Owners Manual
Contents
1. 10 3 3 5 Changing the 10 3 3 6 Replacing the Spark 10 3 4 Service Air 11 3 5 Valve 11 36 11 3 7 LONG Stragi ieissa iaaii n 11 3 8 Storage Tips 11 Troubleshooting 12 4 1 Troubleshooting 12 E E 13 1 Back Cover Introduction INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc This model is a compact high performance air cooled engine driven generator designed to supply electrical power to operate electrical loads where no utility power is available or in place of utility due to a power outage READ THIS MANUAL THOROUGHLY any portion of this manual is not understood contact the nearest Authorized Dealer for starting operating and servicing procedures The operator is responsible for proper and safe use of the equipment We strongly recommend that the operator read this manual and thoroughly understand all instructions before using the equipment We also strongly recommend instructing other users to properly start and operate the unit This prepares them if2. 2000 Compressor 3 4 HP 1800 Compressor 1 2 1400 Curling ION 700 Une DENUMIGIEL 2 650 Disc Sander 1200 Edge TRIMMED 500 50 0 35 40 60 8 16 Electri Blankets Reed tees at iori a 400 a Ga a E 5 a Electric Nall 1200 Electric Range 1500 Electric Skillet 1 1250 700 CAUTION Fath 3 5 875 Any attempt to crank or start the engine Garage Door 500 to 750 before it has been properly serviced with the Hair Dryer 1200 recommended oil may result in an engine Hand 250 to 1100 failure Hedge MME 2 exc odes eed ea ed wena eked 450 Impact Wrench 00 0 cece 500 Place generator on a level surface o 2 POM 1200 e Clean area around fill and remove fill cap and dipstick da eden 800 e Wipe dipstick clean 1200 e Slowly fill engine with through the fill opening until it Light SUID tentials 100
3. 2 5 Don t Overload the 2 6 Wattage Reference 2 7 Before Starting the 2 7 1 Adding Engine 2 7 2 Adding 2 8 Starting Pull Start 2 9 Starting Electric Start 2 10 Stopping the ENGINE sincan 2 11 Low Oil Level Shutdown System 2 11 1 Sensing Low Oil Maintenance 9 3 1 Maintenance 5 9 3 2 5 9 3 2 1 Generator 9 3 2 2 Engine 9 3 3 General 10 3 3 1 Generator 10 3 3 2 Clean the 10 3 3 3 Engine 10 3 3 4 Checking Oil
4. Insert the Cotter Pin through the Axle Pin then bend the tabs of the Cotter Pins outward to lock into place 2 Refer to Figure 1 and install the Frame Foot and Rubber Bumpers as shown Slide the Rubber Bumper studs through the Frame Foot then install the Locking Flange Nuts e Slide the Hex Head Bolts through the holes in the Frame Rail e Slide the Frame Foot onto the Hex Head Bolts then install the Locking Flange Nuts 3 Refer to Figure 1 and install the Handle as shown Slide the long Bolts through the Handle Bracket and Handle then install the Hex Nuts Figure 1 Wheel amp Handle Assembly M8 BOLT M8 ACORN NUT HANDLE ASSEMBLY K AXLE PIN 2X WHEEL 9 1 2 FLAT 7 2X RUBBER X M8 NUT 1 2 2 STARTER CONNECTION ELECTRIC START ONLY The unit has been deliberately shipped with the starter cable disconnected To connect starter 1 Locate starter cable 2 Pull vinyl boot back onto starter cable 3 Remove nut and washer from starter post 4 Put starter cable onto post and re install washer and nut 2 1 KNOW THE GENERATOR Read the Owner s Manual and Safety Rules before operating this generator Compare the generator to Figures 2 through 4 to become familiarized with the locations of various controls and adjustments Save this manual for future reference 1 120 Volt AC 20 Amp Duplex Receptacle Supplies electrical power for
5. asl 500 Allow 3 times the listed watts for starting these devices 2 7 BEFORE STARTING THE GENERATOR 2 6 WATTAGE REFERENCE GUIDE Prior to operating the generator engine oil and gasoline will need to be added as follows All figures are approximate See data label on appliance for wattage requirements Running Watts Air Conditioner 12 000 1700 Air Conditioner 24 000 3800 2 7 1 ADDING ENGINE OIL Air Conditioner 40 000 6000 All oil should meet minimum American Petroleum Institute API Battery Charger 20 500 Service Class SJ SL or better Use no special additives Select Belt Sander 3 reccs cece cece cece e nes 1000 the oil s viscosity grade according to the expected operating Chan tone agi mage Hays ines 1200 temperature also see chart Circular Saw 6 1 2 800 to 1000 5 Clothes Dryer Electric 5750 Clothes Dryer GaS 700 e Below 40 F and down to 10 F use 10W 30 Clothes 5 1150 e Below 10 F use synthetic SW 30 Coffee 1750 Gompressor 1
