GP7500E - Generator Generac - Free user manual and instructions

USER MANUAL GP7500E Generac

SAVE THIS MANUAL FOR FUTURE REFERENCE

(000209b) WARNING Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury. BCTable of Contents

Section 1 Introduction and Safety 1

• Introduction p. 1
• Safety Rules p. 1
• Safety Symbols and Meanings p. 1
• Exhaust and Location Hazards p. 2
• Electrical Hazards p. 3
• Fire Hazards p. 3
• Standards Index p. 3
• Replacement Hazard Labels p. 3

Section 2 General Information and

• Operation and Use Questions p. 13
• Before Starting Engine p. 13
• Verify engine oil level is correct p. 13
• Prepare Generator for Use p. 13
• Grounding the Portable Generator 13 Know Generator Limits p. 14
• Transporting/Tipping of the Unit Starting Gasoline Pull Start Engines . p. 15

Section 4 Maintenance and

• Troubleshooting p. 18
• Maintenance p. 18
• Maintenance Schedule p. 18
• Preventive Maintenance p. 18
• Engine Maintenance p. 18
• Battery Replacement (if applicable) 20 Inspect Muffler and Spark Arrestor 20 Valve Clearance p. 21
• Storage p. 21
• Troubleshooting p. 23
• Wiring Diagram (000759a) CALIFORNIA WARNING Can expose you to benzene, a carcinogen and reproductive toxicant www.P65Warnings.ca.gov.Owner’s Manual for Portable Generator 1 p. 25

Section 1 Introduction and Safety

Introduction Read This Manual Thoroughly If any section of this manual is not understood, contact the nearest Independent Authorized Service Dealer (IASD) or Generac Customer Service at 1-888-436-3722 (1-888-GEN- ERAC), or visit www.generac.com for start- ing, operating, and servicing procedures. The owner is responsible for proper maintenance and safe use of the unit. SAVE THESE INSTRUCTIONS for future ref- erence. This manual contains important instructions that must be followed during placement, operation, and maintenance of the unit and its components. Always supply this manual to any individual that will use this unit, and instruct them on how to correctly start, operate, and stop the unit in case of emer- gency. The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice. Safety Rules The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The alerts in this manual, and on tags and decals affixed to the unit, are not all inclu- sive. If using a procedure, work method, or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others and does not render the equipment unsafe. Throughout this publication, and on tags and decals affixed to the unit, DANGER, WARN- ING, 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. Alert definitions are as follows: NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual. These safety alerts cannot eliminate the haz- ards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents. Safety Symbols and Meanings

• If 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 poison- ing. (000100a)Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and product could result in death or serious injury. WARNING (000001) DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. (000002) WARNING Indicates a hazardous situation which, if not avoided,could result in death or serious injury. (000003) CAUTION Indicates a hazardous situation which, if not avoided,could result in minor or moderate injury. DANGERUsing a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.NEVER use inside a home or garage, EVEN IF doors and windows are open.Only use OUTSIDE and far away from windows, doors, and vents.

(000103) DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury. (000179b) DANGER2 Owner’s Manual for Portable Generator

• For safety reasons, it is recommended that the maintenance of this equipment be per- formed by an IASD. Inspect the generator regularly, and contact the nearest IASD for parts needing repair or replacement. Exhaust and Location Hazards

• If 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 poison- ing.

• NEVER run a generator indoors or in a partly enclosed area such as garages.

• ONLY use outdoors and far away from win- dows, doors, vents, crawl spaces and in an area where adequate ventilation is avail- able and will not accumulate deadly exhaust gas.

• Point muffler exhaust away from people and occupied buildings.

