Simplicity 01652-0 Operator's Manual

Owner’s Manual
Parts Included*
Table of Contents
• Generator
• Wheel kit
• Engine oil
• Locking 20 Amp plug
• Locking 30 Amp plug
• Owner's manual
• Engine manual
*If any parts are missing or damaged, call 1-800-270-1408.
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Know Your Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-19
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Last Page
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
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.
Model No. 1652-0 (4,200 Watt AC Generator) Manual No. 189829GS Revision 0 (10/17/2001)
4200 Watt Heavy Duty Generator
EQUIPMENT
DESCRIPTION
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.
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 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.
This manual contains information for a generator that
operates 120 and/or 240 Volt, single phase, 60 Hz devices
that require up to 4,200 watts (4.2 kW) of power that pull
up to 35 Amps at 120 Volts or 17.5 Amps at 240 Volts
CAUTION! Do Not exceed the generator’s
wattage/amperage capacity. Add up the rated watts of all
devices you are connecting to generator receptacles at one
time.This total should not be greater than 4,200 watts. See
“Don’t Overload the Generator” on page 9.
Read this manual carefully and become familiar
with your generator set. Know its applications, its
limitations and any hazards involved.
The generator’s revolving field is driven at about 3,600 rpm
by a single-cylinder engine.
WARNING:
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 engine exhaust from this product contains
chemicals known to the State of California
to cause cancer, birth defects,
or other reproductive harm.
WARNING! You must isolate the generator
CAUTION! Do Not tamper with engine
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 the unit is providing backup power, the
electric utility must be notified.
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.
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 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.
2
4200 Watt Heavy Duty Generator
• 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).
Figure 1 — Grounding Wing Nut
Grounding
Wing Nut
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.
3
4200 Watt Heavy Duty Generator
INSTALL WHEEL KIT
Your generator requires some assembly and is ready for
use after it has been properly serviced with the
recommended oil and fuel.
The wheel kit is designed to greatly improve the portability
of your generator.
If you have any problems with the assembly of your
generator, please call the generator helpline at
1-800-270-1408.
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.
IMPORTANT: Any attempt to run the unit before it has
been serviced with the recommended oil will result in an
engine failure.
Refer to Figure 2 and install the wheel kit as follows:
• Place the generator on a hard flat surface.
REMOVE GENERATOR
FROM CARTON
• 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.
• Set the carton on a rigid flat surface with “This Side Up”
arrows pointing upward.
• Slide the axle through the holes in the brackets provided
on the generator cradle.
• Carefully open the top flaps of the shipping carton.
• Slide a wheel and flat washer on one end of the axle.
Make sure the air inflation valve is outward. Insert the
retaining pin.
• 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.
• Slide the axle through until wheel is tight against bracket.
• Remove the generator from the shipping carton.
Figure 2 — Install Wheel Kit
Axle
Wheel
Washer
Lock Nut
Support Leg
20mm
Capscrew
Vibration Mount
Flat Washer
30mm Capscrew
Lock Nut
4
Retaining Pin
4200 Watt Heavy Duty Generator
WARNING! Do Not overfill the fuel tank.
Always allow room for fuel expansion.
• 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.
• Use regular UNLEADED gasoline with the generator
engine. Do Not use premium gasoline. Do Not mix oil
with gasoline.
• Attach the vibration mounts to the support leg with
30mm capscrews, washers and lock nuts.
• Clean area around fuel fill cap, remove cap.
• With the wheels on, you can now lift up the handle end
and remove the existing hardware from the left unit
vibration mount with a 13mm wrench. Use the same
hardware to attach the support leg.
• Attach the other side of the support leg with a 20mm
cap screw and lock nut.
• Check each fastener to ensure it is secure and the tires
are inflated between 15-40 PSI.
• Slowly add unleaded regular gasoline to fuel tank. Be
careful not to overfill. Allow about 1.5" of tank space for
fuel expansion (Figure 3).
