Generac 1648-0 Owner's manual

Brand: Generac

Model: 1648-0

Category: Power generators

Type: Owner's manual

Portable Generator Owner's Manual

Questions? Help is just a moment away!

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

Web: www.generac-por tables.corn

Model No. 1648-0 (4,500WattAC Generator) Manual No. 189264GS Revision5 (I 1/19/2002)

EQUIPMENT

DESCRIPTION

_Read this manual carefully and become familiar

with your generator. Know its applications, its

limitations and any hazards involved.

Thisgenerator isan engine-driven,revolvingfield,alternating

current (AC) generator. It was designedto supply electrical

power for operating compatible electrical lighting,appliances,

tools and motor loads.Thegenerator's revolvingfield is

driven at about 3,600rpm by asingle-cylinderengine.

CAUTION! DO NOT exceed the generator's

wattage/amperage capacity.See"Don't Overload the

Generator" on page I I.

Everyeffort hasbeenmadeto ensurethat informationinthis

manualisaccurateand current However,Generacreserves

the right to change,alter or otherwise improvethe product

and this document at anytime without prior notice.

The EmissionControl Systemfor this generator iswarranted

for standardsset by the EnvironmentalProtection Agency.For

warranty informationrefer to the engineowner's manual.

SAFETY RULES

This is the safety alert symbol. It is used toalert you to potential personal injury hazards.

Obey all safety messages that follow this

symbol to avoid possible injury or death.

The safety alert symbol (_.) isusedwith a signalword

(DANGER, CAUTION,WARNING), a pictorial and/or a

safety messageto alert you to hazards.DANGER indicates

a hazardwhich, ifnot avoided,will result in death or serious

injury.WARNING indicatesa hazardwhich, if not avoided,

couldresult in death or serious injury.CAUTION

indicatesa hazardwhich, ifnot 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 messagesto

avoid or reduce the risk of injuryor death.

In the State of California a spark arrester isrequired by lawI

(Section 4442 of the California Public ResourcesCode). I

Other states may havesimilar laws.Federallawsapply on I

federal lands.If you equip the muffler with a spark arrester,

it must be maintained in effective working order.

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.

DANGER

Operate generator ONLY outdoors.

Keep at least 2 feet of clearance on all sidesof generator for

adequateventilation.

DO NOT operategeneratorinsideanybuildingor enclosure,

includingthe generatorcompartment of arecreationalvehicle(RV).

DANGER

National ElectricCode requires generator to be properly

grounded to an approved earth ground. Call an electrician for

local grounding requirements.

DANGER

When usinggenerator for backup power, notify utility

company.Use approved transfer equipment to isolate

generator from electric utility.

Use aground circuit fault interrupter (GFCI) in any damp or

highly conductive area,such asmetal 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 handsor feet are wet.

DO NOT allow unqualified persons or children to operate or

service generator.

ENERATOR

WARNING

Disconnect the spark plug wire from the spark plug and place

the wire where it cannot contact spark plug.

, WARNING

WHEN ADDING FUEL

Turn generator OFF and let it cool at least 2 minutes before

removing gascap.Loosen cap slowly to relieve pressure in tank.

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 a cigarette or smoke.

NHEN OPERATING EQUIPMENT

DO NOT tip engine or equipment at anglewhich causesfuel

to spill.

'HEN TRANSPORTING OR REPAIRING EQUIPMENT

Transport/repair with fuel tank EMPTYor with fuel shutoff

valve OFF.

Disconnect spark plug wire.

NHEN STORING FUEL OR EQUIPMENT WITH FUEL

IN TANK

Store awayfrom furnaces,stoves, water heaters,clothes

dryers or other appliances that havepilot light or other

ignitionsource becausethey can ignitefuel vapors.

DANGER

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

during andfor several minutes after charging abattery.

Wear protective goggles,rubber apron, and rubber gloves.

, WARNING

DO NOT touch hot surfaces.

Allow equipment to cool before touching.

CAUTION

DO NOT tamper with governedspeed.Generator supplies

correct rated frequency and voltage when running at governed

speed.

DO NOT modify generator in any way.

CAUTION

See"Don't Overload Your Generator" on page I h

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

Use generator only for intended uses.

tf you have questions about intended use,askdealer or

contact Generac.