• Using a fan or opening a door will not pro- vide sufficient ventilation. (000104)DANGERElectrocution. Water contact with a power source, if not avoided, will result in death or serious injury. (000116)DANGERElectrocution. Turn utility and emergencypower supplies to OFF before connecting power source and load lines. Failure to do so will result in death or serious injury. (000146) WARNING Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator. (000178a) WARNING Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury. WARNING Equipment and property damage. Do not operate unit on uneven surfaces, or areas of excessive moisture, dirt, dust or corrosive vapors. Doing so could result in death, serious injury, property and equipment damage. (000250) (000111)WARNINGMoving Parts. Keep clothing, hair, and appendagesaway from moving parts. Failure to do so could result in death or serious injury. (000108) WARNING Hot Surfaces. When operting machine, do not touch hot surfaces. Keep machine away from combustables during use. Hot surfaces could result in severe burns or fire. (000142a) WARNING Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage. Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to operate or service this equipment and could result in death or serious injury. (000215a) WARNING (000216) WARNING Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury.

(000103) DANGER Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury. (000179b) DANGER (000178a) WARNING Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury. (000146) WARNING Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.Owner’s Manual for Portable Generator 3 Electrical Hazards

• National Electric Code (NEC) requires the frame and external electrically conductive parts of the generator be properly con- nected 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 (GFCI) in any damp or highly conductive area (such as metal decking or steel work).

• Once generator has been started outside, connect electrical loads to extension cord(s) inside. Fire Hazards

• Allow at least five (5) feet of clearance on all sides of the generator when operating to prevent overheating and fire.

• Do not operate the generator if connected electrical devices overheat, if electrical out- put is lost, if engine or generator sparks, or if flames or smoke are observed while unit is running.

• Keep a fire extinguisher near the generator at all times. Standards Index

TION AND SAFETY CODE available from www.nfpa.org

3. International Building Code available from

nance of Farm Standby Electric Power available from www.asabe.org, American Society of Agricultural & Biological Engi- neers 2950 Niles Road, St. Joseph, MI

generators for installation and use, in accordance with the Rules of the Cana- dian Electrical Code

7. ANSI/PGMA G300 Safety and Perfor-

mance of Portable Generators. Portable Generator Manufacturer’s Association, www.pgmaonline.com IMPORTANT NOTE: This list is not all inclusive. Check with the Authority Having Jurisdiction (AHJ) for any local codes or standards which may be applicable to your jurisdiction. Replacement Hazard Labels The following replacement hazard labels are available free from Generac:

• 0H0115D (000144)DANGERElectrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury. (000104) DANGER Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury. (000145) DANGER Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury. (000105) DANGER Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure todo so will result in death or serious injury. (000166b) DANGER Explosion and Fire. Do not overfill fuel tank. Fill to 1/2 inch from top of tank to allow for fuel expansion. Overfilling may cause fuel to spill onto engine causing fire or explosion, which will result in death or serious injury. (000174) DANGER Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury. (000142a) WARNING Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage.4 Owner’s Manual for Portable Generator

Section 2 General Information and Setup

186 Owner’s Manual for Portable Generator Figure 2-3. Unit Identification Label Know Your Generator Replacement owner’s manuals are available at www.generac.com. Emissions The United States Environmental Protection Agency (US EPA) (and California Air Resources Board (CARB), for engines/equip- ment certified to California standards) requires this engine/equipment to comply with exhaust and evaporative emissions standards. Locate the emissions compliance decal on the engine to determine applicable standards. See the included emissions warranty for emissions warranty information. Follow the maintenance specifications in this manual to ensure the engine complies with applicable emissions standards for the duration of the product’s life.

(000100a)Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and product could result in death or serious injury. WARNING Product Specifications Generator Specifications GP7500E DF-CO Rated Power @1.0 Power Factor 7.5 kW** (Gas) / 6.8 kW (LP) Surge Power 9.4 kW (Gas) / 8.5 kW (LP) Rated AC Voltage 120/240 Rated AC Load Current @ 240V** Current @ 120V**

Rated Frequency 60 Hz @ 3600 RPM Phase Single Phase Weight (dry) Pounds (lb) Kilograms (kg)

** Operating Temperature Range: -18 deg. C (0 deg. F) to 40 Deg. C (104 Deg. F). When operated above 25 deg. C (77 deg. F) there may be a decrease in power. ** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambi- ent 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. 7.5kW Engine Specifications Displacement 420 cc Spark Plug Part No. 0J00620106 Spark Plug Type Bosch F7TC or equivalent Spark Plug Gap 0.028-0.031 inch or (0.70-0.80 mm) Gasoline Capacity 30.0 L (7.9 gal) Oil Type See Chart in Add Engine Oil Oil Capacity 1.0 L (1.06 qt.) Run Time at 25% / 50% Load (Gas) 14 / 10 Hours / (LP*) 7.5 / 5 Hours (*LP run times are based on a 20lb cylinder)

• Go to Generac.com or contact an IASD for replacement parts.Owner’s Manual for Portable Generator 7 Hour Meter See Figure 2-4. The Hour Meter tracks hours of operation for scheduled maintenance.