6. 1 Reset circuit breaker 2 Check and repair 3 Connect another device that is in good condition 4 Contact Authorized Service Facility 1 Disconnect shorted electrical load 2 See Don t Overload the Generator 3 Contact Authorized Service Facility 4 Contact Authorized Service Facility Turn Fuel Shut off ON Clean or replace air filter Fill fuel tank Drain fuel tank and fill with fresh fuel Connect wire to spark plug Replace spark plug Drain fuel tank fill with fresh fuel Put choke knob to No Choke position 9 Fill crankcase to proper level 10 Contact Authorized Service Facility 11 Contact Authorized Service Facility 12 Contact Authorized Service Facility 1 Fill fuel tank 2 Fill crankcase to proper level 3 Contact Authorized Service Facility 1 Reduce load see Don t Overload the Generator 2 Clean or replace air filter 3 Contact Authorized Service Facility 1 Move choke to halfway position until engine runs smoothly 2 Contact Authorized Service Facility 13 POWER SYSTEMS TWO YEAR LIMITED WARRANTY GP SERIES PORTABLE GENERATORS For a period of two years from the date of original sale Generac Power Systems Inc Generac warrants its GP Series generators will be free from defects in materials and workmanship for the items and period set forth below Generac will at its option repai
7. Owner s Manual GP Series Portable Generator CONTA Q 28 27 SS N N R i lt 1 0 Read this Manual a peer Standards Halen eden General 1 Tel SUMPAGKING 1 1 1 Accessory 1 2 1 Assembling the Accessory 1 2 2 Starter Connection Electric Start 2 1 the 2 3 Sets and Connection 2 3 1 120 VAC 20 Amp Duplex Receptacle 2 3 2 120 240 VAC 30 Amp 2 4 How to Use the 2 41 Grounding the 2 4 2 Connecting Electrical 1 0 05
8. 2 PRODUCT SPECIFICATIONS 3 2 1 GENERATOR SPECIFICATIONS 5 0 5 5 6 5 kW Surge 6 25 6 88 8 0 kW Rated AG Voltage eninin 120 240 Rated AC Load Current 240V 5 0 5 5 6 5 20 8 22 9 27 1 Amps Current 120V 5 0 5 5 6 5 41 6 45 8 54 2 Amps Rated Frequent 60 Hz 3600 RPM PIAS Co Single Phase Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine condition etc Maximum power decreases about 3 5 for each 1 000 feet above sea level and will also decrease about 1 for each 6 C 10 F above 16 C 60 F ambient temperature 3 2 2 ENGINE SPECIFICATIONS 989 Spark Plug LDF7TC Champion N9YC Spark Plug 0 028 0 031 inch or 0 70 0 80 mm Gasoline Capacity 7 2 U S gallons Oil See Chart in Before Starting the Generator Section Qil Capacity sirina a 1 L 1 06 Qts Run Time at 50 Load 5 0 5 5 6 5 10 Hours Class 1 Emission Certified The engine manufacturer must warrant the emission control system for a period of two years This warranty coverage is in addition to the warranty p
9. CHOKE position Figure 10 To start engine press and hold the Start Run Stop switch in the Start position The engine will crank and attempt to start When the engine starts release the switch to the run position e When the engine starts move choke knob to 1 2 Choke position until the engine runs smoothly and then fully in to the position If engine falters move choke knob back out to 1 2 Choke position until the engine runs smoothly and then to position This generator is also equipped with a manual recoil starter which may be used if the battery is discharged NOTE The switch must be in the RUN position To start manually firmly grasp the recoil handle and pull slowly until increased resistance is felt Pull rapidly up and away to start engine Then follow the same choke sequence NOTE If engine fires but does not continue to run move choke lever to FULL CHOKE and repeat starting instructions IMPORTANT Do not overload the generator Also do not overload individual panel receptacles These outlets are protected against overload with push to reset type circuit breakers If amperage rating of any circuit breaker is exceeded that breaker opens and electrical output to that receptacle is lost Read Don t Overload the Generator carefully 2 10 STOPPING THE ENGINE Shut off all loads then unplug the electrical loads from generator panel receptacles Never start or stop the e
10. REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC 8 Waukesha WI 53187 Ph 888 GENERAC 436 3722 Fax 262 544 4851 To locate the nearest Authorized Dealer visit our website www generac com Part No 8902 Revision A 05 19 10 Manual Part No 9059 Rev A 05 19 10 Printed in China
11. This product contains or emits chemicals known to the State of California to cause cancer birth defects and other reproductive harm General Information 1 1 UNPACKING e Remove all packaging material e Remove separate accessory box e Remove the generator from carton 1 1 1 ACCESSORY BOX Check all contents If any parts are missing or damaged locate an authorized dealer at 1 888 436 3722 e 1 Owner s Manual 1 Handle Assembly e 1 Liter Oil SAE 30 1 Frame Foot 2 Never Flat Wheels 1 Battery Charger electric start only e 1 Hardware Bag containing the following e 2 Rubber Feet e 2 8 Bolt Long 2 1 2 Axle Pins 2 8 Bolts Short 2 Cotter Pins e 2 8 Acorn Nut e 2 1 2 Flat Washers 4 Flanged M8 Nuts 1 2 ASSEMBLY The generator requires some assembly prior to using it If problems arise when assembling the generator please call the Generator Helpline at 1 888 77LOWES 1 2 1 ASSEMBLING THE ACCESSORY KIT The wheels are designed into the unit to greatly improve the portability of the generator You will need the following tools to properly install the accessory kit e Needle Nose Pliers e Ratchet and 13mm 1 2 socket e 13mm 1 2 box wrench NOTE The wheels are not intended for over the road use 1 Refer to Figure 1 and install the Wheels as follows Slide the Axle Pins through the Wheel 1 2 Flat Washer and Wheel Bracket on the frame
