Generac Power Systems Portable, 1658-0 Generator User Manual

Owner’s Manual

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.

Questions? Help is just a moment away!

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

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

Model No. 1658-0 (5,000 Watt AC Generator) Manual No. 189633GS Revision 1 (08/23/2001)

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

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

Table of Contents

• Generator

• Engine oil

• Owner's manual

• Engine manual
*If any parts are missing or damaged, call 1-800-270-1408.

Parts Included*

2

5,000 Watt Portable Generator

EQUIPMENT

DESCRIPTION

This generator is an engine-driven, revolving field, alternating
current (AC) generator. It was designed to supply electrical
power for operating compatible electrical lighting,appliance,
tool and motor loads.

This manual contains information for a generator that
operates 120 and/or 240 Volt AC, single phase,60Hz devices
that require up to 5,000 watts (5.0 kW) of power that pull
up to 41.7 Amps at 120 Volts or 20.8 Amps at 240Volts.

CAUTION! Do Not exceed the generator’s

wattage/amperage capacity.Add up the rated watts of all
devices you will connect to generator receptacles at one
time.This total should not be greater than 5,000 watts for
this generator. Review “Don’t Overload the Generator” on
page 8.

The generator’s revolving field is driven at about 3,600 rpm
by a single-cylinder engine.

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.

CAUTION! Do Not tamper with engine

governed speed. High operating speeds are
dangerous and increase risk of personal injury or
damage to equipment.The generator supplies
correct rated frequency and voltage only when
running at proper governed speed.Incorrect
frequency and/or voltage can damage some
connected electrical loads. Operating at excessively
low speeds imposes a heavy load.When adequate
engine power is not available engine life may be
shortened.

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

This generator set was designed and manufactured for
specific applications. Do Not attempt to modify the unit or
use it for any application it was not designed for. If you have
any questions about your generator’s application, ask your
dealer or consult the factory.

The manufacturer could not possibly anticipate every
circumstance that might involve a hazard. For that reason
warnings in the manual and warnings on tags or decals
affixed to the unit are not all–inclusive. If you intend to
handle, operate or service the unit by a procedure or
method not specifically recommended by the manufacturer,
first make sure that such a procedure or method will not
render this equipment unsafe or pose a threat to you and
others.

Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.

WARNING! You must isolate the generator

from the electric utility using approved transfer
equipment if this unit is used for backup power.

Failure to isolate the generator from the
power utility may result in injury or death to
electric utility workers and damage to the
generator due to a backfeed of electrical energy.

Whenever unit is providing backup power, the
electric utility must be notified.

DANGER! Generator exhaust gases contain
DEADLY carbon monoxide gas. If breathed in
sufficient concentrations, carbon monoxide
can cause unconsciousness or death. Operate

this equipment outdoors where adequate ventilation
is available.

The engine exhaust from this product contains

chemicals known to the State of California

to cause cancer, birth defects,

or other reproductive harm.

WARNING:

5,000 Watt Portable Generator

3

• The generator produces a very powerful voltage that can

cause serious injury or death by electrocution. Never
touch bare wires or receptacles. Never permit a child or
any unqualified person to operate the generator.

• Never handle any kind of electrical cord or device while

standing in water, while barefoot or while hands or feet
are wet. Death or serious injury from electrocution may
result.

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

• Never use worn, bare, frayed or otherwise damaged
electrical cords with the generator. Death, serious injury
and property damage from electrical shock may result.

• Gasoline is highly FLAMMABLE and its vapors are

EXPLOSIVE. Never allow smoking, open flames,
sparks or heat in the vicinity while handling
gasoline. Avoid spilling gasoline on a hot engine. Comply

with all laws regulating storage and handling of gasoline.

• Do Not overfill the fuel tank.Always allow room for fuel
expansion. If tank is overfilled, fuel can overflow

onto a hot engine and cause a FIRE or an
EXPLOSION.

• Never store a generator with fuel in the tank where
gasoline vapors might reach an open flame, spark or pilot
light (as on a furnace, water heater, clothes dryer). FIRE
or an EXPLOSION may result.

• The unit requires an adequate flow of cooling air for its
continued proper operation. Never operate the unit
inside any room or enclosure where the free flow of
cooling air into and out of the unit might be obstructed.
Allow at least 2 feet of clearance on all sides of generator,
even while operating unit outdoors, or you could damage
the unit.

• Never start, or stop the unit with electrical loads
connected to receptacles with the connected devices
turned ON. Start the engine and let it stabilize before
connecting any electrical loads. Disconnect all electrical
loads before shutting down the generator.

• Do Not insert any object through cooling slots of the
engine.You could damage the unit or injure yourself.

• Never operate the generator:

in rain; in any enclosed compartment; when connected
electrical devices overheat; if electrical output is lost; if
engine or generator sparks; if flame or smoke is observed
while unit is running; if unit vibrates excessively.

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 1).

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.

Figure 1 — Grounding Wing Nut

Grounding Wing Nut

4

5,000 Watt Portable Generator

Your generator is ready for use after it has been properly
serviced with the recommended oil and fuel.

If you have any problems with the 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

• Engine oil

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 9. 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” Air Space

5,000 Watt Portable Generator

5

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

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

Choke Lever — Used when starting a cold engine.
Circuit Breakers (AC) — Each receptacle is provided

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

Fuel Tank — Capacity of five (5) U.S. gallons.
Grounding Wing Nut — Used for proper grounding of

unit.

Oil Fill Cap — Add oil to engine 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.

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 Receptacle

Fuel Tank

Choke Lever

Recoil Starter

Rocker Switch

Circuit
Breakers
(AC)

120/240 Volt AC,
20 Amp Receptacle

Air Cleaner

Grounding
Wing Nut
(not shown)

Oil Fill Cap
(not shown)