• The CHG OIL display will illuminate every 100 hours. The message will flash one hour before and one hour after each 100 hour interval, providing a two hour window to perform service.

• The SVC display will illuminate every 100 hours. The message will flash one hour before and one hour after each 200 hour interval providing a two hour window to per- form service. When the hour meter is in flash alert mode, the maintenance message will 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 automatically resets.

• 100 hours - CHG OIL — Oil Change Inter- val (Every 100 hrs)

• 200 hours - SVC — Service Air Filter (Every 200 hrs) NOTE: The hour glass icon will flash when the engine is running. This signifies the meter is recording hours of operation. Figure 2-4. Hour Meter Connection Plugs 120 VAC, 20 Amp, GFCI Duplex Receptacle See Figure 2-5. The 120 Volt outlet is overload protected by a 20 Amp push-to-reset circuit breaker. Each receptacle will power 120 Volt AC, single phase, 60 Hz electrical loads requiring up to 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). It also pro- vides protection with a Ground Fault Circuit Interrupter with a press to TEST and RESET button. Figure 2-5. 120 VAC, 20 Amp, GFCI Duplex Receptacle NEMA 5-20R 120/240 VAC, 30 Amp Receptacle See Figure 2-6. Use a NEMA L14-30 plug with this receptacle (rotate to lock/unlock). Connect a suitable 4-wire grounded cord set to plug and desired load. The cord set should be rated 250 Volts AC at 30 Amps (or greater). 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 one 30 Amp 2-pole circuit breaker. Figure 2-6. 120/240 VAC, 30 Amp Receptacle NEMA L14-30R COsense

Carbon Monoxide (CO) Detection and Shut-off System (if equipped) The COsense module monitors for the accu- mulation of poisonous CO gas found in engine exhaust when the generator is running. If COsense detects increasing levels of CO gas, it automatically shuts off the engine. COsense only monitors when the engine is running. Generators are intended to be used outdoors, far from occupied buildings and the exhaust pointed away from personnel and buildings. However, if mis-used and operated in a loca- tion that results in the accumulation of CO, like indoors or in a partially enclosed area,

0002048 Owner’s Manual for Portable Generator COsense shuts off the engine, notifies the user of what has happened and directs the user to read the instruction action label for steps to take. See Figure 2-7. COsense is not a substitute for an indoor carbon monoxide alarm. See Figure 2-8. After a shut-off, a blinking RED light in the COsense badge on the side of the generator provides notification that the generator was shut off due to an accumulating CO hazard. The RED light will blink for at least five minutes after a CO shut-off. Move the generator to an open, outdoor area and point the exhaust away from people and occupied buildings. Once relocated to a safe area, the generator can be restarted and the proper electrical connections made to supply electri- cal power. The RED light will stop blinking automatically upon engine re-start. Introduce fresh air and ventilate the location where the generator had shut down. See Figure 2-8. If a COsense system fault has occurred and no longer provides protection, the portable generator is shut off automatically and the YELLOW light will blink for at least five minutes in the COsense badge to notify the user of the fault. The COsense module can only be diagnosed and repaired by a trained technician at the dealer. The generator can be re-started, but may continue to shut- off. COsense will detect the accumulation of Car- bon Monoxide from other fuel burning sources such as engine powered tools or propane heaters used in the area of operation. For example, if another generator is used and the exhaust is pointed at a COsense equipped generator, COsense may initiate a shut-off due to rising CO levels. This is not an error. Hazardous Carbon Monoxide has been detected. The user must take action to move and re-direct these devices to better dissipate Carbon Monoxide far away from personnel and occupied buildings. Figure 2-7. Instruction Action Label Figure 2-8. Instruction Badge

1. Open carton completely by cutting each

corner from top to bottom.