1.5” Air Space
Figure 3 — Typical Fuel Expansion Space
Tank
Fuel
BEFORE STARTING THE
ENGINE
• Install fuel cap and wipe up any spilled gasoline.
Add Oil
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.
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.
To avoid engine problems, the fuel system should be
emptied before storage of 30 days or longer. See “Storage”
on page 10. Never use engine or carburetor cleaner
products in the fuel tank or permanent damage may occur.
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.
5
4200 Watt Heavy Duty Generator
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.
Oil Fill Cap
Recoil Starter
Engine Switch
Fuel Tank
Circuit Breakers (AC)
Air Cleaner
120 Volt AC, 30 Amp
Receptacle
Choke Lever
120/240 Volt AC,
20 Amp Receptacle
Spark Arrester Muffler
120 Volt AC, 20 Amp
Duplex Receptacle
Grounding Wing Nut
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 Volt AC, 30 Amp Locking Receptacle — May be
used to supply electrical power for the operation of
120 Volt AC, 30 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 seven (7) 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.
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.
6
4200 Watt Heavy Duty Generator
OPERATING THE
GENERATOR
Figure 6 — Engine Switch
Engine Switch
Off
CAUTION! Never start or stop unit with
electrical loads connected AND with the connected
devices turned ON.
Starting the Engine
Disconnect all electrical loads from the generator. Follow
these start instruction steps in numerical order:
1.
On
Turn the fuel valve to the “On” position (Figure 4).
Figure 4 — Fuel Valve
Fuel Valve is shown
in the “On” position
2.
Grasp starter grip and pull slowly until you feel some
resistance.Then pull cord out with rapid full arm
stroke. Let rope return slowly. Do Not let rope
“snap back” against starter.
5.
If the choke lever has been moved to the “CLOSED”
position to start the engine, gradually move it to the
“OPEN” position as the engine warms up.
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. See engine manual.
To start a cold engine, move the choke lever to the
“CLOSED” position.To restart a warm engine, leave
the choke lever in the “OPEN” position (Figure 5).
Refer to the engine owner’s manual for complete
starting instructions.
Figure 5 — Choke Positions
Connecting Electrical Loads
Choke Lever
• 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.
Open
Closed
3.
4.
Set the engine switch to the “ON” position (Figure 6).
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 engine switch to “OFF” position.
• Move the fuel valve to the “OFF” position.
7
4200 Watt Heavy Duty Generator
RECEPTACLES
Use this receptacle to operate 120 Volt AC, 60 Hz, single
phase loads requiring up to 3,600 watts (3.6 kW) of power
at 30 Amps.The outlet is protected by a 30 Amp
push-to-reset circuit breaker.
120 Volt AC, 20 Amp, Duplex
Receptacle
120/240 Volt AC, 20 Amp Locking
Receptacle
Each receptacle (Figure 7) is protected against overload by
a 20 Amp push–to–reset circuit breaker.
Figure 7 — 120 Volt AC, 20 Amp Duplex Receptacle
Use a NEMA L14-20 plug with this receptacle. Connect a
4-wire cord set rated for 250 Volts at 20 Amps (or greater)
(Figure 9).You can use the same 4-wire cord if you plan to
run a 120 Volt load.
Figure 9 — 120/240 Volt AC, 20 Amp Receptacle
4-Wire Cord Set
240V
120V
120V
W (Neutral)
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).
Y (Hot)
120 Volt AC, 30 Amp Locking
Receptacle
NEMA L14-20
Ground (Green)
This receptacle powers 120/240 Volt AC, 60 Hz, single
phase loads requiring up to 2,400 watts of power at
20 Amps for 120 Volts; 4,200 watts of power (4.2 kW) at
17.5 Amps for 240 Volts.The outlet is protected by a
20 Amp push-to-reset circuit breaker.
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 8).
Figure 8 — 120 Volt AC, 30 Amp, Locking Receptacle
3-Wire Cord Set
X (Hot)
CAUTION! Although this outlet is rated for
240 Volt 20 Amp (up to 4,800 watts), the generator
is only rated for 4,200 watts. 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 17.5 Amps of current draw.