Operate generator only on levelsurfaces.

DO NOT expose generator to excessive moisture, dust,dirt,

or corrosive vapors.

DO NOT insert any obiects through cooling slots.

tf connected devices overheat, turn them off anddisconnect

them from generaton

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 illustrationswith your generator, to familiarize yourself with the locationsof variouscontrols and

adjustments.Savethis manualfor future reference.

EngineSwitch Recoil Starter

FuelTank

Oil Fill

Air Cleaner

Choke Lever

120/240VoltAC,

30 Amp

Receptacle

Idle Control Switch

Spark Attester Muffler

Minder

Wing Nut

12Volt DC, 10Amp

Receptacle

120Volt AC, 20 Amp

Duplex Receptacles

Circuit

Breakers (AC)

12Volt DC, I0 Amp Receptacle -- Rechargea discharged

12Volt automotive type battery through this receptacle.

120Volt AC, 20 Amp GFCI Duplex Receptacles --

May be usedto supply electrical power for the operation

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

lighting,appliance,tool and motor loads.

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

be usedto supply electrical power for the operation of

120and/or 240Volt AC, 30Amp, singlephase,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 suckedinto the engine.

Choke Lever -- Usedwhen starting acold engine.

Circuit Breakers (AC) -- Pushto reset circuit breakers

are provided to protect the generator againstelectrical

overload.

FuelTank -- Capacity of seven (7) U.S.gallons.

GroundingWing Nut -- Used for proper grounding of

unit (see page 7).

Maintenance Minder --Alerts you to change the oil and

service the air filter when needed.

Idle Control Switch --The idlecontrolruns the engineat

normal (high)speedswhen there isa loadpresent and runs

the engineat idle (low) speedswhen a load isnot present.

Oil Fill --Add engine oil here.

Recoil Starter-- Used to start the engine.

Engine 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.

ASSEMBLY

Your generator requires some assembly and isready for

use after it hasbeen 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 carton on a rigid fiat surfacewith "This Side Up"

arrows pointing upward.

• Carefully open the top flapsof the shippingcarton.

• Cut down corners at one end of carton from top to

bottom and laythat side of carton down fiat

• Removeall packing material, carton fillers, etc.

• Removethe generator from the shipping carton.

Carton Contents

Check all contents. If anyparts are missingor damaged,call

the generator helpline at 1-800-270-1408.

• The generator

• Generator and engine owner's manuals

• Locking 30Amp plug

• Engineoil

• Wheel kit

Install Wheel Kit

The wheel kit isdesignedto greatly improvethe portability

of your generator.

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

You will need a socket wrench with I/2" or 13mm sockets

and a needle-nose pliers to install this kit.

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

I. Placethe generator on a hard fiat surface.

2. Standat the engine end of the generator and gently tilt

the generator forward, high enough to placewooden

blocks beneath the cradle.This will allow you to add

the wheels.

Wheel

Axle /

Hex Nut

Support Leg

Vibration

_20mm

Cap Screw /

FlatWasher

Hex Nut

30mm Cap Screw

E-Ring

3. Slide the axle through the holes in the brackets

provided on the generator cradle.

4. Slide a wheel and fiat washer over the axle.

NOTE: Be sure to installboth wheels with the air

pressure valve on the outboard side.

5. Placethe e-ring onto the groove in the axle.

NOTE: Use retaining pins insteadof e-clip, if applicable.

6. Placeone end of the needle nose pliers on the bottom

of the axle and the other end of the pliers on top of

the e-ring.Seatthe e-ring by pressingthe pliers closed.

7. Repeat step 4 through 6 to secure second wheel

Removethe wooden blocks.

8. Attach the vibration mounts to the support leg with

30mm capscrews,washers and lock nuts.

9. With the wheels on, you can now lift up the handle

end and attach the support leg with 20mm capscrews

and lock nuts.

10. Check eachfastener to ensure it issecure 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 hasbeen properly ftled with the recommended

oil may result in an engine failure.

To fill your engine with oil:

• Place generator on a Jevel surface.

• Follow the oil grade recommendationsand oil fill

instructionsgiven in the engine owner's manual.