2. Remove and verify carton contents prior to

assembly. Carton contents should contain the following: Accessories

3. Call Generac Customer Service 1-888-

GENERAC (1-888-436-3722) with the unit model and serial number for any missing carton contents.

4. Record model, serial number, and date of

purchase on front cover of this manual. Assembly Call Generac Customer Service at 1-888- GENERAC (1-888-436-3722) for any assem- bly issues or concerns. Please have model and serial number available. The following tools are required to install the accessory kit.

• 8mm Wrench (2) (electric start only)

• 19mm Wrench NOTE: The wheels are not intended for over- the-road use. See Figure 2-9. Install wheels as follows:

1. Slide axle pin (E) through the wheel (B),

wheel bracket on frame, and 1/2” flat washer (G).

2. Insert cotter pin (F) through axle pin (E).

Bend tabs (of cotter pins) outward to lock into place. Install frame foot and rubber bumpers as fol- lows:

1. Slide hex head bolts (L) through rubber

bumper (D), then through frame foot (C) (if not pre-assembled).

2. Slide hex head bolts (K) through holes in

(K). Install locking flange nuts (J). Figure 2-9. Wheel & Foot Assembly See Figure 2-10. Install handle as follows:

1. Slide long bolts (K) through handle bracket

and handle (A). Install hex nuts (J). Item Qty. Main Unit 1 Owner’s Manual 1 Liter Oil SAE 30 1 Handle Assembly (A) 1 Never-flat Wheel (B) 2 Frame Foot (C) 2 Product Registration Card 3 Service Warranty 1 Emissions Warranty 1 25’ Power Cord (if equipped) 1 Battery Charger (electric start mod- els)

1st Stage LP Regulator and Hose 1 Hardware Bag Qty. Rubber Feet (D) 2 1/2” Axle Pin (E) 2 Cotter Pin (F) 2 1/2” Flat Washer (G) 2 Hex Flanged M6 Nut (H) 2 Hex Flanged M8 Nut (J) 6 M8 Bolt (Long) (K) 6 M6 Bolt (Long) (L) 2 M8 Nylon Flat Washer (M) 4 (000100a)Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and product could result in death or serious injury. WARNING

B10 Owner’s Manual for Portable Generator Figure 2-10. Handle Assembly Battery Cable Connection (electric start only) The unit has been shipped with the battery cables disconnected. See Figure 4-5. You will need two 8mm box wrenches to connect the battery cables.

1. Cut off cable ties securing battery cables

and remove red cover from battery termi- nal.

2. First, connect the red cable to the positive

(+) battery terminal with the bolt and nut supplied.

3. Make sure connections are secure and

slide rubber boot over the positive (+) bat- tery terminal and connection hardware.

4. Connect the black cable to the negative (-)

battery terminal with the bolt and nut sup- plied. Slide rubber boot over the negative (-) battery terminal and connection hard- ware.

5. Make sure all connections are secure.

NOTE: If the battery is unable to start the engine, charge it with the 12V charger included in the accessory box (see the Charging the Battery (electric start units only) section for details). Add Engine Oil

1. Place generator on a level surface.

2. Verify oil fill area is clean.

3. See Figure 2-11. Remove oil fill cap/dip-

stick and wipe dipstick clean. Figure 2-11. Remove Dipstick

4. Add recommended engine oil as shown in

the following chart. NOTE: Use petroleum based oil (supplied) for engine break-in before using synthetic oil. NOTE: Some units have more than one oil fill location. It is only necessary to use one oil fill point. NOTE: Verify oil level often during filling pro- cess. DO NOT overfill.

5. Thread dipstick into oil filler neck. Oil level

is checked with dipstick fully installed.

6. See Figure 2-12. Remove dipstick and ver-

ify oil level is within safe operating range. Figure 2-12. Safe Operating Range

7. Install oil fill cap/dipstick and hand-tighten.

(000135)Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage. CAUTION

(000105)Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury. DANGEROwner’s Manual for Portable Generator 11 Fuel requirements are as follows:

• Clean, fresh, unleaded gasoline.