NEMA L5-30
Neutral
120V
Hot
Ground (Green)
8
4200 Watt Heavy Duty Generator
DON'T OVERLOAD YOUR
GENERATOR
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.
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 10.
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.
Figure 10 - Wattage Reference Chart
Tool or Appliance
Essentials
Light Bulb - 75 watt
Deep Freezer
Sump Pump
Refrigerator/Freezer - 18 Cu. Ft.
Water Well Pump - 1/3 HP
Heating/Cooling
Window AC - 10,000 BTU
Window Fan
Furnace Fan Blower - 1/2 HP
Kitchen
Microwave Oven - 1000 Watt
Coffee Maker
Electric Stove - Single Element
Hot Plate
Family Room
DVD/CD Player
VCR
Stereo Receiver
Color Television - 27”
Personal Computer w/17” monitor
Other
Security System
AM/FM Clock Radio
Garage Door Opener - 1/2 HP
Electric Water Heater - 40 Gallon
DIY/Job Site
Quartz Halogen Work Light
Airless Sprayer - 1/3 HP
Reciprocating Saw
Electric Drill - 1/2 HP
Circular Saw - 7 1/4”
Miter Saw - 10”
Table Planer - 6”
Table Saw/Radial Arm Saw - 10”
Air Compressor - 1-1/2 HP
Example:
Tool or Appliance
Window Air
Conditioner
Refrigerator
Deep Freezer
Television
Light (75 Watts)
Rated (Running)
Watts
1200
Additional Surge
(Starting) Watts
1800
800
500
500
75
3075 Total
Running Watts
1600
500
1800 Highest
Surge Watts
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.
Rated*
(Running)
Watts
Additional
Surge
(Starting)
Watts
75
500
800
800
1000
500
1200
1600
2000
1200
300
800
1800
600
1300
1000
1500
1500
2500
-
100
100
450
500
800
-
180
300
480
4000
520
-
1000
600
960
1000
1500
1800
1800
2000
2500
1200
960
1000
1500
1800
1800
2000
2500
*Wattages listed are approximate only. Check tool or
appliance for actual wattage.
9
4200 Watt Heavy Duty Generator
SPECIFICATIONS
and dirt buildup on the generator internal windings will
eventually decrease the insulation resistance of these
windings.
Maximum Surge Watts . . . . . . . . . . . . . . . . .5,250 watts
Continuous Wattage Capacity . . . . . . . . . . .4,200 watts
Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.0
Rated Maximum Continuous AC Load Current:
At 120 Volts . . . . . . . . . . . . . . . . . . . . . . . . .35 Amps
At 240 Volts . . . . . . . . . . . . . . . . . . . . . . .17.5 Amps
Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–phase
Rated Frequency . . . . . . . . . . . . . . . . . . . . . . .60 Hertz
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . 7 U.S. gallons
Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . . . 175 lbs.
To Clean the Generator
• 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.
GENERAL MAINTENANCE
RECOMMENDATIONS
STORAGE
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.
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, use the following guidelines to prepare it for
storage.
Engine Maintenance
Generator Storage
See engine owner’s manual for instructions.
• Clean the generator as outlined in “To Clean the
Generator.”
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.
• Check that cooling 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.
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.
Engine Storage
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
• 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 in clean and dry area.
See engine owner’s manual for instructions.
Other Storage Tips
• Do Not store gasoline from one season to another.
10
4200 Watt Heavy Duty Generator
NOTES
11
4200 Watt Heavy Duty Generator
NOTES
12
4200 Watt Heavy Duty Generator
TROUBLESHOOTING
Problem
Engine is running, but
no AC output is
available.
Engine runs good but
bogs down when
loads are connected.
Engine will not start;
or starts and runs
rough.
Engine shuts down
during operation.
Engine lacks power.
Engine “hunts” or
falters.
Cause
Solution
1.
2.
3.
Circuit breaker is open.