12. start engine firmly grasp the recoil handle and pull slowly until increased resistance is felt Pull rapidly up and away e When engine starts move choke knob to 1 2 CHOKE position until engine runs smoothly and then fully into RUN position If engine falters move choke back out to 1 2 CHOKE position until engine runs smoothly and then to RUN position NOTE If engine fires but does not continue to run move choke lever to FULL CHOKE and repeat starting instructions Figure 9 Fuel Shut off Valve Figure 10 Choke Position CHOKE LEVER LEFT CHOKE RIGHT RUN A IMPORTANT Do not overload the generator Also do not overload individual panel receptacles These outlets are protected against overload with push to reset type circuit breakers If amperage rating of any circuit breaker is exceeded that breaker opens and electrical output to that receptacle is lost Read Don t Overload the Generator carefully 2 9 STARTING ELECTRIC START ENGINES AWARNING Never start or stop engine with electrical devices plugged into the receptacles AND devices turned on e Unplug all electrical loads from the unit s receptacles before starting the engine Make sure the unit is in a level position Open the fuel shut off valve Figure 9 Move engine CHOKE knob outward to FULL
13. the fuel tank and the unit is to be stored for some time use a commercially available fuel stabilizer added to the gasoline to increase the life of the gasoline e Cover the unit with a suitable protective cover that does not retain moisture DANGER NEVER cover the generator while engine and exhaust area are warm 11 Troubleshooting 4 1 TROUBLESHOOTING GUIDE 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 hunts or falters 12 1 Circuit breaker is open 2 Poor connection or defective cord set 3 Connected device is bad 4 Fault in generator 1 Short circuit in a connected load 2 Generator is overloaded 3 Engine speed is too slow 4 Shorted generator circuit Fuel Shut off is OFF Dirty air filter Out of gasoline Stale gasoline Spark plug wire not connected to spark plug Bad spark plug Water in gasoline Overchoking 9 Low oil level 10 Excessive rich fuel mixture 11 Intake valve stuck open or closed 12 Engine has lost compression 1 2 3 4 5 6 7 8 1 Out of gasoline 2 Low oil level 3 Fault in engine 1 Load is too high 2 Dirty air filter 3 Engine needs to be serviced 1 Choke is opened too soon 2 Carburetor is running too rich or too lean CORRECTION
14. the operation of 120 Volt AC 20 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 2 120 240 Volt AC 30 Amp Locking Receptacle Supplies electrical power for the operation of 120 and or 240 Volt AC 30 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 3 Circuit Breakers AC Each receptacle is provided with a push to reset circuit breaker to protect the generator against electrical overload Oil Drain Use to drain engine oil Air Filter Filters intake air as it is drawn into the engine Choke Knob Used when starting a cold engine Fuel Tank See generator Specifications for tank capacity Grounding Lug Ground the generator to an approved earth ground here See Grounding the Generator for details 9 Run Stop Switch Controls the operation of the generator pull start models only 9A Start Switch Used to start engine from the starter motor electric start models only 10 Muffler Quiets the engine gt 18 19 Figure 2 Control Panel Handle Pivot and retract for storage Press the spring loaded button to move handles Gas Cap Fuel fill location Fuel Gauge Shows fuel level in tank Oil Fill Add oil here Recoil Starter Use to start engine manually Fuel Shut Off Valve between fuel tank and carburetor Bat
15. this generator be properly connected to an approved earth ground Figure 7 Local electrical codes may also require proper grounding of the unit For that purpose connecting a No 10 AWG American Wire Gauge stranded copper wire to the grounding lug and to an earth driven copper or brass grounding rod electrode provides adequate protection against electrical shock However local codes may vary widely Consult with a local electrician for grounding requirements in the area 6 Figure 7 Grounding the Generator Proper grounding of the generator will help prevent electrical shock in the event of a ground fault condition in the generator or in connected electrical devices Proper grounding also helps dissipate static electricity which often builds up in ungrounded devices 24 2 CONNECTING ELECTRICAL LOADS DO NOT connect 240 Volt loads to 120 Volt receptacles DO NOT connect 3 phase loads to the generator DO NOT connect 50 Hz loads to the generator e Let engine stabilize and warm up for a few minutes after starting Plug in and turn on the desired 120 or 240 Volt AC single phase 60 Hz electrical loads Add up the rated watts or amps of all loads to be connected at one time This total should not be greater than a the rated wattage amperage capacity of the generator or b circuit breaker rating of the receptacle supplying the power See Don t Overload the Generator 2 5 DON T OVERLOAD THE GENERATOR O