• Minimum rating of 87 octane/87 AKI (91 RON).

• Up to 10% ethanol (gasohol) is acceptable (where available; non-ethanol fuel is rec- ommended).

• DO NOT use a gas oil mix.

• DO NOT modify engine to run on alternate fuels. Stabilize fuel prior to storage.

1. Verify unit is OFF and cooled for a mini-

mum of two minutes prior to fueling.

2. Place unit on level ground in a well venti-

3. Clean area around fuel cap and remove

mended fuel (A). Do not overfill (B).

5. Install fuel cap.

Figure 2-13. Add Recommended Fuel NOTE: Allow spilled fuel to evaporate before starting unit. IMPORTANT NOTE: It is important to pre- vent 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. LP Requirements NOTE: LP vapor 1st stage regulator inlet pressure is approximately 30 psi at 0 °F, and 218 psi at 100 °F. Use only standard 20 or 30 pound capacity LP cylinders with Type 1, right hand Acme threads with this generator. Verify qualification date on cylinder has not expired. Do not use rusted or damaged cylinders. All new cylinders must be purged of air and moisture prior to filling. Used cylinders that have not been plugged or kept closed must also be purged. The purging process should be done by the propane gas supplier. (Cylinders from an exchange supplier should have been purged and properly filled by supplier).

1. Remove safety plugs or caps from cylinder

valve, generator mounted regulator, and regulator connecting hose ends.

2. See Figure 2-14. With LP tank closed,

attach LP regulator connecting hose into valve. Turn plastic coupling from the hose right (clockwise) to tighten hose assembly onto LP tank. Figure 2-14. Connect Hose Assembly to LP Tank (000199) DANGER Explosion and Fire. LP vapors are extremely flammable and explosive. Do not use or store LP cylinder in a building, garage, or enclosed area except as authorized by NFPA 58 or B149.2 (Canada). Failure to do so will result in death or serious injury. (000200)WARNINGExplosion and fire. The cylinder valve should be left off (closed) when generator is not in use. Failure to do so could result in death or serious injury. (000106b) Fluid Injection. This machine produces high-pressure fluid streams that can pierce skin. Fluid injection could result in death or serious injury. WARNING

(000201) WARNING Risk of burns. Contact with liquid contents of cylinder will cause freeze burns to the skin. If liquid contents contacts skin or eyes, seek immediate medical attention. (000128a) WARNING Personal injury. Keep out of reach of children. Failure to do so could result in death or serious injury. 00260512 Owner’s Manual for Portable Generator

3. See Figure 2-15. Connect opposite regula-

tor connecting hose end to generator at mounted LP primary regulator with the 19mm wrench. Figure 2-15. Connect Hose to Regulator

4. See Figure 2-16. Turn LP tank valve ON

and check for leaks by spraying soapy water to check connections. If bubbles appear, become larger in size, or increase in number, a leak exists. NOTE: Always position cylinder so the con- nection between the valve and regulator won’t cause sharp bends or kinks in hose. Figure 2-16. Turn LP Tank Valve On NOTE: If a leak exists, this must be corrected before using generator. Contact your local IASD for assistance. NOTE: When transporting and storing, keep cylinder secured in an upright position with cylinder valve turned off and the outlet plugged. Keep cylinders away from heat and ventilated when in a vehicle.

Operation and Use Questions Call Generac customer service at 1-888-GEN- ERAC (1-888-436-3722) with questions or concerns about equipment operation and maintenance. Before Starting Engine Verify engine oil level is correct.

1. Verify engine oil level is correct.

2. Verify correct fuel is selected.

3. If using gasoline, verify fuel level is correct.

4. If using LP, verify the fuel hose is properly

connected to the LP cylinder and the sec- ond stage regulator.

5. If using LP, verify the LP cylinder is located

away from the muffler, the cylinder is not empty and the fuel valve is open.