Poor connection or defective cord set.
Connected device is bad.
1.
2.
3.
4.
Fault in generator.
4.
1.
2.
Short circuit in a connected load.
Generator is overloaded.
1.
2.
3.
4.
Engine speed is too slow.
Shorted generator circuit.
3.
4.
Disconnect shorted electrical load.
See “Don’t Overload the Generator” on
page 9.
Contact Honda service facility.
Contact Generac service facility.
1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.
7.
Set switch to “On”.
Turn fuel valve to the “On” position.
Fill crankcase to proper level.
Clean or replace air cleaner.
Fill fuel tank.
Drain gas tank and fill with fresh fuel.
Connect wire to spark plug.
8.
9.
10.
11.
12.
13.
1.
2.
3.
1.
Engine switch set to “Off”.
Fuel valve is in the “Off” position.
Low oil level.
Dirty air cleaner.
Out of gasoline.
Stale gasoline.
Spark plug wire not connected to
spark plug.
Bad spark plug.
Water in gasoline.
Overchoking.
Excessively rich fuel mixture.
Intake valve stuck open or closed.
Engine has lost compression.
Out of gasoline.
Low oil level.
Fault in engine.
Load is too high.
8.
9.
10.
11.
12.
13.
1.
2.
3.
1.
2.
3.
1.
Dirty air filter.
Engine needs to be serviced.
Choke is opened too soon.
2.
3.
1.
2.
Carburetor is running too rich or too
lean.
2.
Replace spark plug.
Drain gas tank; fill with fresh fuel.
Set choke to “Off” position.
Contact Honda service facility.
Contact Honda service facility.
Contact Honda service facility.
Fill fuel tank.
Fill crankcase to proper level.
Contact Honda service facility.
See “Don’t Overload the Generator” on
page 9.
Replace air filter.
Contact Honda service facility.
Move choke to halfway position till engine
runs smoothly.
Contact Honda service facility.
13
Reset circuit breaker.
Check and repair.
Connect another device that is in good
condition.
Contact Generac service facility.
4200 Watt Heavy Duty Generator
SCHEMATIC
14
4200 Watt Heavy Duty Generator
WIRING DIAGRAM
15
4200 Watt Heavy Duty Generator
EXPLODED VIEW – MAIN UNIT
16
4200 Watt Heavy Duty Generator
PARTS LIST – MAIN UNIT
Item Part #
Qty
1 B189811GS
1
2 67989GS
6
3 73054GS
1
4 76222GS
2
5 70642GS
2
6 66365GGS
1
7 86307GS
4
8 91844JGS
1
9 65791GS
1
10 96796GS
1
11 47480GS
1
12 91859AGS
1
13 81917GS
1
14 84242GS
1
15 86308CGS
4
16 74908GS
4
17 B4871GS
1
18 SRV66825DGS 1
19 91825GS
1
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
66849GS
67022GS
22695GS
84409GS
B4986GS
14353621GS
82857GS
86494GS
26850GS
23762GS
B189434GS
20566GS
92982GS
77816GS
190020GS
B2153GS
B4244GS
J189818GS
189160GS
2
1
1
1
1
1
2
1
2
1
1
1
1
1
1
8
1
1
2
Description
CRADLE
NUT, M8 - 1.25, Flanged Serrated
DECAL, Fuel Shut-Off
PPHS, M8-1.25 x 40mm
MOUNT, 45° Vibration
HOUSING, Adapter
SCREW, 5/16"-24 x 3/4" SEMS
ASSEMBLY, Rotor
BEARING
WASHER, Special
BOLT, Rotor
ASSEMBLY, Stator
PIN, M4 x 10mm Roll
GROMMET, Plastic
BOLT, Stator
SCREW, M5-0.8 x 10mm
COVER, Bearing Carrier
CARRIER, Rear Bearing
ASSEMBLY, Brush & Bridge
Rectifier
SCREW, M5-0.8 x 15mm
GROMMET, Rubber
CONNECTOR, 6-pin Male
SLEEVING, Flexo, .75ft
DECAL, Ground
WIRE, Ground
MOUNT,Vibration
SCREW, M6 x 16mm Wing
WASHER, 1/4" Shakeproof
WASHER, #10 Ext. Shakeproof
COVER, Engine
DECAL, 1-800
DECAL, Danger