16. D gasoline with the generator engine Do not use any gasoline with more than 10 added ethanol Do not use E85 gasoline Do not mix oil with gasoline e Clean area around fuel fill cap remove cap e Slowly add unleaded regular gasoline to fuel tank Fill to bottom of screen filter Be careful not to overfill Figure 8 e Install fuel and wipe up any spilled gasoline Figure 8 Fuel Tank Fuel Tank Fuel DO NOT Fill Above Lip IMPORTANT It is important to prevent gum deposits from forming in fuel system parts such as the carburetor fuel hose or tank during storage Alcohol blended fuels called gasohol ethanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer See the Storage section Never use engine or carburetor cleaner products in the fuel tank as permanent damage may occur 2 8 STARTING PULL START ENGINES AWARNING Never start or stop engine with electrical devices plugged into the receptacles AND devices turned on Unplug all electrical loads from the unit s receptacles before starting the engine Make sure the unit is in a level position OPEN the Fuel Shut off Valve Figure 9 Turn engine RUN STOP switch to ON position Slide engine choke to the LEFT to FULL CHOKE position Figure 10 To
17. H IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY WARNING Indicates a hazardous situation or action which if not avoided could result in death or serious injury A CAUTION Indicates a hazardous situation or action which if not avoided could result in minor or moderate injury NOTE Notes contain additional information important to a procedure and will be found within the regular text body of this manual These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety information that if not followed could endanger personal safety and or property of others This symbol points potential explosion sA hazard Ay This symbol points out potential fire hazard This symbol points out potential electrical shock hazard GENERAL HAZARDS Never operate in an enclosed area or indoors For safety reasons the manufacturer recommends that the maintenance of this equipment is carried out by an Authorized Dealer Inspect the generator regularly and contact the nearest Authorized Dealer for parts needing repair or replacement Operate generator only on level surfaces an
18. aused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earth quake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing e Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s e Failure due to misapplication e Telephone cellular phone facsimile internet access or other communication expenses e Expenses related to customer instruction or troubleshooting where no manufacturing defect is found e Rental equipment used while warranty repairs are being performed Overnight freight or special shipping costs for replacement part s Overtime holiday or emergency labor e Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Any implied warranties allowed by law shall be limited in duration to the terms of the express warranty provided herein Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE
19. d where it will not be exposed to excessive moisture dirt dust or corrosive vapors Keep hands feet clothing etc away from drive belts fans and other moving parts Never remove any fan guard or shield while the unit is operating Certain parts of the generator get extremely hot during operation Keep clear of the generator until it has cooled to avoid severe burns Do NOT operate generator in the rain Do not alter the construction of the generator or change controls which might create an unsafe operating condition Never start or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON Start the engine and let it stabilize before connecting electrical loads Disconnect all electrical loads before shutting down the generator Do not insert objects through unit s cooling slots When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Safety Rules Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc On electric start models disconnect the POSITIVE battery cable from the engine starter OR the NEGATIVE battery cable from the battery terminal whichever is easier before transporting the generator NOTE This generator is equipped with a spark arrestor m
20. ean and free from debris and keep a Clearance of five 5 feet on all side to allow for proper ventilation of the generator Safety Rules Do not insert objects through unit s cooling slots Do not operate the generator if connected electrical devices MODEL NO overheat if electrical output is lost if engine or generator sparks or if flames or smoke are observed while unit is running e Keep a fire extinguisher near the generator at all times STANDARDS INDEX In the absence of pertinent standards codes regulations and laws the published information listed below may be used as a guideline for operation of this equipment Always reference the latest revision available for the standards listed 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE 2 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 3 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 4 ASAE EP 3634 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph 49085 CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNING
21. hanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer as follows Remove all gasoline from the fuel tank A DANGER Drain fuel into approved container outdoors away from open flame Be sure engine is cool Do not smoke Start and run engine until engine stops from lack of fuel While engine is still warm drain oil from crankcase Refill with recommended grade Remove spark plug and pour about 1 2 ounce 15 ml of engine oil into the cylinders Cover spark plug hole with rag Pull the recoil starter a couple times to lubricate the piston rings and cylinder bore A CAUTION Avoid spray from spark plug hole when cranking engine e Install and tighten spark plug Do not connect spark plug wire e Clean the generator outer surfaces Check that cooling air slots and openings on generator are open and unobstructed e Store the unit in clean dry place 3 8 OTHER STORAGE TIPS e Do not store gasoline from one season to another e Replace the gasoline can if it starts to rust Rust and or dirt in the gasoline will cause problems with the carburetor and fuel system If possible store the unit indoors and cover it to give protection from dust and dirt BE SURE TO EMPTY THE FUEL TANK If it is not practical to empty
22. if equipped to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG first Reconnect that cable last In case of accident caused by electric shock immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a non conducting implement such as a rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help FIRE HAZARDS Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flames sparks or heat in the vicinity while handling gasoline Never add fuel while unit is running or hot Allow engine to cool completely before adding fuel Never fill fuel tank indoors 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 over filled fuel can overflow onto a hot engine and cause FIRE or an EXPLOSION Never store generator with fuel in tank where gasoline vapors might reach an open flame spark or pilot light as on a furnace water heater or clothes dryer FIRE or EXPLOSION may result Allow unit to cool entirely before storage Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left on or near the generator Keep the area surrounding the generator cl
23. ngine 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 e Move Run Stop switch to OFF position e Close fuel valve 2 11 LOW OIL LEVEL SHUTDOWN SYSTEM The engine is equipped with a low oil level sensor that shuts down the engine automatically when the oil level drops below a specified level If the engine shuts down by itself and the fuel tank has enough gasoline check engine oil level 2 11 1 SENSING LOW OIL LEVEL If the system senses a low oil level during operation the engine shuts down The engine will not run until the oil has been refilled to the proper level 3 1 MAINTENANCE SCHEDULE Follow the calendar intervals More frequent service is required when operating in adverse conditions noted below Check Oil Level Change Oil Check Valve Clearance Service Air Filter Replace Spark Plug At Each Use Every 100 hours or Every Season Fvery Season Every 200 hours or Every Season Every Season Change oil after first 30 hours of operation then every season Change oil and oil filter every month when operating under heavy load or in high temperatures Clean more often under dirty or dusty operating conditions Replace air filter parts if they cannot be adequately cleaned Check valve clearance and adjust if necessary after first 50 hours of Operation and every 100 hours thereafter 3
24. oil Thoroughly wash exposed areas with soap Use the following instructions to change the oil after the engine cools down Clean area around oil drain plug Remove oil drain plug from engine and oil fill plug to drain oil completely into a suitable container e When oil has completely drained install oil drain plug and tighten securely Fill engine with recommended oil See Before Starting the Generator for oil recommendations e Wipe up any spilled oil e Dispose of used oil at a proper collection center 3 3 6 REPLACING THE SPARK PLUG Use Champion N9YC spark plug or equivalent Replace the plug once each year This will help the engine start easier and run better 1 Stop the engine and pull the spark plug wire off of the spark plug 2 Clean the area around the spark plug and remove it from the cylinder head Set the spark plug s gap to 0 70 0 80 mm 0 028 0 031 Install the correctly gapped spark plug into the cylinder head Figure 11 Figure 11 Spark Plug Gap Maintenance 3 4 SERVICE AIR FILTER The engine will not run properly and may be damaged if using a dirty air filter Clean the air filter every 200 hours or once a year Figure 12 Clean or replace more often if operating under dusty conditions Remove air filter cover e Wash in soapy water Squeeze filter dry in clean cloth DO NOT TWIST e Clean air filter cover before re installing it NOTE To
