GP Series
Portable Generator
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODELS: 005734-0 (15,000 Watt)
005735-0 (17,500 Watt)
Owner’s
Manual
• SAFETY
• ASSEMBLY
• OPERATION
• TROUBLESHOOTING
• WARRANTY
AUTHORIZED DEALER SUPPORT:
or
1-888-436-3722
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INTRODUCTION
DANGER
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.
Using a generator indoors WILL KILL YOU IN
MINUTES. Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.
NEVER use in the home, or in partly enclosed areas
such as garages. ONLY use outdoors and far from
open windows, doors, vents, and in an area that will
not accumulate deadly exhaust gas.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest
Authorized Dealer for starting, operating and servicing procedures.
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
After this heading, read instructions that, if not strictly
complied with, will result in serious personal injury,
including death and/or property damage.
Always disconnect the spark plug wire and place
the wire where they cannot contact the spark plug
to prevent accidental starting when setting up,
transporting, adjusting or making repairs to the
generator.
After this heading, read instructions that, if not strictly
complied with, may result in serious personal injury
and/or property damage.
• The generator produces dangerously high voltage that can cause
extremely hazardous electrical shock. Avoid contact with bare wires,
terminals, etc. Never permit any unqualified person to operate or
service 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 will result.
• The National Electric Code 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.
• Do not use worn, bare, frayed or otherwise damaged electrical cord
sets with the generator.
After this heading, read instructions that, if not strictly
complied with, could result in damage to equipment
and/or property.
NOTE:
After this heading, read explanatory statements that require special
emphasis.
These safety warnings cannot eliminate the hazards that they indicate.
Common sense and strict compliance with the special instructions while
performing the service are essential to preventing accidents.
• Operate generator only on level surfaces and where it will not be
exposed to excessive moisture, dirt, dust or corrosive vapors.
• Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE. Do
not permit 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.
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.
Never add fuel while unit is running. Allow unit to
cool entirely before adding fuel.
This symbol points out potential explosion
Do not overfill the fuel tank. Always allow room for
hazard.
fuel expansion. If tank is over-filled, fuel can overflow
This symbol points out potential fire hazard.
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.
This symbol points out potential electrical shock
hazard.
• Generator exhaust gases contain DEADLY carbon monoxide gas. This
dangerous gas, if breathed in sufficient concentrations, can cause
unconsciousness or even death. Operate this equipment only in the
open air where adequate ventilation is available.
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 if they need to operate the
equipment in an emergency.
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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's
installation site. Safety should be stressed to all operators and potential operators of this equipment.
• Never start or stop the unit with electrical loads connected to
DANGER
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.
Despite the safe design of this generator, operating
this equipment imprudently, neglecting its
maintenance or being careless can cause possible
• Do not insert objects through unit's cooling slots.
• Never operate generator: Indoors or in any enclosed compartment; in
rain; if connected electrical devices overheat; if electrical output is lost;
if engine or generator sparks; if flames or smoke are observed while
unit is running; if unit vibrates excessively.
injury or death. Permit only responsible and capable
persons to operate or maintain this equipment.
Potentially lethal voltages are generated by these
machines. Ensure all steps are taken to render the
machine safe before attempting to work on the
generator.
NOTE:
This generator is equipped with a spark arrestor muffler. 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.
Parts of the generator are rotating and/or hot during
operation. Exercise care near running generators.
GENERAL HAZARDS
• Never operate in an enclosed area or indoors.
Study these SAFETY RULES carefully before installing, operating or
servicing this equipment. Become familiar with this Owner’s Manual and
with the unit. The generator can operate safely, efficiently and reliably only
if it is properly installed, operated and maintained. Many accidents are
caused by failing to follow simple and fundamental rules or precautions.
• For safety reasons, the manufacturer recommends that the maintenance
of this equipment is carried out by an Authorized Dealer.
• The engine exhaust fumes contain carbon monoxide, which can be
DEADLY. This dangerous gas, if breathed in sufficient concentrations,
can cause unconsciousness or even death. This exhaust system must
be properly maintained. Do nothing that might render the exhaust
system unsafe or in noncompliance with any local codes and/or
standards.
WARNING:
The engine exhaust from this product contains
chemicals known to the state of California to cause
cancer, birth defects or other reproductive harm.
• Keep hands, feet, clothing, etc., away from drive belts, fans, and other
moving or hot parts. Never remove any drive belt or fan guard while
the unit is operating.
WARNING
• 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 product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
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 the manufacturer does
not specifically recommend, satisfy yourself that it is safe for others. Make
sure the procedure, work method or operating technique chosen does not
render the generator unsafe.
• When working on this equipment, remain alert at all times. Never work
on the equipment when physically or mentally fatigued.
• Inspect the generator regularly, and contact the nearest Authorized
Dealer for parts needing repair or replacement.
• Before performing any maintenance on the generator, disconnect its
battery cables to prevent accidental start up. Disconnect the cable
from the battery post indicated by a NEGATIVE, NEG or (–) first.
Reconnect that cable last.
• 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.