DECAL, Caution, Hot Muffler
SET, Decals
SCREW, Self Drill, 12 - 14 x 7/8"
PANEL, Control
HEATSHIELD, Muffler
NUT, 5/16-18, Flange Serrated
Item Part #
39 189564GS
40
41
42
43
44
45
46
47
B4605GS
BB5586GS
39287GS
22145GS
49820GS
187104GS
B4135GS
B1998AGS
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
900
B4363GS
188333GS
93826GS
78831AGS
189155GS
83465GS
78299GS
80270GS
48031CGS
30340GS
B1232GS
56893GS
BB3061BGS
B1464GS
189829GS
37806GS
43483GS
38750GS
22097GS
22473GS
45771GS
42909GS
22129GS
189127GS
NSP
Qty Description
1 CONNECTOR, Reducer, 3/16 x
1/4"
2 GRIP
2 HANDLE (Includes Item 40)
2 HHCS, M8 - 1.25 x 45
6 WASHER, Flat, 5/16 - M8
2 NUT, M8 Nylok
4 WASHER, Nylon
2 PIN, with Lanyard
1 TANK ASSY., Fuel (Includes
Items 54 & 55)
1 CAP, Fuel Gauge
1 DECAL, Instructions, Fuel Level
1 DECAL, Starting Instructions
4 HHCS, M6 - 1.0 x 45, SEMS
4 WASHER, Flat
4 GROMMET,Tank
1 BUSHING, Gas Tank
1 VALVE, Fuel
1 CLAMP, Hose Band
1 HOSE, Fuel, 1/4 ID .075ft.
1 CLAMP, Hose
1 CRIMPTITE, 10-24 x 1/2"
2 OIL BOTTLE
1 MANUAL, Engine
1 MANUAL, Owners
1 PLUG, 125V 30 Amp, 3-Prong
1 PLUG, 120/240V, 20 Amp
1 HHCS, M6 - 1.0 x 30
1 WASHER, Lock 1/4" - M6
1 WASHER, Flat 1/4" - M6
2 NUT, M8 - 1.25
2 HHCS, M8 - 1.25 x 30
2 WASHER, Lock 5/16 - M8
1 GROMMET, Bushing, Rubber
1 ENGINE
Optional Accessories Not Included:
84883GS
Cord Wrap
17
4200 Watt Heavy Duty Generator
EXPLODED VIEW AND PARTS LIST – CONTROL PANEL
Item Part #
1 NSP
2 75475GS
3 82881GS
4 82308GS
5 B2153GS
6 23365GS
7 68868GS
8 38150GS
9 22264GS
10 51715GS
11 68867GS
12 68759GS
13 75207GS
14 75207AGS
15 81919GS
16 22694GS
Qty
1
6
3
4
4
6
1
6
6
6
1
1
2
1
1
1
Description
PANEL, Control
SCREW, M4 - 0.7 x 10mm
WASHER, Internal Lock
SCREW, Self Tapping
SCREW, No. 10 Self Drilling x 7/8"
WASHER, No. 8 Serrated Lock
RECEPTACLE, 120 Volt, 30 Amp Twistlock
WASHER, No. 8 Flat
WASHER, No. 8 Lock
NUT, M4 0.7 Hex
RECEPTACLE, 120/240 Volt, 20 Amp Twistlock
OUTLET, 120 Volt, 20 amp Duplex
CIRCUIT BREAKER, 20 Amp
CIRCUIT BREAKER, 30 Amp
CONTROL PANEL, Back
CONNECTOR, 6-Pin Male
18
4200 Watt Heavy Duty Generator
EXPLODED VIEW AND PARTS LIST – WHEEL KIT
Item Part #
1 B187113GS
2 B4966GS
3 93693KGS
4 87005AGS
5 39287GS
6 B187101GS
7 27007GS
8 42909GS
9 52858GS
10 22247GS
11 39253GS
12 22145GS
13 49820GS
14 187104GS
15 B4605GS
16 B4135GS
Qty
2
2
1
2
2
1
2
2
3
2
1
6
2
4
2
2
Description
HANDLE, Assembly (Includes Item 15)
WHEEL
AXLE
PIN, Retaining
HHCS, M8 - 1.25 x 45
LEG, Support
MOUNT,Vibration
CAPSCREW, Hex Hd. M8 - 1.25 x 30
NUT, Lock M8
WASHER,Wheel
CAPSCREW, Hex Hd. - M8 - 1.25 x 20
WASHER, Flat, 5/16-M8
NUT, M8 Nylok
WASHER, Nylon
GRIP
PIN, with Lanyard
19
LIMITED WARRANTY
FOR PORTABLE GENERATORS
GENERAC PORTABLE PRODUCTS, LLC (hereafter referred to as the COMPANY) warrants to the original purchaser that the
components in its portable generator will be free from defects in materials or workmanship for the items and period set forth
below from the date of original purchase.This warranty does not include the gasoline engine when furnished or attached because
such engine is covered solely by the engine manufacturer’s warranty. Starting batteries are not warranted by the COMPANY.The