NOTE:The generator's revolving field rides on a

prelubricated and sealedbait bearing that requires no

additional lubrication for the life of the bearing.

Add Fuel

_ ARNING! NEVERfillfuel tank indoors. NEVER

flit fuel tank whenengine isrunning 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 fuel with the generator

engine.DO NOT usepremium fuel. DO NOT mix oil

with fuel

• Clean areaaround fuel flit cap,remove cap.

• Slowly add unleaded regular fuel to fuel tank. Be careful

not to overfitLAliow about 1.5"of tank spacefor fuel

expansion (Figure2).

Fuel

..... N--N 22Nr

• Install fuel capand wipe up any spilled fuel.

IMPORTANT: It isimportantto prevent gum deposits

from forming in essentialfuel system parts,such asthe

carburetor, fuel filter, fuel hose or tank during storage.Also,

experience indicatesthat alcohol-blended fuels (called

gasohol,ethanol or methanol) can attract moisture, which

leadsto separation and formation of acids during storage.

Acidic fuel can damagethe fuel system of an enginewhile in

storage.

To avoid engine problems, the fuel system should be

emptied before storage of 30 claysor longer.See"Storage"

on page 13.NEVER use engine or carburetor cleaner

products in the fuel tank or permanent damagemay occur.

GROUNDING THE

G EN ERATO R

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 mayalso require proper grounding of the

unit. For that purpose, a GROUNDING WING NUT is

provided on the generator end (Figure 3).

Wing Nut

Generally,connecting a No. 12AWG (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 keepthe grounding wire attached after

connecting the stranded copper wire. However, local codes

may vary widely.Consult with a localelectrician for

grounding requirements in your area.

Properly grounding the generator helps prevent electrical

shock if aground fault condition exists in the generator or

in connected electrical devices,especiallywhen the unit is

equipped with a wheel kit. Proper grounding also helps

dissipate static electricity, which often builds up in

ungrounded devices.

OPERATING THE

G EN ERATO R

A AUTION! Never start or stop the engine with

electrical loadsconnected to the receptaclesAND

with the connected devices turned ON.

Starting the Engine

Disconnect all electrical loadsfrom the generator. Use the

following start instructionsteps by numerical order:

I. Turn the fuel valve to the "On" position (Figure 4).

Fuel Valve is shown

in the "On" position

Placethe chokelever in the "Closed" position

(Figure5).

Closed

Setthe engine switch to the "On" position (Figure6).

EngineSwitch

Off

Grasp the recoil handle and pull slowly until slight

resistance is felt.Then pull rapidly to start engine.

Move choke lever to "Open" 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 "Open" position.

NOTE: If engine still fails to start after 3 pulls,check for

proper oil level in crankcase.This unit is equipped with a

low oil device.Seeengine manual.

Refer to the engine owner's manual for more

detailed starting instructions.

Connecting Electrical Loads

• Let enginestabilize and warm up for a few minutes after

starting.

• Plugin and turn on the desired 120and/or 240 VottAC,

single phase,60 Hz electrical loads.

• DO NOT connect 240Vott loads to the 120Volt duplex

receptacles.

• DO NOT connect 3-phase loads to the generator.

• DO NOT connect 50 Hz loadsto the generator.

• DO NOT OVERLOADTHE GENERATOR. See

"Don't Overload the Generator" on page I I.

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.

• Movethe engineswitch to "Off' position.

• Movethe fuel valveto the "Off' position.

Operating Automatic Idle Control

This switch isdesignedto greatly improve fuel economy.

When this switch is turned ON, the engine will only

run at its normal high governed engine speed when an

electrical load is connected.When an electrical load is

removed,the enginewill run at a reduced speed.With the

switch off, the enginewill run at the normal high engine

speed.Always have the switch off when starting and

stopping the engine.

Charging a Battery

_ ARNING! Storage batteries give off explosive

hydrogen gaswhile recharging.An explosive mixture

will remain around the battery for a long time after

it hasbeen charged.The slightest spark canignite

the hydrogen and causean explosion, resulting in

blindness or other serious injury.

_ ARNING! DO NOT permit smoking,open

flame,sparks or anyother source of heat around a

battery.Wear protective goggles,rubber apron and

rubber gloves when working around a battery.