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IMPORTANT SAFETY INSTRUCTIONS
ELECTRICAL HAZARDS
EXPLOSION HAZARDS
• All generators covered by this manual produce dangerous electrical
voltages and can cause fatal electrical shock. Utility power delivers
extremely high and dangerous voltages as does the generator when it
is in operation. Avoid contact with bare wires, terminals, connections,
etc., while the unit is running. Ensure all appropriate covers, guards
and barriers are in place before operating the generator. If work must
be done around an operating unit, stand on an insulated, dry surface
to reduce shock hazard.
• Do not smoke around the generator. Wipe up any fuel or oil spills
immediately. Ensure that no combustible materials are left on or
near the generator, as FIRE or EXPLOSION may result. Keep the area
surrounding the generator clean and free from debris.
• Gasoline is extremely EXPLOSIVE.
STANDARDS INDEX
• Do not handle any kind of electrical device while standing in water, while
barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL
SHOCK MAY RESULT.
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.
• The National Electrical Code (NEC) requires the frame and external
electrically conductive parts of the generator to be connected to an
approved earth ground. Local electrical codes also may require proper
grounding of the generator electrical system.
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, MI
49085.
• 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.
• Never wear jewelry when working on this equipment. Jewelry can
conduct electricity resulting in electric shock, or may get caught in
moving components causing injury.
5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE.
FIRE HAZARDS
• For fire safety, the generator must be operated and maintained properly.
Operation must always comply with applicable codes, standards, laws
and regulations. Adhere strictly to local, state and national electrical
and building codes. Comply with regulations the Occupational Safety
and Health Administration (OSHA) has established. Also, ensure that
the generator is operated in accordance with the manufacturer’s
instructions and recommendations. Do not alter the construction of the
generator or change controls which might create an unsafe operating
condition.
• Keep a fire extinguisher near the generator at all times. Extinguishers
rated “ABC” by the National Fire Protection Association are appropriate
for use on the standby electric system. Keep the extinguisher properly
charged and be familiar with its use. If there are any questions
pertaining to fire extinguishers, consult the local fire department.
• Avoid spilling gasoline on a hot engine. NEVER add fuel while the unit is
running. Allow unit/engine to cool entirely before adding fuel. DO NOT
overfill the fuel tank. Always allow room for fuel expansion. NEVER fill
fuel tank indoors.
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Section 1 – General Information
1.1 UNPACKING
1.2 ASSEMBLY
• Set the palleted carton on a rigid flat surface.
The generator requires some assembly prior to using it. If problems arise
when assembling the generator, please call the Generator Helpline at
1-888-436-3722.
• Remove staples along bottom of carton that fasten carton to pallet.
Open carton from top.
• Remove all packaging material.
• Remove separate accessory box.
• Lift carton off the generator.
1.2.1 ASSEMBLING THE WHEEL KIT
The wheel kit is designed to greatly improve the portability of the
generator. A socket wrench with a 9/16” socket, a 1/2” socket, a 1/2”
wrench and a pair of pliers are the tools that will be needed for assembly
of the wheel kit.
• Remove generator from shipping pallet by removing bolts through the
shipping brackets (Figure 1).
Figure 1 - Bracket Removal
NOTE:
The wheel kit is not intended for over-the-road use.
• Refer to Figure 2 and install the wheel kit as follows:
• Place the generator on a hard flat surface.
• Stand at the engine end of the unit and gently tilt the generator forward,
high enough to place wooden blocks beneath the cradle. This will allow
space to install the wheel assemblies.
Shipping
Bracket (x4)
• Attach an axle bracket assembly with attached sleeve to either side of
the frame. Ensure the sleeve faces outward.
• Slide the axle through the sleeves on the axle brackets.
• Slide one wheel with flat washer to the outside and a spacer to the
inside onto each end of the axle. Make sure the air inflation valve on
the wheel is facing outward.
• Insert retaining pins and using pliers, bend out the ends to prevent the
pins from falling out of the axle. Remove the wooden blocks.
1.2.2 ASSEMBLING THE HANDLE
• Attach the handle by aligning one side of the handle on the cradle, then
spread the handle around the cradle and let it spring into place. Secure
the handle to the frame using the 5/16’ hex head bolts provided. Check
each fastener to ensure that it is secure.
1.1.1 ACCESSORY BOX
Check all contents. If any parts are missing or damaged locate an
authorized dealer at 1-888-436-3722.
• Using the handle, lift the unit high enough to place wooden blocks
under the unit. Attach the front support foot to the underside of the
cradle using the 3/8” carriage bolts provided.
Contents include:
• Wheel Axle
•
•
•
•
•
•
•
Bolt-on tubular handle
2 – Pneumatic Wheels
2 – Axle Bracket Assemblies
Bolt-on Foot
• Remove the shipping brackets from the cradle, if it has not already
been done.
• 2 – Washers
• 2 – Wheel Spacers
• 2 – Cotter Pins
• 2 – Spark Plugs
• Air Filter
Spark Plug Wrench
Oil Filter
• Pre-cleaner
Battery Charge Cable
• 6 – Carriage Bolts, Washers, Nuts
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Section 1 - General Information
Figure 2 - Handle Assembly
Figure 3 - Battery Connections
1.2.3 BATTERY CONNECTION
• The battery shipped with the generator has been provided fully charged.
Caution must be taken when connecting the battery.
Positive
Cable
Negative
Cable
NOTE:
A battery may lose some of it’s charge when not in use for prolonged
periods of time.