25. olt AC single phase 60 Hz electrical loads requiring up to a combined 2400 watts 2 4 kW or 20 Amps of current Use only high quality well insulated 3 wire grounded cord sets rated for 125 Volts at 20 Amps or greater Keep extension cords as short as possible preferably less than 15 feet long to prevent voltage drop and possible overheating of wires 5 Figure 5 120 Volt AC 20 Amp Duplex Receptacle 2 3 2 120 240 VAC 30 RECEPTACLE Use a NEMA 114 30 plug with this receptacle rotate to lock unlock Connect a suitable 4 wire grounded cord set to the plug and to the desired load The cord set should be rated for 250 Volts AC at 30 Amps or greater Figure 6 Figure 6 120 240 VAC 30 Amp Receptacle 120V 240V 30A Use this receptacle to operate 120 Volt AC 60 Hz single phase loads requiring up to 3600 watts 3 6 kW of power at 30 Amps or 240 Volt AC 60 Hz single phase loads requiring up to 7200 watts 7 2 kW of power at 30 Amps The outlet is protected by two 25 Amp 5 0 5 5kW or two 30 Amp 6 5kW push to reset circuit breakers 2 4 HOW TO USE THE GENERATOR lf there are any problems operating the generator please call the generator helpline at 1 888 436 3722 2 4 1 GROUNDING THE GENERATOR The National Electrical Code requires that the frame and external electrically conductive parts of
26. order a new air filter please contact the nearest authorized service center at 1 888 436 3722 Figure 12 Air Filter CLIPS 3 5 VALVE CLEARANCE e Intake 0 15 0 02mm cold 0 006 0 0008 inches e Exhaust 0 0020 0 02mm cold 0 008 0 0008 inches After the first 50 hours of operation check the valve clearance in the engine and adjust if necessary Important If feeling uncomfortable about doing this procedure the proper tools are not available please take the generator to the nearest service center to have the valve clearance adjusted This is a very important step to ensure longest life for the engine 3 6 GENERAL The generator should be started at least once every seven days and be allowed to run at least 30 minutes If this cannot be done and the unit must be stored for more than 30 days use the following information as a guide to prepare it for storage A DANGER M NEVER store engine with fuel in tank indoors Aor in enclosed poorly ventilated areas where fumes may reach an open flame spark or pilot light as on a furnace water heater clothes dryer or other gas appliance A Allow unit to cool entirely before storage 3 1 LONG TERM STORAGE It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor fuel hose or tank during storage Also experience indicates that alcohol blended fuels called gasohol et
27. r occurs first Limited comprehensive coverage on labor and parts listed All COMPONENTS NOTE For the purpose of this warranty consumer use means personal residential household or recreational use by original purchaser This warranty does not apply to units used for Prime Power in place of utility where utility power service is present or where utility power service does not normally exist Once a generator has experienced commercial or rental use it shall thereafter be considered a non consumer use generator for the purpose of this warranty All warranty expense allowances are subject to the conditions defined in the Generac Service Policy Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac built portable generators built prior to June 2010 e Generac portable generators that utilize non Generac replacement parts e Costs of normal maintenance and adjustments e Failures caused by any contaminated fuels oils or lack of proper oil levels Repairs or diagnostics performed by individuals other than Generac authorized dealers not authorized in writing by Generac Power Systems e Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper use As with all mechanical devices the Generac engines need periodic part s service and replacement to perform as designed This warranty will not cover repair when normal use has exhausted the life of a part s or engine e Failures c
28. r or replace any part which upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Dealer is found to be defective Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac GP Series portable generators and is not transferable from original purchaser Save your proof of purchase receipt If you do not provide proof of the initial purchase date the manufacturer s shipping date of the product will be used to determine the warranty period WARRANTY SCHEDULE Consumer applications are warranted for two 2 years Commercial and Rental applications are warranted for one 1 year or 1000 hours maximum whichever comes first CONSUMER APPLICATION YEAR ONE 100 one hundred percent coverage on Labor and Part s proof of purchase and maintenance is required All Components YEAR TWO 100 one hundred percent coverage on Part s proof of purchase and maintenance is required All Components COMMERCIAL RENTAL APPLICATION YEAR ONE 100 one hundred percent or 1 000 hours whichever occurs first coverage on Labor and Part s proof of purchase and maintenance is required All Components INTERNATIONAL YEAR ONE or 1000 hours whicheve
