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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-portables.com or www.briggsandstratton.com

Model No. 1645-0 (4,000 Watt AC Generator) Manual No. 189189GS Revision 1 (01/03/2002)

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page

• Generator

• Wheel kit

• Battery

• Battery charge cables

• Battery float charger

• Locking 20 Amp plug

• Locking 30 Amp plug

• Engine oil

• Two packets of fuel stabilizer

• Owner's manual

• Engine manual

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

Parts Included*

Table of Contents

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Содержание 1645-0

Страница 1: ...3 Assembly 4 Know Your Generator 5 Operation 6 10 Product Specifications 11 Maintenance 11 Storage 12 Troubleshooting 13 Schematic 14 Wiring Diagram 15 Replacement Parts 16 19 Warranty Last Page Generator Wheel kit Battery Battery charge cables Battery float charger Locking 20 Amp plug Locking 30 Amp plug Engine oil Two packets of fuel stabilizer Owner s manual Engine manual If any parts are missi...

Страница 2: ...en 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 g...

Страница 3: ...tor 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 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 ta...

Страница 4: ... 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 ...

Страница 5: ...ce tool and motor loads 120 240 Volt AC 20 Amp 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 Break...

Страница 6: ...a 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 unit with electrical loads connected AND with the connected devices turned ON IMPORTANT Always...

Страница 7: ...the fuel shut off valve Operating Automatic Idle Control This switch is designed to 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 engine will run at a reduced speed With the switch off the engine will run at the normal high engine speed Always h...

Страница 8: ... end away from wind and elements Enclosure should hold enough heat created by the generator to prevent problems CAUTION Never run unit indoors Do Not enclose generator any more than shown Remove generator from shelter when temperature is above 40 F 4 C How to Use the Battery Charger Use battery float charger jack to keep the starting battery charged and ready for use Battery charging should be don...

Страница 9: ...atts Powering loads that exceed the wattage amperage capacity of the generator can damage it or cause serious injuries 240 Volt loads powered through this outlet should not exceed 16 7 Amps of current draw 120 Volt AC 30 Amp Locking Receptacle Use a NEMA L5 30 plug with this receptacle Connect a 3 wire cord set rated for 125 Volts AC at 30 Amps to the plug Figure 13 Use this receptacle to operate ...

Страница 10: ...nerator 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 appl...

Страница 11: ...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...

Страница 12: ...ling air slots and openings on generator are open and unobstructed CAUTION Storage covers can be flammable Do Not place a storage cover over a hot generator Let the unit cool for a sufficient time before placing the cover on the unit Engine Storage See engine owner s manual for instructions Other Storage Tips To prevent gum from forming in fuel system or on essential carburetor parts empty all two...

Страница 13: ... Stale gasoline 6 Spark plug wire not connected to spark plug 7 Bad spark plug 8 Water in gasoline 9 Overchoking 10 Excessively rich fuel mixture 11 Intake valve stuck open or closed 12 Engine has lost compression 13 Failed battery 1 Set switch to Run 2 Turn the fuel valve to the On position 3 Clean or replace air cleaner 4 Fill fuel tank 5 Drain gas tank fill with fresh fuel 6 Connect wire to spa...

Страница 14: ...14 4000EXL Extended Life Generator SCHEMATIC ...

Страница 15: ...4000EXL Extended Life Generator 15 WIRING DIAGRAM ...

Страница 16: ...16 4000EXL Extended Life Generator EXPLODED VIEW MAIN UNIT ...

Страница 17: ...Red 42 77395GS 4 NUT M6 Flange Lock 43 J189312GS 1 SHIELD Heat 44 188989GS 1 ASM Jack DC 45 189198GS 1 DECAL Instructions ES 46 58359GS 1 LUG 5 16 22 18 I S Item Part Qty Description 47 78549GS 1 DECAL Electric Start 48 187079GS 1 BATTERY 12V 10A 49 J188988GS 1 TRAY Battery 50 189740GS 1 HARNESS Wire Starter 51 52858GS 4 NUT M8 Flange Lock 52 185939FGS 1 ASSY Wire 16 Red 53 22127GS 5 NUT 1 4 20 He...

Страница 18: ...KER 18 Amp 9 82538GS 1 SWITCH On Off Rocker 10 84134GS 1 GROMMET Rubber 11 83514GS 1 CIRCUIT BREAKER 10 Amp 12 83970GS 1 CONTROL BOARD System Item Part Qty Description 13 84028GS 1 TRANSFORMER Idle Control 14 67022GS 1 GROMMET Rubber 15 85584GS 1 BAR Bus 16 84543AGS 2 SCREW 3 0 x 12mm 17 84543CGS 9 SCREW 3 5 x 18mm 18 84198GS 3 SHIELD Circuit Breaker 19 84197GS 1 BAR Circuit Breaker Retaining 21 7...

Страница 19: ... LIST WHEEL KIT Item Part Qty Description 1 B4217GS 1 ASSEMBLY Handle 2 B1764GS 1 LEG Mounting 3 52858GS 2 NUT Locking Hex M8 1 25 4 39287GS 2 HHCS M8 1 25 x 45 5 93693FGS 1 AXLE 6 B4966GS 2 WHEEL 10 Diameter 7 87005AGS 2 PIN Retaining 8 22247GS 2 WASHER Flat ...

Страница 20: ...een subjected to improper or unauthorized installation or alteration misuse negligence accident overloading overspeeding improper maintenance repair or storage so as in Generac Portable Products judgment to adversely affect its performance and reliability This warranty also does not cover normal maintenance such as adjustments fuel system cleaning and obstruction due to chemical dirt carbon or lim...

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