• Cut the tie wrap cable holding the RED and BLACK battery cables to
the stator.
• Connect the RED battery cable to the battery Positive terminal (+).
After making sure that the connection is tight, slip the rubber boot over
the terminal connection.
• Connect the BLACK battery cable to the battery Negative terminal (–).
Make sure the connection is tight.
• Double check all connections to ensure they are in the correct location
and secure. See Figure 3.
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Section 2 – Operation
Figure 5 - Generator Controls
2.1 KNOW THE GENERATOR
Read the Owner’s Manual and Safety Rules before operating this
generator.
11
Compare the generator to Figures 4 through 6 to become familiarized with
the locations of various controls and adjustments. Save this manual for
future reference.
7
Figure 4 - Control Panel
10
1
17
13
2
3
12
15
4
11. Fuel Tank – Tank holds 16 U.S. gallons of fuel.
12. Grounding Lug – Ground the generator to an approved earth ground
here. See "Grounding the Generator" for details.
13. Idle Control Switch – The idle control runs the engine at normal
(high) speeds when there is an electrical load present and runs the
engine at idle (low) speeds when a load is not present.
6
5
10
14. Start/Run/Stop Switch – Controls the operation of the generator.
15. Oil Fill – Use this point to add oil to engine.
16. Fuse - 10 Amp (Located at rear of control panel) – Protects the DC
control circuit from overload. If this fuse element has melted open
the engine will not be able to crank and start.
1. 12 Volt DC, 10 Amp Receptacle – This receptacle allows the
capability to recharge a 12 volt DC storage battery with provided
battery charge cables.
17. Hourmeter - Tracks hours of operation.
2. 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies electrical
power for the operation of 120 Volt AC, 20 Amp, single-phase, 60
Hz electrical lighting, appliance, tool and motor loads.
Figure 6 - Engine Control Panel
3. 120 Volt AC, 20A Duplex GFCI Receptacle – Supplies ground fault
protected electrical power for operation of 120 volt AC 20 amp,
single-phase, 60 Hz electric lighting, appliances, tools and motor
loads.
4. 120 Volt AC, 30 Amp Locking Receptacle – Supplies electrical
power for the operation of 120 Volt AC, 30 Amp, single-phase, 60
Hz electrical lighting, appliance, tool and motor loads.
5. 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.
6. 120/240 Volt AC, 50 Amp Receptacle (17.5kW, Located on
underside of control panel)– Supplies electrical power for the
operation of 120/240 Volt AC, 50 Amp, single-phase, 60 Hz, welder
or motor loads.
7. Air Cleaner – Filters intake air as it is drawn into the engine.
8. Choke Knob – Used when starting a cold engine.
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14
9
9. Winter/Summer Valve – See “Cold Weather Operation/De-icer”
section.
10. Circuit Breakers (AC) – Each receptacle is provided with a push-
to-reset circuit breaker to protect the generator against electrical
overload. (50 amp uses toggle reset)
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Section 2 – Operation
2.3.2 120 VAC, 20 AMP, GFCI RECEPTACLE
2.2 HOURMETER
The Hourmeter tracks hours of operation for scheduled maintenance:
This unit is equipped with a ground fault circuit interrupter (GFCI). This
device meets applicable federal, state and local codes (Figure 8).
There will be a one time break in "CHG OIL" message that flashes with the
elapsed time in hours and tenths after the first 30 hours of operation.
A GFCI receptacle is different from conventional receptacles. In the event
of a ground fault, a GFCI will trip and quickly stop the flow of electricity to
prevent serious injury.
This message will actually begin flashing at 29 hours and disable itself at
31 hours providing a two hour window to perform the service.
Definition: Instead of following its normal safe path, electricity passes
through a persons body to reach the ground. For example, a defective
appliance can cause a ground fault.
There will be a subsequent "CHG OIL" message every 100 hours. The
message will flash one hour before and one hour after each 100 hour
interval, again providing a two hour window to perform service.
A GFCI receptacle does NOT protect against circuit overloads, short
circuits, or shocks. For example, electric shock can still occur if a person
touches charged electrical wires while standing on a non-conducting
surface, such as a wood floor.
Every 200 hours the "SVC" icon on the lower left hand corner of the display
will flash. The message will flash one hour before and one hour after each
200 hour interval providing a two hour window to perform service.
When the hour meter is in the Flash Alert mode, the maintenance message
will always alternate with elapsed time in hours and tenths. The hours will
flash four times, then alternate with the maintenance message four times
until the meter resets itself.
Figure 8 - 120 VAC, 20 Amp GFCI Receptacle
• 30 hours - CHG OIL — Break-in Interval (First 30 hrs only)
• 100 hours - CHG OIL — Oil Change Interval (Every 100 hrs)
• 200 hours - SVC — Air Filter Interval (Every 200 hrs)
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 7). Use each socket to power 120 Volt
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.
Figure 7 - 120 Volt AC, 20 Amp, Duplex Receptacle
Testing the GFCI: Test the GFCI outlet every month as follows:
• Plug a test lamp into the receptacle.
• Start the generator, the test lamp should be on.
• Press the “Test” button located on the front of the receptacle to trip
the device.
• This should stop the flow of electricity making the lamp shut off. The
yellow trip indicator should now be on.
