which causes gasoline to spill.

WHEN TRANSPORTING OR REPAIRING EQUIPMENT

• Transport/repair with fuel tank EMPTY or with fuel shutoff valve OFF.

• Disconnect spark plug wire.

WHEN STORING GASOLINE OR EQUIPMENT WITH FUEL IN TANK

• Store away from furnaces, stoves, water heaters,clothes dryers or other appliances that have pilot light or other ignition source because they can ignite gasoline vapors.

Gasoline and its vapors are extremely flammable and explosive.

Fire or explosion can cause severe burns or death.

WARNING

5500 Watt Heavy Duty Generator

• When using generator for backup power, notify utility company. Use approved transfer equipment to isolate generator from electric utility.

• National Electric Code requires generator to be properly grounded to an approved earth ground. Call an electrician for local grounding requirements.

• Use a ground fault circuit interrupter (GFCI) in any damp 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 in water, while barefoot, or while hands or feet are wet.

• Do not allow unqualified persons or children to operate or service generator.

Generator produces powerful voltage. Failure to properly ground generator can result

in electrocution. Failure to isolate generator from power utility

can result in death or injury to electric utility workers due to backfeed of electrical energy.

WARNING

• Do not allow any open flame, spark, heat, or lit cigarette during and for several minutes after charging a battery.

• Wear protective goggles, rubber apron, and rubber gloves.

Storage batteries give off explosive hydrogen gas during recharging.

Hydrogen gas stays around battery for a long time after battery has been charged.

Slightest spark will ignite hydrogen and cause explosion.

You can be blinded or severely injured. Battery electrolyte fluid contains acid and is

extremely caustic. Contact with battery fluid will cause severe

chemical burns.

DANGER

• Do not touch hot surfaces.

• Allow equipment to cool before touching.

Running engines produce heat.Temperature of muffler and nearby areas can reach or exceed 150°F (65°C).

Severe burns can occur on contact.

WARNING

• 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.

Excessively high operating speeds increase risk of injury and damage to generator.

Excessively low speeds impose a heavy load.

CAUTION

• See “Don’t Overload Your Generator” on page 9.

• 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.

Exceeding generators wattage/amperage cappacity can damage generator and/or electrical devices connected to it.

CAUTION

• Use generator only for intended uses.

• If you have questions about intended use, ask dealer or contact Generac.

• Operate generator only on level surfaces.

• Do not expose generator to excessive moisture, dust, dirt, or corrosive vapors.

• Do not insert any objects through cooling slots.

• If connected devices overheat, turn them off and disconnect them from generator.

• Shut off generator if:

-electrical output is lost;

-equipment sparks, smokes, or emits flames;

-unit vibrates excessively.

Improper treatment of generator can damage it and shorten its life.

CAUTION

5500 Watt Heavy Duty Generator

Your generator requires some assembly and 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.

IMPORTANT: Any attempt to run the unit before it has

been serviced with the recommended oil will result in an engine failure.

REMOVE GENERATOR

FROM CARTON

• Set the carton on a rigid flat surface with “This Side Up” arrows pointing upward.

• Carefully open the top flaps of the shipping carton.

• Cut down corners at one end of carton from top to bottom and lay that side of carton down flat.

• Remove all packing material, carton fillers, etc.

• Remove the generator from the shipping carton.

CARTON CONTENTS

Check all contents. If any parts are missing or damaged, call the generator helpline at 1-800-270-1408.

• The generator

• Generator and engine owner’s manuals

• Locking 30 Amp plug

• Engine oil

• Wheel kit

INSTALL WHEEL KIT

The wheel kit is designed to greatly improve the portability of your generator.

NOTE:Wheel kit is not intended for over-the-road use. You will need a socket wrench with 1/2" or 13mm sockets

and a needle-nose pliers to install this kit.

Refer to Figure 1 and install the wheel kit as follows:

1. Place the generator on a hard flat surface.

2. Stand at the engine end of the generator and gently tilt the generator forward, high enough to place wooden blocks beneath the cradle.This will allow you to add the wheels.

Support Leg

Hex Nut

Axle

Flat Washer

Cap Screw

Handle Assembly

Hex Nut

Wheel

Retaining Pin

Figure 1 — Install Wheel Kit

Cap Screw

Hex Nut

Flat Washer

Cap Screw

Vibration Mount

Use existing hardware to attach left side of support leg to unit

5500 Watt Heavy Duty Generator

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

4. Slide a wheel and flat washer on one end of the axle. Make sure the air inflation valve is outward. Insert the retaining pin.