29. r the exhaust system unsafe or in noncompliance with any local codes and or standards Always use a battery operated carbon monoxide alarm indoors installed according to the manufacturers instructions you start to feel sick dizzy or weak after the generator has been running move to fresh air IMMEDIATELY See a doctor as you could have carbon monoxide poisoning ELECTRICAL HAZARDS The generator produces dangerously high voltage when in operation Avoid contact with bare wires terminals connections etc while the unit is running even on equipment connected to the generator Ensure all appropriate covers guards and barriers are in place before operating the generator Never handle any kind of electrical cord or device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electric Code NEC requires the frame and external electrically conductive parts of the generator be properly connected to an approved earth ground Local electrical codes may also require proper grounding of the generator Consult with a local electrician for grounding requirements in the area Use a ground fault circuit interrupter in any damp or highly conductive area such as metal decking or steel work Do not use worn bare frayed or otherwise damaged electrical cord sets with the generator Before performing any maintenance on the generator disconnect the engine starting battery
30. reaches the full mark Stop filling occasionally to check oil level Microwave 700 to 1000 Be careful not to over fill pe e Install oil fill cap and finger tighten securely Oi Fred Space Heater 40000 Bu oil tevel before starting each time Oil Fired Space Heater 85 000 225 Oil Fired Space Heater 30 000 150 2 7 2 ADDING GASOLINE Paint Sprayer Airless 1 3 600 ADANGER Paint Sprayer Airless 150 50 to 200 Never fill fuel tank indoors Never fill fuel tank PPOTMOSNAON aie 700 when engine is running or hot Avoid spilling SlOW COOKEr cece cette teenies 200 gasoline engine Allow engine Submersible Pump 1 1 2 2800 entirely before filling fuel tank DO NOT light Submersible Pump 1 5000 cigarette or smoke when filling the fuel tank A Do not overfill the fuel tank Always leave room AA for fuel expansion If the fuel tank is overfilled fuel can overflow onto a hot engine and cause FIRE or EXPLOSION Wipe up any spilled fuel immediately Do not light a cigarette ro smoke whin filling the fuel tank Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE e Use regular UNLEADE
31. rovided by Generac and may cover the engine even if Generac s warranty does not Maintenance 3 3 GENERAL RECOMMENDATIONS The warranty of the generator does not cover items that have been subjected to operator abuse or negligence To receive full value from the warranty the operator must maintain the generator as instructed in this manual Some adjustments will need to be made periodically to properly maintain the generator All adjustments in the Maintenance section of this manual should be made at least once each season Follow the requirements in the Maintenance Schedule NOTE Once a year replace the spark plug and replace the air filter A new spark plug and clean air filter assure proper fuel air mixture and help the engine run better and last longer 3 3 1 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 Check the cleanliness of the generator frequently and clean when dust dirt oil moisture or other foreign substances are visible on its exterior surface A CAUTION Never insert any object or tool through the air cooling slots even if the engine is not running NOTE DO NOT use a garden hose to clean generator Water can en
32. ter the engine fuel system and cause problems In addition if water enters the generator through cooling air slots some water will be retained in voids and crevices 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 3 3 2 CLEAN THE GENERATOR Use a damp cloth to wipe exterior surfaces clean A soft bristle brush may be used to loosen caked on dirt oil etc e A vacuum cleaner may be used to pick up loose dirt and debris e Low pressure air not to exceed 25 psi may be used to blow away dirt Inspect cooling air slots and openings on the generator These openings must be kept clean and unobstructed 3 3 3 ENGINE MAINTENANCE A DANGER When working on the generator always disconnect spark plug wire from spark plug and keep wire away from spark plug 10 3 3 4 CHECKING OIL LEVEL See the Before Starting the Generator section for information on checking the oil level The oil level should be checked before each use or at least every eight hours of operation Keep the oil level maintained 3 3 9 CHANGING THE OIL Change the oil after every 100 hours If running this unit under dirty or dusty conditions or in extremely hot weather change the oil more often A CAUTION Hot oil may cause burns Allow engine to cool before draining oil Avoid prolonged or repeated skin exposure with used