• To restore the flow of electricity, press the “Reset” button on the front
of the receptacle. If the GFCI does not perform in this manner, do not
use the receptacle. Contact a local service dealer.
• This outlet is protected against overload by a 20A push-to-reset
circuit breaker. Use the outlet to power 120V AC, single-phase, 60 Hz,
electrical loads requiring up to a combined 2400 watts (2.4 kW) or 20
amps of current.
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Section 2 – Operation
Figure 11 - 12 Volt DC, 10 Amp Receptacle
2.3.3 120 VAC, 30 AMP RECEPTACLE
Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire cord set
rated for 125 Volts AC at 30 Amps (or greater) to the plug (Figure 9).
Figure 9 - 120 VAC, 30 Amp Receptacle
2.3.6 120/240 VAC, 50 AMP RECEPTACLE
Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire cord set
rated for 250 Volts AC at 50 Amps to the plug (Figure 12).
Figure 12 - 120/240 VAC, 50 Amp Receptacle
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. The outlet is
protected by a 30 Amp push-to-reset circuit breaker.
2.3.4 120/240 VAC, 30 AMP RECEPTACLE
Use a NEMA L14-30 plug with this receptacle. 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 10).
Figure 10 - 120/240 VAC, 30 Amp Receptacle
50 A
Use this receptacle to operate 120/240 Volt AC, 60 Hz electrical loads
requiring up to 12,000 watts (12.0 kW) of power. This receptacle is
protected by a 50 Amp 2-pole circuit breaker.
2.4 HOW TO USE THE GENERATOR
If there are any problems operating the generator, please call the generator
helpline at 1-888-436-3722.
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 30 Amp push-to-reset circuit
breakers.
2.4.1 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 (Figure 13). Local electrical codes may
also require proper grounding of the unit. For that purpose, generally,
connecting a No. 10 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.
However, local codes may vary widely. Consult with a local electrician
for grounding requirements in the area.
2.3.5 12 VOLT DC, 10 AMP RECEPTACLE
This receptacle permits recharging a 12-Volt automotive or utility style
storage battery with the battery charge cables provided (Figure 11).
This receptacle can not recharge 6-Volt batteries and can not be used to
crank an engine having a discharged battery. See the section "Charging a
Battery" before attempting to recharge a battery.
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Section 2 – Operation
1. Figure the watts needed to start the largest motor.
Figure 13 - Grounding the Generator
2. Add to that figure the running watts of all other connected loads.
The Wattage Reference Guide is provided to assist in determining how
many items the generator can operate at one time.
NOTE:
All figures are approximate. See data label on appliance for wattage
requirements.
Generator Ground Lug
2.6 WATTAGE REFERENCE GUIDE
Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Running Watts
*Air Conditioner (12,000 Btu). . . . . . . . . . . . . . . . . . . . . . . . . . 1700
*Air Conditioner (24,000 Btu). . . . . . . . . . . . . . . . . . . . . . . . . . 3800
*Air Conditioner (40,000 Btu). . . . . . . . . . . . . . . . . . . . . . . . . . 6000
Battery Charger (20 Amp). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Circular Saw (6-1/2") . . . . . . . . . . . . . . . . . . . . . . . . . . .800 to 1000
*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5750
*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150
Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750
*Compressor (1 HP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400
Curling Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
*Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
Disc Sander (9"). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Electric Blanket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Electric Range (per element). . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250
*Freezer . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..700
*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875
*Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 to 750
Hair Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100
Hedge Trimmer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
Lawn Mower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Light Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Microwave Oven. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 to 1000
*Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100
Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . . . . . . . . . . 400
Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . . . . . . . . . . . . 225
Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . . . . . . . . . . 150
*Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . . . . . . . . . . . 600
Paint Sprayer, Airless (handheld). . . . . . . . . . . . . . . . . . . . . . . . . 150
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 200
*Refrigerator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
Slow Cooker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
*Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . 2800
*Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
*Sump Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 to 1050
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.
2.4.2 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.
• 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"
below.
2.5 DON’T OVERLOAD THE
GENERATOR
Overloading 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:
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Section 2 – Operation
*Table Saw (10") . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750 to 2000
Television . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500
Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650
Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
* Allow 3 times the listed watts for starting these devices.
Do not overfill the fuel tank. Always leave room for
fuel expansion.
• To reduce lead and carbon deposits use high quality UNLEADED
gasoline with the generator engine. Leaded REGULAR grade gasoline
is an acceptable substitute. Do not use premium gasoline. Do not mix
oil with gasoline.
2.7 BEFORE STARTING THE
GENERATOR
• Clean area around fuel fill cap, remove cap.
Prior to operating the generator, engine oil and gasoline will need to be
added, as follows:
• Slowly add unleaded regular gasoline to fuel tank. Be careful not to
overfill. Allow about 1/2" of tank space for fuel expansion, as shown
in Figure 14.
2.7.1 ADDING ENGINE OIL
• Install fuel cap and wipe up any spilled gasoline.
All oil should meet minimum American Petroleum Institute (API) Service
Class SJ, SL or better. Use no special additives. Select the oil's viscosity
grade according to the expected operating temperature (also see chart).