5. Slide the axle through until wheel is tight against bracket.

6. Slide the other wheel and flat washer on the other end of the axle. Make sure the air inflation valve is outward. Insert the retaining pin using the needle-nose plier. Remove the wooden blocks.

7. Attach the vibration mounts to the support leg with 30mm capscrews, washers and lock nuts.

8. To aid support leg assembly, rest generator on cradle, engine end down. Remove the existing hardware from the left unit vibration mount with 13mm wrench. Use the same hardware to attach the support leg.

9. Attach the other side of the support leg with a 20mm cap screw and lock nut. Rest generator on wheels and support leg.

10. Center the handle bracket on generator frame at support leg end of cradle, as shown.

11. Attach handle bracket with two M8 x 45mm cap screws and two locking hex nuts.

12. Check each fastener to ensure it is secure and the tires are inflated between 15-40 PSI.

BEFORE STARTING THE

ENGINE

Add Oil

CAUTION! Any attempt to crank or start the engine

before it has been properly filled with the recommended oil may result in an engine failure.

To fill your engine with oil:

• Place generator on a level surface.

• Follow the oil grade recommendations and oil fill

instructions given in the engine owner’s manual.

NOTE:The generator’s revolving field rides on a prelubricated and sealed ball bearing that requires no additional lubrication for the life of the bearing.

Add Gasoline

WARNING! Never fill fuel tank indoors. Never

fill fuel tank when engine is running or hot.Allow unit to cool for two minutes before refueling. Do Not light a cigarette or smoke when filling the fuel tank.

WARNING! Do Not overfill the fuel tank.

Always allow room for fuel expansion.

• Use regular UNLEADED gasoline with the generator engine. Do Not use premium gasoline. Do Not mix oil with gasoline.

• Clean area around fuel fill cap, remove cap.

• Slowly add unleaded regular gasoline to fuel tank. Be careful not to overfill.Allow about 1.5" of tank space for fuel expansion (Figure 2).

• Install fuel cap and wipe up any spilled gasoline.

IMPORTANT: It is important to prevent gum deposits from forming in essential fuel system parts, such as the carburetor, fuel filter, fuel hose or tank during storage. Also, experience indicates that alcohol–blended fuels (called gasohol, ethanol or methanol) can attract moisture, which leads to separation and formation of acids during storage. Acidic fuel can damage the fuel system of an engine while in storage.

To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer.See “Storage” on page 11. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur.

Figure 2 — Typical Fuel Expansion Space

Fuel

Tank

1.5” Airspace

5500 Watt Heavy Duty Generator

120 Volt AC, 20 Amp, Duplex Receptacles — May be

used to supply electrical power for the operation of 120 Volt AC, 20 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 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz electrical, lighting, appliance, tool and motor loads.

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

Choke Lever — Used when starting a cold engine.

Circuit Breakers (AC) — Push to reset circuit breakers

are provided to protect the generator against electrical overload.

Fuel Tank — Capacity of seven (7) U.S. gallons. Grounding Wing Nut — Used for proper grounding of

unit (see page 7).

Oil Fill — Add engine oil here. Recoil starter — Used to start the engine. Rocker Switch — Set this switch to "On" before using

recoil starter. Set switch to "Off" to switch off engine. Spark Arrester Muffler — Exhaust muffler lowers

engine noise and is equipped with a spark arrester screen.

KNOW YOUR 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.

120 Volt AC, 20 Amp Duplex Receptacles

Fuel Tank

Choke Lever

Recoil Starter

Rocker Switch (on engine shroud)

Circuit Breakers (AC)

120/240 Volt AC, 30 Amp Receptacle

Spark Arrester Muffler

Air Cleaner

Grounding Wing Nut

Oil Fill

5500 Watt Heavy Duty Generator

GROUNDING THE

GENERATOR

The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of the unit. For that purpose, a GROUNDING WING NUT is provided on the generator end (Figure 3).

Generally, connecting a No. 12 AWG (American Wire Gauge) stranded copper wire to the grounding wing nut and to an earth–driven copper or brass grounding rod (electrode) provides adequate protection against electrical shock. Be careful to keep the grounding wire attached after connecting the stranded copper wire. However, local codes may vary widely. Consult with a local electrician for grounding requirements in your area.

Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the generator or in connected electrical devices. Proper grounding also helps dissipate static electricity, which often builds up in ungrounded devices.

OPERATING THE

GENERATOR

CAUTION! Never start or stop the engine with

electrical loads connected to the receptacles AND with the connected devices turned ON.