33. tery Charger Input This receptacle allows the capability to recharge the 12 volt DC storage battery provided with the 12 Volt Adaptor Plug Charger which is included in the Accessory Box Located behind the battery charger input is a 1 50 Amp in line fuse which is inside the control panel to protect the batter electric start only Battery Powers the electric starter electric start only Hourmeter Tracks hours of operation Figure 3 Generator Controls Operation Figure 4 Generator Controls 2 2 HOURMETER Operation Push and release the mode button to toggle between functions To reset service alert depress and hold down button for 9 seconds while in the alert to be cleared Service Alert Features When service is required soon a message will flash temporarily interrupting the hour display The message will continue to display until it is reset by the operator When a service interval reaches 0 hours the word NOW replaces the hours remaining e 30 hours CHG OlL one time break in interval e 100 hours CHG OIL Oil change interval Every 100 hours e 200 hours SVC FILTER Air filter Interval Every 200 hours e 200 hours SVC SPARK PLUG Spark Plug Interval Every 200 hours 2 3 CORD SETS AND CONNECTION PLUGS 2 3 1 120 VAC 20 AMP_DUPLEX RECEPTACLE This is a 120 Volt outlet protected against overload by a 20 Amp push to reset circuit breaker Figure 5 Use each socket to power 120 V
34. they need to operate the equipment in an emergency The generator can operate safely efficiently and reliably only if it is properly located operated and maintained Before operating or servicing the generator Become familiar with and strictly adhere to all local state and national codes and regulations Study all safety warnings in this manual and on the product carefully Become familiar with this manual and the unit before use The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique utilized does not render the generator unsafe THE INFORMATION CONTAINED HEREIN WAS BASED ON MACHINES IN PRODUCTION AT THE TIME OF PUBLICATION GENERAC RESERVES THE RIGHT TO MODIFY THIS MANUAL AT ANY TIME SAFETY RULES Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows DANGER INDICATES A HAZARDOUS SITUATION OR ACTION WHIC
35. uffler The Spark arrestor must be maintained in effective working order by the owner operator In the State of California a spark arrestor is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands EXHAUST amp LOCATION HAZARDS Never operate in an enclosed area or indoors NEVER use in the home or in partly enclosed areas such as garages even if doors and windows are open ONLY use outdoors and far from open windows doors vents and in an area that will not accumulate deadly exhaust A DANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell A NS Ela Only use OUTSIDE and far away from windows doors and vents 9 NEVER use inside a home or garage EVEN IF doors and windows are open The engine exhaust fumes contain carbon monoxide which can you cannot see or smell This poisonous gas if breathed in sufficient concentrations can cause unconsciousness or even death Adequate unobstructed flow of cooling and ventilating air is Critical to correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator The generator MUST be operated outdoors This exhaust system must be properly maintained Do nothing that might rende
36. verloading a generator in excess of its rated wattage capacity can result in damage to the generator and to connected electrical devices Observe the following to prevent overloading the unit Add up the total wattage of all electrical devices to be connected at one time This total should NOT be greater than the generator s wattage capacity The rated wattage of lights can be taken from light bulbs The rated wattage of tools appliances and motors can usually be found on a data label or decal affixed to the device If the appliance tool or motor does not give wattage multiply volts times ampere rating to determine watts volts x amps watts Some electric motors such as induction types require about three times more watts of power for starting than for running This surge of power lasts only a few seconds when starting such motors Make sure to allow for high starting wattage when selecting electrical devices to connect to the generator 1 Figure the watts needed to start the largest motor Submersible Pump 1 2 1500 2 Add to that figure the running watts of all other connected A SUMP PUMP 800 to 1050 loads 1750 to 2000 The Wattage Reference Guide is provided to assist in determining tae 200 to 500 how many items the generator can operate at one time TOASTEN 1000 to 1650 NOTE Weed 191
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