Figure 14 - Fuel Tank
• Above 40° F, use SAE 30
• Below 40° F and down to 10° F, use 10W-30
• Below 10° F, use synthetic 5W-30
Any attempt to crank or start the engine before it has
been properly serviced with the recommended oil
may result in an engine failure.
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.
SAE 30
10W-30
Synthetiic 5W-30
• Place generator on a level surface.
• Clean area around oil fill and remove oil fill cap and dipstick.
• Wipe dipstick clean.
The manufacturer does not recommend using any
gasoline containing alcohol (such as “gasohol”). If
using any gasoline containing alcohol, it must not
contain more than 10 percent ethanol, and it must
be removed from the generator during storage. Do
NOT use any gasoline containing methanol. If using
gasoline with alcohol, inspect more frequently for fuel
leaks and other abnormalities.
• Slowly fill engine with oil through the oil fill opening until it reaches the
full mark. Stop filling occasionally to check oil level. (Engine oil is full
when level is up to the threads of the oil fill plug.) Do not overfill.
• Install oil fill cap and finger tighten securely.
• Check engine oil level before starting each time thereafter.
2.8 TO START THE ENGINE
2.7.2 ADDING GASOLINE
Never start or stop engine with electrical devices plugged into
the receptacles AND devices turned on.
Never fill fuel tank indoors. Never fill fuel tank when
engine is running or hot. Allow unit/engine to cool
• Unplug all electrical loads from the unit's receptacles before starting
the engine.
entirely before adding fuel. DO NOT light a cigarette
or smoke when filling the fuel tank.
• Make sure the unit is in a level position.
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Section 2 – Operation
• Open the fuel shut-off valve (Figure 15).
• 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.
Figure 15 - Fuel Shut-off Valve
• When the engine starts, move choke knob to “1/2 Choke” position
until the engine runs smoothly and then fully in to the “Run” position.
If engine falters, move choke knob back out to “1/2 Choke” position
until the 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.
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 STOPPING THE ENGINE
• Shut off all loads, then unplug the electrical loads from generator panel
receptacles. Never start or stop the engine with electrical devices
plugged in and turned on.
• Locate the Idle Control ON/OFF switch on the control panel and set it
to the “OFF” position (Figure 16).
• Turn “Off” the Idle Control switch (if on).
Figure 16 - Idle Control Switch
• Let engine run at no-load for several minutes to stabilize the internal
temperatures of engine and generator.
• Move Start/Run/Stop switch to “Off” position.
• Close fuel valve.
2.10 AUTOMATIC IDLE CONTROL
This feature is designed to greatly improve fuel economy. When this switch
is turned “On,” the engine will only run at its normal fast governed engine
speed when electrical load is connected. When the load is removed, the
engine will run at a reduced speed of 2100 RPM. With the switch “Off,”
the engine runs at the normal fast engine speed all the time. Always have
the switch OFF when starting and stopping the engine.
• Move engine CHOKE knob outward to “Full Choke” position (Figure
2.11 COLD WEATHER OPERATION/
DE-ICER
17).
Figure 17 - Full Choke Position
Under certain weather conditions (temperatures below 40° F (4° C) and
a high dew point), the engine may experience icing of the carburetor
and/or the crankcase breather system. To eliminate this problem, this
generator engine is fitted with a winter/summer valve. This directs hot
air into the carburetor during cold weather operation. Always make sure
the winter/summer valve is in the correct location relative to the weather
conditions.
2.12 LOW OIL PRESSURE
SHUTDOWN SYSTEM
The engine is equipped with a low oil pressure sensor that shuts down
the engine automatically when the oil pressure drops below 10 psi. If the
engine shuts down by itself and the fuel tank has enough gasoline, check
engine oil level.
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Section 3 — Maintenance
• Connect battery charge cable clamp with red handle to the positive (+)
battery terminal.
2.12.1 INITIAL START-UP
A delay built into the low oil shutdown system allows oil pressure to build
during starting. The delay allows the engine to run for about 10 seconds
before sensing oil pressure.
• Connect battery charge cable clamp with black handle to the negative
(-) battery terminal.
• Start engine. Let the engine run while battery recharges. Engine idle
control switch must be in off position for battery charging.
2.12.2 SENSING LOW OIL PRESSURE
• When battery has charged, shut down engine.
If the system senses low oil pressure during operation, the engine shuts
down.
NOTE:
Use an automotive hydrometer to test battery state of charge and
condition. Follow the hydrometer manufacturer's instructions carefully.
Generally, a battery is considered to be at 100% state of charge when
specific gravity of its fluid (as measured by hydrometer) is 1.260 or
higher.
2.12.3 RESTARTING
If trying to restart the engine within 10 seconds after it shuts down, the
engine may NOT start. The system needs five (5) to 10 seconds to reset.
If the engine is restarted after such a shutdown and the low oil pressure
has not been corrected, the engine will run for about 10 seconds as
described above and then stop.
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
***Every Season
** Every 200 hours or Every Season
Every Season
2.13 CHARGING A BATTERY
DANGER
Storage batteries give off explosive hydrogen gas
while recharging. An explosive mixture will remain
‡
*
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.
around the battery for a long time after it has been
charged. The slightest spark can ignite the hydrogen
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or other
serious injury.