Battery electrolyte fluidis an extremely caustic

sulfuric acid solution that can causesevere burns. If

spill occurs flush area with clear water immediately.

Your generator hasthe capability of recharging a discharged

12Volt automotive or utility style storage battery. DO

NOT use the unit to chargeany 6Volt batteries. DO NOT

usethe unit to crank an engine havinga discharged battery.

To recharge 12Volt batteries, proceed as follows:

• Check fluidlevel in all battery cells.If necessary,add

ONLY distilled water to cover separators in battery cells.

DO NOT use tap water.

• If the battery isequipped with vent caps,make sure they

are installed and are tight.

• If necessary,clean battery terminals.

• Connect battery charge cable connector plug to panel

receptacle identified by the words "12-VOLTS D.C".

• Connect battery charge cable clampwith red handle to

the positive (+) battery terminal (Figure7).

12 VOLT D.C.

RECEPTACLE

POS NEG

12 VOLT BA'n'ERY

• Connect battery charge cable clampwith black handle

to the negative (-) battery terminal (Figure7).

• Start engine.Let the engine run while battery recharges.

• When battery hascharged,shut down engine

NOTE: Use an automotive hydrometer to test battery state

of chargeand condition. Follow the hydrometer

manufacturer'sinstructions carefully.Generally,abattery is

consideredto be at 1(30°/ostateof chargewhen specificgravity

of its fluid (asmeasuredby hydrometer) is 1.260or higher.

RECEPTACLES

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 8).You can usethe same4-wire cord if you

)lan to run a 120Volt load.

4-WireCord Set

(Neutral)

Y (Hot) | X (Hot)

NEMA L14-30 /--_ Ground(Green)

This receptacle powers 120/240Volt AC, 60 Hz,single

phaseloads requiring up to 4,500 watts of power (4.5 kW)

at 30 Amps for 120Volts or 240Volts.The outlet is

protected bya 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 4,500 watts. Powering

loads that exceed the wattage/amperage capacity of

the generator can damage it or cause serious

injuries.

120 Volt AC, 20 Amp, GFCI Duplex

Receptacles

Eachduplex receptacle (Figure 9) isprotected against

overload by a push-to-reset circuit breaker.

•11 I

Use each receptacle to operate 120Volt AC, single-phase,

60 Hz electrical loadsrequiring 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).

Ground Fault Protection

Thisunit isequippedwith a Ground Fault Circuit

Interrupter (GFCI).This device meets applicablefederal,

state and localcodes.

The GFCI protects againstelectrical shock that may be

caused ifyour body becomes a path which electricity

travels to reach ground.This could happenif you touch a

"Live" applianceor wire, or are touching plumbing or other

materials that connect to the ground.

When protected by a GFCI, one may still feel a shock, but

the GFCI should cut current off quickly enough so that a

person in normal health should not suffer anyserious

electrical injury.

_ CAUTION!The GFCI will not protect you

against the following situations: (I) Line-to-line

shocks;(2) Current overloads or line-to-lineshort

circuits.The fuse or circuit breaker at the

distribution panel must provide such protection.

Testing the GFCI

Test your GFCI outlet every month, asfollows:

• Pushthe black*'Test" button.The red "Reset" button

should pop out, which should allow no power to reach

the outlet. Use a test lamp in eachoutlet to test this.

I[o_ IIP_LV_ilDZeelIJ[!]r_]:i _tI

_ AUTION! Ifthe"Reset" button does not pop

out or the test tamp remains lit when the "Reset"

button ispopped out, do not useany outlets on the

circuit Call a qualified electrician.

• If the GFCI tests good, restore power by pressingthe

"Reset" button firmly until it isfully in place and locksin

that position. If the GFCI outlet does not reset

properly, do not use the outlet _ call a Generac

service center.

• If the GFCI trips by itselfat anytime, reset and test the

outlet. If the reset button does pop out when the

test button is pressed, do not use the outlet. Call

a Generac service center.

12Volt DC, I 0 Amp Receptacle

This receptacle (Figure10) allows you to recharge a 12Volt

automotive or utility style storage battery with the battery

chargecables provided.