Starting the Engine

Disconnect all electrical loads from the generator. Use the following start instruction steps by numerical order:

1. Turn the fuel valve to the “On” position (Figure 4).

2. Place the choke lever in the “Choke” position

(Figure 5).

3. Set the rocker switch to “On” position (Figure 6).

4. Grasp the recoil handle and pull slowly until slight

resistance is felt.Then pull rapidly to start engine.

5. Move choke lever to “Run” position a short distance at

a time over several seconds in warm weather or minutes in cold weather. Let engine run smoothly before each change. Operate with choke in “Run” position.

NOTE: If engine still fails to start, see engine manual.This engine may be equipped with a low oil device.

Refer to the engine owner’s manual for more detailed starting instructions.

Fuel Valve is shown in the On position

Figure 4 — Fuel Valve

Figure 5 — Choke Lever

Figure 6 — Rocker Switch

Figure 3 — Grounding Wing Nut

Grounding Wing Nut

5500 Watt Heavy Duty Generator

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes after starting.

• Plug in and turn on the desired 120 and/or 240 Volt AC, single phase, 60 Hz electrical loads.

• Do Not connect 240 Volt loads to the 120 Volt duplex receptacles.

• Do Not connect 3–phase loads to the generator.

• Do Not connect 50 Hz loads to the generator.

• DO NOT OVERLOAD THE GENERATOR. See “Don’t Overload the Generator” on page 9.

Stopping the Engine

• Unplug all electrical loads from generator panel receptacles. Never start or stop engine with electrical devices plugged in and turned ON.

• Let engine run at no-load for several minutes to stabilize the internal temperatures of engine and generator.

• Move rocker switch to “Off” position.

• Move the fuel valve to the “Off” position.

RECEPTACLES

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a NEMA L14–30 plug with this receptacle. Connect a 4–wire cord set rated for 250 Volt AC loads at 30 Amps (or greater) (Figure 7).You can use the same 4–wire cord if you plan to run a 120 Volt load.

This receptacle powers 120/240 Volt AC, 60 Hz, single phase loads requiring up to 5,500 watts of power (5.5 kW) at 30 Amps for 120 Volts or 240 Volts.The outlet is protected by a push–to–reset circuit breaker.

CAUTION! Although this outlet states it has a

120/240 Volt 30 Amp rating (up to 7,200 watts), the generator is only rated for 5,500 watts. Powering loads that exceed the wattage/amperage capacity of the generator can damage it or cause serious injuries.

120 Volt AC, 20 Amp, Duplex

Receptacles

Each duplex receptacle (Figure 8) is protected against overload by a push–to–reset circuit breaker.

Use each receptacle to operate 120 Volt AC, single–phase, 60 Hz electrical loads requiring up to 2,400 watts (2.4 kW) at 20 Amps of current. Use cord sets that are rated for 125 Volt AC loads at 20 Amps (or greater).

CAUTION!These outlets are rated at 120 Volt

20 Amp each (up to 80 Amps).The generator is only rated for up to 45.8 Amps. Powering loads that exceed the wattage/amperage capacity of the generator can damage it or cause serious injuries.

Figure 8 — 120 Volt, 20 Amp Duplex Receptacle

Figure 7 — 120/240 Volt AC, 30 Amp Receptacle

4-Wire Cord Set

240V

120V

W (Neutral)

X (Hot)

Y (Hot)

NEMA L14-30

Ground (Green)

5500 Watt Heavy Duty Generator

DON'T OVERLOAD YOUR

GENERATOR

Capacity

You must make sure your generator can supply enough rated (running) and surge (starting) watts for the items you will power at the same time. Follow these simple steps:

1. Select the items you will power at the same time.

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

the amount of power your generator must produce to keep your items running. See Figure 9.

3. Estimate how many surge (starting) watts you will

need. Surge wattage is the short burst of power needed to start electric motor-driven tools or appliances such as a circular saw or refrigerator. Because not all motors start at the same time, total surge watts can be estimated by adding only the item(s) with the highest additional surge watts to the total rated watts from step 2.

Example:

Total Rated (Running) Watts = 3075 Highest Additional Surge Watts = 1800 Total Generator Output Required = 4875

Power Management

To prolong the life of your generator and attached devices, it is important to take care when adding electrical loads to your generator.There should be nothing connected to the generator outlets before starting it's engine.The correct and safe way to manage generator power is to sequentially add loads as follows:

1. With nothing connected to the generator, start the

engine as described in this manual.