** 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.
DANGER
Do not permit smoking, open flame, sparks or any
other source of heat around a battery. Wear protective
3.2 PRODUCT SPECIFICATIONS
goggles, rubber apron and rubber gloves when
working around a battery. Battery electrolyte fluid is
an extremely caustic sulfuric acid solution that can
cause severe burns. If spill occurs flush area with
clear water immediately.
3.2.1 GENERATOR SPECIFICATIONS
MODEL
15 KW
15.0 kW
22.5 kW
120/240
17.5 KW
17.5 kW
26.25 kW
120/240
Rated Max. Power
Surge Power
This generator has the capability of recharging a discharged 12 Volt
automotive or utility style storage battery. Do not use the unit to charge
any 6 Volt batteries. Do not use the unit to crank an engine having a
discharged battery.
Rated AC Voltage
Rated Max AC Load
Current @ 240V
Current @ 120V
Rated Frequency
Phase
62.5 Amps
72.9 Amps
This battery charger is a pulse type designed to provide a quality charge
current into the battery. The voltage measured at the outlet should be 8-12
VDC. This is normal and does not indicate a faulty charging system.
125.0 Amps
145.8 Amps
60 Hz @ 3600 RPM 60 Hz @ 3600 RPM
To recharge 12 Volt batteries, proceed as follows:
Single Phase
12 Volts
Single Phase
12 Volts
Rated DC Voltage
Rated Max DC Load
Current @ 12 Volts
Weight
• Check fluid level in all battery cells. If necessary, add ONLY distilled
water to cover separators in battery cells. Do not use tap water.
• If the battery is equipped with vent caps, make sure they are installed
and are tight.
10 Amperes
373 lbs.
10 Amperes
400 lbs.
• If necessary, clean battery terminals.
• Connect battery charge cable connector plug to panel receptacle
identified by the words "12-VOLT D.C."
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Section 3 — Maintenance
3.2.2 ENGINE SPECIFICATIONS
3.3.2 TO CLEAN THE GENERATOR
• Use a damp cloth to wipe exterior surfaces clean.
Rated Horsepower @ 3600 RPM 30
• A soft, bristle brush may be used to loosen caked on dirt, oil, etc.
• A vacuum cleaner may be used to pick up loose dirt and debris.
Displacement
Spark Plug Type
Spark Plug Gap
Gasoline Capacity
Oil Type
992cc
Champion RC14YC or Equivalent
0.040 inch or (1.01 mm)
16 U.S. gallons
• 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.
Summer – SAE 30, Winter –
3.3.3 ENGINE MAINTENANCE
5W-30 Synthetic or 10W-30
Oil Capacity
w/ Filter Change = 1.7 Qts., w/o
Filter Change = 1.4 Qts.
DANGER
When working on the generator, always disconnect
negative cable from battery. Also disconnect spark
plug wires from spark plugs and keep wire away from
spark plugs.
Run Time/Fuel Consumption-1/2
Load
10 Hours / 1.6 gallons per hour
3.3 GENERAL RECOMMENDATIONS
3.3.4 CHECKING OIL LEVEL
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.
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.
Some adjustments will need to be made periodically to properly maintain
the generator.
Hot oil may cause burns. Allow engine to cool before
All adjustments in the Maintenance section of this manual should be made
at least once each season. Follow the requirements in the "Maintenance
Schedule" chart.
draining oil. Avoid prolonged or repeated skin
exposure with used oil. Thoroughly wash exposed
areas with soap.
NOTE:
3.3.5 CHANGING THE OIL AND OIL FILTER
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.
Change the oil and filter after the first 30 hours of operation. Change the
oil every 100 hours thereafter. If running this unit under dirty or dusty
conditions, or in extremely hot weather, change the oil more often.
3.3.1 GENERATOR MAINTENANCE
NOTE:
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.
Whenever possible, run engine for approximately five (5) minutes to
get the engine oil hot. This will aid in draining the oil.
Use the following instructions to change the oil while the engine is still
warm:
Check the cleanliness of the generator frequently and clean when dust,
dirt, oil, moisture or other foreign substances are visible on its exterior
surface.
• Clean area around oil drain hose and plug.
• Remove oil drain plug from end of hose and oil fill plug to drain oil
completely into a suitable container.
• When oil has completely drained, install oil drain plug and tighten
securely.
Never insert any object or tool through the air cooling
slots, even if the engine is not running.
• Place a suitable container beneath the oil filter and turn filter
counterclockwise to remove. Discard according to local regulations.
• Coat gasket of new filter with clean engine oil. Turn filter clockwise until
gasket contacts lightly with filter adapter. Then tighten an additional
3/4 turn.
NOTE:
DO NOT use a garden hose to clean generator. Water can enter 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.
• Fill oil sump with recommended oil. (See “Before Starting the
Generator” for oil recommendations).
• Wipe up any spilled oil.
• Dispose of used oil at a proper collection center.
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Section 3 — Maintenance
To clean or replace paper air filter:
3.3.6 REPLACING THE SPARK PLUGS
• Remove air cleaner cover; then remove foam pre-filter (service if
necessary) and remove paper filter.
Use Champion RC14YC spark plug or equivalent. The correct air gap is
1.01 mm (0.040 in.). Replace the plugs once each year. This will help
the engine start easier and run better.
• Clean paper filter by tapping it gently on a solid surface. If the filter is
too dirty, replace it with a new one. Dispose of the old filter properly.