This receptacle can not recharge 6Volt batteries and can

not be usedto crank an engine havinga discharged battery.

See"Charging a Battery" on page8 before attempting to

recharge a battery.This outlet isprotected by a l0 Amp self

resetting circuit breaker.

DON'T OVERLOAD YOUR

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 I I.

3. Estimate how 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)

Rated (Running)

Watts

1200

8O0

50O

3075 Total

Running Watts

Total Rated (Running)Watts = 3075

Highest Additional SurgeWatts = 1800

Total Generator Output Required = 4875

Additional Surge

(Starting)Watts

1800

1600

500

1800 Highest

Surge Watts

Power Management

To prolong the life of your generator and attached devices,

it is important to take care when addingelectrical loads to

your generator.There should be nothing connected to the

generator outlets before starting it's engine.The correct

and safeway to managegenerator power isto sequentially

add loads asfollows:

I. With nothing connected to the generator, start the

engine asdescribed in this manual

2. Plugin 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

specialcare to consider surgeloads in generator capacity,

asdescribed above.

Tool or Appliance

Essentials

Light Bulb - 75 watt

Deep Freezer

SumpPump

Refrigerator/Freezer - 18Cu. Ft.

Water Well Pump- I/3 HP

Heating/Cooling

Window AC - 10,000BTU

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)

Watts

500

8O0

1000

12O0

3OO

8O0

1000

1500

2500

Additional

Surge

(Starting)

Watts

5O0

1200

1600

20O0

1800

6O0

1300

100

450

5o0

8o0

18o

3O0

480 520

40O0

1000

600 1200

960 960

1000 1000

1500 1500

1800 1800

2000 2000

2500 2500

*Wattages listed are approximate only. Check toot or

appliance for actual wattage.

SPECIFICATIONS

Maximum SurgeWatts ................. 5,625 watts

Continuous Wattage Capacity ........... 4,500 watts

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

Rated Maximum Continuous AC Load Current:

At 120Volts ....................... 37.5Amps

At 240 Volts ....................... 18.7Amps

Phase................................. I-phase

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

FuelTank Capacity................... 7 U.S.gallons

ShippingWeight ......................... 164 Ibs.

GENERAL MAINTENANCE

RECOMMENDATIONS

The Owner/Operator is responsible for making sure that

all periodic maintenance tasks are completed on atimely

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 engineowner's manualfor instructions.

Maintenance Minder

The maintenance minder displaysand records how many

hours your generator has run (up to 9,999.9).It also alerts

you when to changeyour oil and to service your air filter.

The message"CHG OIL" will flash after the first 20 hours

of unit operation.This isto remind you to replace the

'break-in' oil with regular duty oiLThe same messagewill

againflash after intervalsof 100 hours.The maintenance

reminder does not sensethat the oil changehasoccurred -

it merely flashesthe messagefor a two hour period to

permit you to observe the reminder.

Similarly,the message"SVC AIR FILTER" willflashafter

intervalsof 50 hours to remind you to service or change

the air filter element

_ii CAUTION!When working on the generator,

alwaysdisconnect spark plug wire from spark plug

and keepit awayfrom spark plug.

_ii AUTION! Avoid prolonged or repeated skin

contact with used motor oil. Used motor oil has

been shown to causeskin cancer in certain

laboratory animals.Thoroughly wash exposed areas

with soapand water.

KEEPOUT 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 dean dry

environment where it w{{{ 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 dean generator.

Water can enter engine fuel system and cause problems. In

addition, if water enters generator through cooling air slots,

some of the water wilt 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

_ii AUTION! NEVER insertany object or tool

through the air cooling slots, even ifthe engine is

not running.

• Use adamp cloth to wipe exterior surfaces clean.

• A soft bristle brush maybe 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 awaydirt. Inspectcooting air slots and opening on

generator.These openings must be kept clean and

unobstructed.

STO RAG E

The generator should be started at least once every seven

days and allowed to run at least 30 minutes. If this cannot

be done and you must store the unit for more than

30 days,usethe following guidelinesto prepare it for

storage.

Generator Storage

• Clean the generator asoutlined in"To Clean the

Generator"

• Check that cooling air slots andopenings on generator

are open and unobstructed.