term “original purchaser” means the person for whom the generator is originally purchased.This warranty is not transferable and
applies only to portable generators driven by an overhead valve engine.
Warranty Schedule:
Commercial*
Engine
Consumer*
Warranted solely by the engine manufacturer
All other parts
2 years (2nd year parts only)
1 Year
With the exception of European Community Countries, all units bound for export shall be warranted for One (1) Year in
Consumer applications, and 90 days in Commercial applications as defined below.
*NOTE: For the purpose of this warranty "consumer use" means personal residential household use by original
purchaser.This warranty does not apply to units used for prime power in place of utility. "Commercial Use" means
all other uses, including rental, construction, commercial and income producing purposes. Once a generator has
experienced commercial use, it shall thereafter be considered a commercial use generator for the purposes of this
warranty.
During the warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination by the
COMPANY, is found to be defective under normal use and service**. All transportation costs under warranty, including return to
the factory if necessary, are to be borne by the purchaser and prepaid by the purchaser.This warranty does not cover normal
maintenance and service and does not apply to a generator set, alternator, or parts which have been subjected to improper or
unauthorized installation or alteration, misuse, negligence, accident, overloading, overspeeding, improper maintenance, repair or
storage so as, in the COMPANY’s judgement, to adversely affect its performance and reliability.
**NORMAL WEAR: As with all mechanical devices, the generator needs periodic parts service and replacement to
perform well.This warranty will not cover repair when normal wear has exhausted the life of a part or generator.
THERE IS NO OTHER EXPRESS WARRANTY.THE COMPANY HEREBY DISCLAIMS ANY AND ALL IMPLIED
WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW.THE DURATION OF ANY IMPLIED WARRANTIES
WHICH CANNOT BE DISCLAIMED IS LIMITED TO THE TIME PERIOD AS SPECIFIED IN THE EXPRESS
WARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES UNDER ANY AND ALL
WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SUCH AS THE LOSS OF TIME OR THE USE OF THE POWER EQUIPMENT, OR ANY
COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT:AND ANY IMPLIED WARRANTIES ARE
LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or
consequential damages, so the above limitations or exclusions may not apply to you.This warranty gives you specific legal rights and
you may also have other rights, which vary from state to state.
For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982. Or look on the internet at
www.generac-portables.com.Warranty service can be performed only by a COMPANY authorized service facility.This warranty will
not apply to service at any other facility. At the time of requesting warranty service, evidence of original purchase date must be
presented.
GENERAC PORTABLE PRODUCTS, L.L.C.
Jefferson,Wisconsin U.S.A.

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