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.
• Clean air cleaner cover then slip pre-cleaner over filter. Next insert new
paper filter into the base of the air cleaner. Re-install air cleaner cover.
NOTE:
3. Set the spark plug's gap to 1.01 mm (0.040 in.). Install the correctly
gapped spark plug into the cylinder head.
To order a new air filter, please contact the nearest authorized service
center at 1-800-333-1322.
Figure 18 - Spark Plug Gap
3.5 CLEAN SPARK ARRESTOR
SCREEN
The engine exhaust muffler has a spark arrestor screen. Inspect and clean
the screen at least once each year (Figure 20). If unit is used regularly,
inspect and clean more often.
NOTE:
If using the generator on any forest-covered, brush-covered or grass-
covered unimproved land, it must equipped with a spark arrestor. The
spark arrestor must be maintained in good condition by the owner/
operator.
3.4 SERVICE AIR CLEANER
The engine will not run properly and may be damaged if using a dirty air
cleaner. Clean or replace the air cleaner paper filter every 200 hours. Clean
or replace more often if operating under dusty conditions. Clean foam pre-
cleaner every month or more often under dusty conditions.
Clean and inspect the spark arrestor as follows:
• Remove the screen retaining bracket by removing the screw.
• Slide the spark arrestor screen out from the tail pipe.
Figure 19 - Air Cleaner
• Inspect screen and replace if torn, perforated or otherwise damaged.
DO NOT USE a defective screen. If screen is not damaged, clean it with
commercial solvent.
Cover
• Replace the screen and the retaining bracket.
Figure 20 - Spark Arrestor
Pre-Cleaner
Base
Filter
To clean or replace foam pre-cleaner:
• Remove air cleaner cover, then foam pre-filter.
• Wash pre-cleaner in soapy water. Squeeze pre-filter dry in clean cloth
(DO NOT TWIST).
• Clean air cleaner cover before re-installing it.
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Section 3 — Maintenance
When valve clearance is correct, hold the pivot ball stud in place with the
allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to
174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to
make sure it did not change.
3.6 ADJUSTING VALVE CLEARANCE
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 or 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 insure longest life for the engine.
• Install new valve cover gasket.
• Re-attach the valve cover.
NOTE:
To check valve clearance:
Start all four screws before tightening or it will not be possible to get all
the screws in place. Make sure the valve cover gasket is in place.
• Make sure the engine is at room temperature (60° - 80° F).
• Make sure that the spark plug wire is removed from the spark plug and
out of the way.
• Re-attach the spark plug wire to the spark plug.
• Repeat the process for the other cylinder.
• Remove the four screws attaching the valve cover.
• Make sure the piston is at Top Dead Center (TDC) of its compression
stroke (both valves closed). To get the piston at TDC, remove the
intake screen at the front of the engine to gain access to the flywheel
nut. Use a large socket and socket wrench to rotate the nut and hence
the engine in a clockwise direction while watching the piston through
the spark plug hole. The piston should move up and down. The piston
is at TDC when it is up as high as it can go.
3.7 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.
• Insert a 0.002 - 0.004 inch (0.05 - 0.1mm) feeler gauge between the
rocker arm and valve stem. Correct clearance is when a slight drag is
felt when sliding the gauge back and forth. If the clearance is either
excessively loose or tight the rocker arms will need adjusting.
DANGER
NEVER store engine with fuel in tank indoors or
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.
To adjust valve clearance:
• Loosen the rocker jam nut (Figure 21). Use an 10mm allen wrench to
turn the pivot ball stud while checking clearance between the rocker
arm and the valve stem with a feeler gauge. Correct clearance is
0.002-0.004 inch (0.05-0.1 mm).
3.8 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,
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.
Figure 21 - Valve Clearance Adjustment
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.
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 plugs and pour about 1/2 ounce (15 ml) of engine oil
into the cylinders. Cover spark plug hole with rag. Press the “Start”
button and allow engine to crank for 2 seconds. Then press the “Stop”
button.
NOTE:
The rocker arm jam nut must be held in place as the pivot ball stud
is turned.
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Section 3 — Maintenance
3.9 OTHER STORAGE TIPS
• Do not store gasoline from one season to another.
Avoid spray from spark plug holes when cranking
engine.
• 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
• Install and tighten spark plugs. Do not connect spark plug wires.
dust and dirt. BE SURE TO EMPTY THE FUEL TANK.
• Clean the generator outer surfaces. Check that cooling air slots and
openings on generator are open and unobstructed.
• If it is not practical to empty 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.
• Store the unit in a clean, dry place.
• Cover the unit with a suitable protective cover that does not retain
moisture.
DANGER
NEVER cover the generator while engine and/or
exhaust area are warm.
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Section 4 — Troubleshooting
4.1 TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
CORRECTION
Engine is running, but no AC
output is available.
1. Circuit breaker is open.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in good
condition.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Fault in generator.
4. Contact Authorized Service Facility.
Engine runs good but
bogs down when loads are
connected.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator” .
3. Contact Authorized Service Facility.
4. Contact Authorized Service Facility.
Engine will not crank.
1. 10 amp fuse at rear of generator control panel
has melted open.
1. Replace fuse with only an identical 10-amp
replacement fuse.