_ AUTION! Storage covers canbe flammable.

DO NOT place a storage cover over a hot

generator. Let the unit coot for a sufficient time

before placingthe cover on the unit.

Engine Storage

See engine owner's manualfor instructions.

Other Storage Tips

• To prevent gum from forming in fuel system or on

essential carburetor parts, add fuel stabilizer into fuel

tank and fill with fresh fuel. Run the unit for several

minutes to circulate the additive through the carburetor.

The unit and fuel can then be stored for up to

24 months. Fuel stabilizer can be purchased locally.

• DO NOT store fuel from one season to another unless

it has been treated as described above.

• Replace fuel container if it starts to rust. Rust and/or dirt

in fuel can cause problems if it's used with this unit.

• Store unit in a clean and dry area.

NOTES

TROUBLESHOOTING

Problem

Engine is running, but

no AC output is

available.

Engine runs good but

bogs clown when

loads are connected.

Engine will not start;

or starts and runs

rough.

Cause

I. Circuit breaker isopen.

2. Poor connection or defective cord set.

3. Connected device isbad.

4. Fault ingenerator.

I. Short circuit in a connected load.

2. Generator is overloaded.

3. Enginespeed istoo slow.

4. Shorted generator circuit.

I. Engineswitch set to "Off'.

2. Low oil level.

3. Dirty air cleaner.

4. Out of gasoline.

5. Stalegasoline.

6. Sparkplug wire not connected to

spark plug.

7. Badspark plug.

8. Water in gasoline.

9. Overchoking.

10. Excessivelyrich fuet mixture.

I I. Intake valve stuck open or closed.

12. Enginehaslostcompression.

Solution

I. Resetcircuit breaker.

2. Check and repair.

3. Connect another device that is ingood

condition.

4. Contact Generac service facility.

I. Disconnect shorted electrical load.

2. See"Don't Overload the Generator" on

page II.

3. Contact Honda service facility.

4. Contact Generac service facility.

I. Setswitch to "On".

2. Fill crankcaseto proper level.

3. Cleanor replace air cleaner.

4. Fillfuet tank.

5. Drain gastank and fill with fresh fuel.

6. Connect wire to spark plug.

7. Replacespark plug.

8. Drain gastank; fill with fresh fuel.

9. Setchoke to "Off' position.

10. Contact Honda service facility.

I I. Contact Honda service facility.

12. Contact Honda service facility.

Engine shuts down I. Out of gasoline. I. Fitl fuet tank.

during operation. 2. Fault in engine. 2. Contact Honda service facility.

I. Load istoo high. See "Don't Overload the Generator" on

page II.

Engine lacks power. 2. Dirty air filter. Replace air filter.

3. Engine needs to be serviced. Contact Honda service facility.

I. Choke is opened too soon.

Engine "hunts" or

falters.

2. Carburetor is running too rich or too

lean.

Move choke to halfway position titl engine

runs smoothly.

Contact Honda service facility.

SCHEMATIC

BATTERY CHARGE

L 77 12V PC

HOURMETER/

MAINTENANCE REMINDER

IIA

13 55

RESET

lOA CB

IIA

14)