2. Plug in and turn on the first load, preferably the largest

load you have.

3. Permit the generator output to stabilize (engine runs

smoothly and attached device operates properly.

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 loads than the generator capacity.Take

special care to consider surge loads in generator capacity, as described above.

*Wattages listed are approximate only. Check tool or appliance for actual wattage.

Tool or Appliance

Rated (Running)

Watts

Additional Surge

(Starting) Watts Window Air Conditioner

1200 1800

Refrigerator 800 1600 Deep Freezer 500 500 Television 500 Light (75 Watts) 75 -

3075 Total

Running Watts

1800 Highest

Surge Watts

Tool or Appliance

Rated*

(Running)

Watts

Additional

Surge

(Starting)

Watts

Essentials

Light Bulb - 75 watt

Deep Freezer

500

Sump Pump

800

1200

Refrigerator/Freezer - 18 Cu. Ft.

800

1600

Water Well Pump - 1/3 HP

1000

2000

Heating/Cooling

Window AC - 10,000 BTU

1200

1800

Window Fan

300

600

Furnace Fan Blower - 1/2 HP

800

1300

Kitchen

Microwave Oven - 1000 Watt

1000

Coffee Maker

1500

Electric Stove - Single Element

1500

Hot Plate

2500

Family Room

DVD/CD Player

100

VCR

100

Stereo Receiver

450

Color Television - 27”

500

Personal Computer w/17” monitor

800

Other

Security System

180

AM/FM Clock Radio

300

Garage Door Opener - 1/2 HP

480

520

Electric Water Heater - 40 Gallon

4000

DIY/Job Site

Quartz Halogen Work Light

1000

Airless Sprayer - 1/3 HP

600

1200

Reciprocating Saw

960

Electric Drill - 1/2 HP

1000

Circular Saw - 7 1/4”

1500

Miter Saw - 10”

1800

Table Planer - 6”

1800

Table Saw/Radial Arm Saw - 10”

2000

Air Compressor - 1-1/2 HP

2500

Figure 9 - Wattage Reference Chart

5500 Watt Heavy Duty Generator

SPECIFICATIONS

Maximum Surge Watts . . . . . . . . . . . . . . . . .8,500 watts

Continuous Wattage Capacity . . . . . . . . . . .5,500 watts

Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0

Rated Maximum Continuous AC Load Current:

At 120 Volts . . . . . . . . . . . . . . . . . . . . . . .45.8 Amps

At 240 Volts . . . . . . . . . . . . . . . . . . . . . . .22.9 Amps

Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase

Rated Frequency . . . . . . . . . . . . . . . . . . . . . . .60 Hertz

Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . 7 U.S. gallons

Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . 175 lbs.

GENERAL MAINTENANCE

RECOMMENDATIONS

The Owner/Operator is responsible for making sure that all periodic maintenance tasks are completed on a timely basis; that all discrepancies are corrected; and that the unit is kept clean and properly stored. Never operate a

damaged or defective generator.

Engine Maintenance

See engine owner’s manual for instructions. If you need service for your engine, you need to determine

the engine identification number.To do so, remove the rocker arm cover hood, item number 55 shown on page 16, by removing the four nuts and washers holding it in place.The engine model-type-trim number is stamped on the side of the inner cover attached to the engine. Have this number in hand when you call the engine service center for assistance.

CAUTION! Avoid prolonged or repeated skin

contact with used motor oil. Used motor oil has been shown to cause skin cancer in certain laboratory animals.Thoroughly wash exposed areas with soap and water. KEEP OUT OF REACH OF CHILDREN. DON'T POLLUTE. CONSERVE RESOURCES. RETURN USED OIL TO COLLECTION CENTERS.

Generator Maintenance

Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture or any corrosive vapors. Cooling air slots in the generator must not become clogged with snow, leaves or any other foreign material.

NOTE: Do Not use a garden hose to clean generator. Water can enter engine fuel system and cause problems. In addition, if water enters generator through cooling air slots, some of the water will be retained in voids and cracks of the rotor and stator winding insulation.Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.

To Clean the Generator

CAUTION! Never insert any object or tool

through the air cooling slots, even if the engine is not running.

• Use a damp cloth to wipe exterior surfaces clean.

• A soft bristle brush may be used to loosen caked on dirt or oil.

• A vacuum cleaner may be used to pick up loose dirt and debris.

• Low pressure air (not to exceed 25 psi) may be used to blow away dirt. Inspect cooling air slots and opening on generator.These openings must be kept clean and unobstructed.

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