2. Battery weak or dead.
2. Recharge or replace battery.
Engine will not start; or
starts and runs rough.
1. Dirty air cleaner.
2. Out of gasoline.
1. Clean or replace air cleaner.
2. Fill fuel tank.
3. Stale gasoline.
4. Spark plug wire not connected to spark plug.
5. Bad spark plug.
3. Drain fuel tank and fill with fresh fuel.
4. Connect wire to spark plug.
5. Replace spark plug.
6. Water in gasoline.
7. Overchoking.
8. Low oil level.
9. Excessive rich fuel mixture.
10. Intake valve stuck open or closed.
11. Engine has lost compression.
6. Drain fuel tank; fill with fresh fuel.
7. Put choke knob to No Choke position.
8. Fill crankcase to proper level.
9. Contact Authorized Service Facility.
10. Contact Authorized Service Facility.
11. Contact Authorized Service Facility.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Authorized Service Facility.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
1. See “Don’t Overload the Generator”.
2. Replace air filter.
3. Engine needs to be serviced.
3. Contact Authorized Service Facility.
Engine “hunts” or falters.
1. Choke is opened too soon.
2. Carburetor is running too rich or too lean.
1. Move choke to halfway position until engine
runs smoothly.
2. Contact Authorized Service Facility.
No Battery Charge DC
output.
1. Battery posts are corroded.
2. Battery cable is bad.
3. Battery is defective.
4. Receptacle is bad.
1. Clean battery posts.
2. Replace cable.
3. Check battery condition; replace if defective.
4. Contact Authorized Service Facility.
17
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Section 5 – Warranty
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System warranty on
your new engine. In California, new off-road Large Spark-Ignition (LSI) engines must be designed, built and equipped to meet the state's stringent anti-smog
standards. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect,
unapproved modification or improper maintenance of your engine.
Your emission control system may include parts such as the carburetor, ignition system, exhaust system and crankcase ventilation system. Generac will repair
your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 2001 and later model year LSI engines are warranted for two years as hereinafter noted. If, during such warranty period any
emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by a
Generac Authorized Warranty Service Dealer.
PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES:
As the engine owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner's Manual. For warranty
purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely due to the
lack of receipts or for your failure to ensure the completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility if your engine, or a
part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or the use of counterfeit and/or "grey market"
parts not made, supplied or approved by Generac.
You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs. The warranty repairs should be completed in a
reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer. To locate the Generac Authorized
Warranty Service Dealer nearest you, call our toll free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty), which is
provided to you by Generac pursuant to California law. See also the "Generac Limited Warranties for Generac Power Systems, Inc.," which is enclosed herewith
on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict
in terms between the ECS Warranty and the Generac Warranty, the ECS warranty shall apply except in circumstances where the Generac Warranty may provide
a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented
showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at one of the following addresses:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Part 1
18
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Section 5 – Warranty
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS warranty) for 2001 and later model year LSI engines:
(a) Applicability: This warranty shall apply to 2001 and later model year engines. The ECS Warranty period shall begin on the date the new
engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months
thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment and
to each subsequent purchaser/owner that each of its engines are:
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted emissions-
related part to fail to be identical in all material respects to the part as described in the engine manufacturer's application for certification.
The ECS Warranty pertains only to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner's Manual shall be
warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac
according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of
the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for
the ECS Warranty Period. A statement in such written instructions to the effect of "repair or replace as necessary" shall not reduce the ECS
Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty
Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted
for the period of time prior to first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part
shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under
the ECS warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such
emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at
a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for
diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components caused by a failure under warranty of any emission-related part
covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected
demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS warranty
maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac ECS Warranty
obligations.
(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts nay not be used to modify or repair a Generac engine. Such use voids
this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for
failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or "grey
market" part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
3) Ignition System including:
a) Spark plug
b) Ignition module
1.2) LPG/Natural Gas carburetion assembly and its internal components.
a) Fuel controller (if so equipped)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)
5) Crankcase Breather Assembly including:
a) Breather connection tube
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
* Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Portable Generator
4) Standby Generator
Part 2
19
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Section 5 – Warranty
GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR
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, repair 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
YEARS ONE and TWO - 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):
• Engine- All Components
• Alternator- All Components
COMMERCIAL/RENTAL APPLICATION
YEAR ONE – 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):
• Engine- All Components
• Alternator- 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 Generac’s Warranty Policies, Procedures and Flat Rate Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Generac built portable generators built prior to May 2008.
• Generac portable generators that utilize non-Generac replacement parts.
• Costs of normal maintenance and adjustments.
• Failures caused by any contaminated fuels, oils or lack of proper oil levels.
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac Power Systems.
• 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.
• Failures caused 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.
• 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).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.
• Expenses related to “customer instruction” or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Overnight freight or special shipping costs for replacement part(s).
• Overtime, holiday or emergency labor.
• 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. 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 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.
P.O. BOX 8 • Waukesha, WI 53187
Ph: (888) GENERAC (436-3722) • Fax: (262) 544-4851
Part No. 0G9451
Revision D (10/27/08)
Printed in U.S.A.
Part No. 0H0676
Rev. B (02/18/09)
Printed in U.S.A.
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