/ff) EXOTATION

FIELD

POWER POWER

ii 22 44

IDLE

CONTROL

TRAN3FORMER

155 156 22 44

IDLE CONTROL

CIRCUIT BOARD

IDLE

SWITCH

120/240V

30A 44A

22 22

44A

IIA

WIRING DIAGRAM

IIA

IlA

IIA

20A CB ]20/240V 30A

IDLE CONTROL

SWITCH

120V 20A

GFCI

12V/IOA DC

L 22

F 156

155 GRY

GR%

IIA

13 DC CB

156

155 ORY

CRY

2 ¸

_rs

EXPLODEDVIEW- MAIN UNIT

27 2B

37_

\\\\\\

_ 6_

2 ¸

_r3

PARTS LIST - MAIN UNIT

Item Part # Qty

I K189252GS I

2 67989GS 8

3 70642GS 2

4 76222GS 2

5 91844JGS I

6 66365GGS I

7 SRV66825DGS I

8 26850GS 2

9 86494GS I

10 67022GS I

II 86307GS 4

12 22695GS I

13 86308CGS 4

14 189127GS I

15 74908GS 4

16 B4871GS I

17 66849GS 2

18 91825GS I

19 84242GS I

20 B4986GS I

21 20566GS I

22 85652GS 2

23 22769GS

24 86292GS

25 189540GS

26 81917GS

27 47480GS

28 96796GS

30 14353621GS

31 38750GS

32 22097GS

33 22473GS

34 BI89434GS

35 42909GS 2

36 22145GS 2

37 22129GS 2

38 45771GS 2

39 78299GS I

40 80270GS I

41 48031CGS 2

Description

CRADLE

NUT

MOUNT, Vibration

SCREW

ASSY,Rotor

HOUSING,Adapter

CARRIER,Rear Bearing

WASHER

SCREW,Wing

GROMMET,Rubber

SCREW

CONNECTOR, 6-pin Male

BOLT,Stator

GROMMET,Bushing,Rubber

SCREW

COVER, Bearing Carrier

SCREW

ASSY,Brush & Bridge Rectifier

GROMMET,Plastic,RBC

DECAL, Ground

DECAL, b800

MOUNT, Vibration

WASHER

SCREW

ASSY,Stator

PIN,Roll

BOLT,Rotor

WASHER

ASSY,Wire, Ground

SCREW

WASHER, Lock

WASHER

COVER, Engine

SCREW

WASHER

WASHER, Lock

NUT

BUSHING, GasTank

VALVE,Fuel

CLAMP,Hose Band

Item Part #

42 30340GS

43 189564GS

44 83465GS

45 78831AGS

46 93826GS

47 B4363GS

48 188333GS

49 B1998AGS

50 92982GS

51 189273GS

52 189272GS

53 189275GS

54 77816GS

55 73054GS

56 189274GS

57 189155GS

58 J189384GS

59 B2153GS

60 22413GS

61 22473GS

62 189377GS

63 189249GS

64 BB3061BGS

65 B1464GS

66 189264GS

67 65787GS

68 43438GS

69 84409GS

70 23762GS

71 189521AGS

72 66849AGS

73 65795GS

74 189454AGS

76 56893GS

77 BI232GS

78 28739AGS

900 NSP

Qty Description

I HOSE,Fuel

I CONNECTOR, Reducer

4 GROMMET,Tank

4 SCREW

I DECAL, Start Instructions

I CAP,Fuel Gauge

I DECAL, Instructions, Fuel Level

I ASSY,Tank,Fuel

(Includes Items 39 & 40)

DECAL, Danger

DECAL, Unit

DECAL, Control Panel

DECAL, Powered By Honda

DECAL, Caution, Hot Muffler

DECAL, FuelShut-Off

DECAL, Starting Instructions

WASHER

HEAT SHIELD,Muffler

SCREW

WASHER

NUT,Well

ASSY,Control Panel

(see page21)

BOTTLE,Oil

MANUAL, Engine

MANUAL, Owners

CABLE, Battery Charge

PLUG, 120/240V,30A

SLEEVING,Flexo

WASHER

WIRE, PanelGround

SCREW

RECTIFIER

WIRE, Rectifier

SCREW

CLAMP,Hose

WRAP,Tie

ENGINE

2 ¸

_r3

EXPLODEDVIEWAND PARTS LIST-WHEEL KIT

10'

Item Part # Qty Description

I BB5586GS 2 HANDLE (Includes Item 15)

2 B4966GS 2 WHEEL

3 191267KGS I AXLE

4 191265GS 2 E-RING

5 39287GS 2 SCREW

6 BI89522GS I LEG,Support

7 191413GS 2 MOUNT, Vibe,with Washer

8 42909GS 2 SCREW

9 52858GS 4 NUT, Lock

10 22247GS 2 WASHER

II 39253GS 2 SCREW

12 22145GS 4 WASHER

13 49820GS 2 NUT

14 187104GS 4 WASHER,Nylon

15 B4605GS 2 GRIP

16 B4135GS 2 PIN, with Lanyard

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Generac 1648-0 Owner's manual

Brand: Generac

Model: 1648-0

Category: Power generators

Type: Owner's manual

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Generac 1648-0 Owner's manual

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