Generac Power Systems PowerBOSS 8000 PowerMaster Bedienungsanleitung

WATTS TM

Portable Generator Owner's Manual

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

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)

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 isan 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 3,600rpm by the engine.

CAUTION! DO NOT exceed the generator's

wattage/amperagecapacity.See"Don't Overload

Generator" on page I I.

Every effort hasbeen madeto ensure that informationin

this manualis accurate and current. 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 State of 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.

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 indicatesa hazardwhich, 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 safety messagesto

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.

Hazard Symbols and Meanings

Electrocution Electrical Shock Electrical Shock

Toxic Fumes

Explosive Pressure

Explosion Fire

Chemical Burn Hot Surface

DANGER

Operate generator ONLY outdoors.

Keepat least 2 feet of clearance on all sidesof generator for

adequate ventilation.

DO NOT operategenerator insideanybuildingor enclosure,

includingthe generator 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 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

inwater, while barefoot, or while handsor feet are wet.

DO NOT allow unqualified persons or children to operate or

service generator.

DANGER

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.

, WARNING

WHEN ADDING FUEL

Turngenerator OFF and let it cool at least 2 minutes before

removing gascap.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 ignitionsources.

DO NOT light a cigarette 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 plug wire.

_HEN STORING FUEL OR EQUIPMENT WITH FUEL

IN TANK

Store awayfrom furnaces, stoves, water heaters, clothes

dryers or other appliancesthat have pilot light or other

ignition source becausethey can ignite fuel vapors.

, 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 3

WARNING

;ENERATOR

Disconnect the spark plug wire from the spark plug and place

the wire where it cannot contact spark plug.

, WARNING

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.

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

Use generator onlyfor intended uses.

tf you have questions about intended use,askdealer or call

1-800-270-1408.

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.

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

.'leaner

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.

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 -- Used when 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 -- Setthis 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 and is equipped with a spark arrester screen.

ASSEMBLY

Your generator requires some assemblyand 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 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. If any parts are missingor damaged,call

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

The generator

Electric start battery cables

Generator and engine owner's manuals

Locking 30Amp plugs

Battery mounting bracket/hardware

2 bottles engine oil

Wheel kit

INSTALL WHEEL KIT

NOTE: Wheel kit isnot intendedfor over-the-road use.

To installyour wheel kit, you need the 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.Seate-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

Flatwasher

/Vibration

_ Mount --

E-Ring

,_port Leg

_-- Flatwasher

__ Lockwasher

30mm _ 20mm

-Capscrew Capscrew

9. Withwheelson,securesupportlegassemblytocradle

with20mmlongcapscrews,flatwashers,andlock

washers.

10.Checkeachfastenertoensureitissecureandtires

areinflatedbetween15-40PSI.

INSTALLING BATTERY

NOTE: The generator canbe 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 loosein 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 (Figure2).

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 life of 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 Safetyand

Health Administration (OSHA) regulations,localcodes,or

ordinances that apply to the intendeduseof 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 isusedat 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 applicablelawsand

electrical codes.

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 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

inwater, while barefoot, or while handsor feet are wet.

DO NOT allow unqualified persons or children to operate or

service generator.

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).

Fuel Valve is shown

in the On position

3. Follow start instructions given in engine owner's

manual.

NOTE: If engine starts after 3pulls 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 engine stabilize 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 loadsto 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 engine with 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. Move fuel valve to "Off" position.

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.

2. Ensurea minimum of two feet clearance between open

side of box and nearest object.

3. Faceexposed end away from wind and elements.

4. Enclosure should hold enough heat created by

generator to prevent problems.

_, 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

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 plug with this receptacle (Figure5).

Connect a 4-wire cord set rated for 250Volt AC loads at

50 Amps to the plug.

Y(Hot)

_240 Volts AC

rame Ground

X (Hot)

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 usethe same 4-wire cord if you

)lanto run a 120Volt load.

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 isprotected bya 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 30 Amps to

the plug (Figure 7).

_ire Cord Set NEMA L5-30

Neutral

120V

Hot

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 (Figure8) isprotected 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. Usecord sets that are rated for

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

i10

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