6. Verify unit is secure on level ground, with

proper clearance and is in a well ventilated area. Prepare Generator for Use Grounding the Portable Generator See Figure 3-1. The portable generator is equipped with a terminal for the connection of a field grounding electrode conductor where a grounding electrode system is required by NEC Article 250.34(A). The equipment grounding conductor terminals of the genera- tor receptacles are bonded to the generator frame. Where the generator supplies power to cord and plug connected equipment, like power tools, the frame of the generator is not required by the NEC to be connected to a field grounding electrode. The generator neutral conductor is bonded to the generator frame in accordance with NEC Article 250.34(C).

See Figure 3-1. Where the generator is con- nected to a manual transfer switch, the trans- fer switch must also switch the neutral upon transfer to be NEC code compliant (3-Pole switch). A grounding electrode is required to be connected to the generator frame to prop- erly ground the generator. The ground wire (000103)Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. DANGER (000199) DANGER Explosion and Fire. LP vapors are extremely flammable and explosive. Do not use or store LP cylinder in a building, garage, or enclosed area except as authorized by NFPA 58 or B149.2 (Canada). Failure to do so will result in death or serious injury. DANGER(000751)Inspect LP hose and regulator before each use for cuts, burrs or other damage. Replace damaged LP hose or regulator before use. Operating unit with a damaged LP hose or regulator will result in death or serious injury. (000103)Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury. DANGER (000178a) WARNING Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury. Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury. (000179b) DANGER WARNING (000118a) Risk of fire. Do not use generator without spark arrestor installed. Failure to do so could result in death or serious injury. (000110) WARNING Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury. (000108) WARNING Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire. (000136) CAUTION Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.14 Owner’s Manual for Portable Generator connected from the generator terminal/frame to a field ground electrode shall be of equal or larger ampacity than the largest conductor used in the generator. Generac HomeLink manual transfer switches and kits meet this requirement and are recommended for use. Figure 3-1.Grounding the Generator Special Requirements Review all Federal or State Occupational Safety and Health Administration (OSHA) reg- ulations, local codes, or ordinances that apply to the intended use of the generator. Consult a qualified electrician, electrical inspector, or the local agency having jurisdic- tion:

• In some areas, generators are required to be registered with local utility companies.

• If the generator is used at a construction site, there may be additional regulations which must be observed. Connecting the Generator to a Building Electrical System It is recommended to use a manual transfer switch when connecting directly to a building electrical system to prevent hazardous back- feeding and avoid injuring utility line workers. When connecting a portable generator to a building electrical system, a transfer switch must isolate the generator power from the util- ity power at all times. Failure to comply will result in a hazardous condition. Installation is to be made in strict compliance with all national and local electrical codes and laws, and be completed by a qualified electrician. Know Generator Limits Overloading a generator can result in damage to the generator and connected electrical devices. Observe the following to prevent overload:

• Add the total wattage of all electrical devices to be connected at one time. This total should NOT be greater than the gener- ator's wattage capacity.

• The rated wattage of lights can be taken from light bulbs. The rated wattage of tools, appliances, and motors can 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 approximately 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 con- nect to the generator:

1. Calculate the watts needed to start the

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 gen- erator can operate at one time. NOTE: All figures are approximate. See data label on appliance for wattage requirements. Wattage Reference Guide

1. Unplug all electrical loads from the unit's

receptacles before starting engine.

2. Place generator on a level surface.

3. See Figure 3-2. Open the fuel shut-off

valve (A). Figure 3-2.Fuel Shut-off Valve

4. See Figure 3-3. Turn engine GAS/LP dial

to GAS. Figure 3-3.Gas/LP Dial

START switch to RUN (manual start only).

6. See Figure 3-4. Slide engine choke (C) to

Full Choke position (left). Figure 3-4.Choke PositionHand Drill 250 to 1100Hedge Trimmer 450Impact Wrench 500Iron 1200*Jet Pump 800Lawn Mower 1200Light Bulb (Incandescent) 100Microwave Oven 700 to 1000*Milk Cooler 1100Oil Burner on Furnace 300Oil Fired Space Heater (140,000 Btu)

Oil Fired Space Heater (85,000 Btu) 225Oil Fired Space Heater (30,000 Btu) 150*Paint Sprayer, Airless (1/3 HP) 600Paint Sprayer, Airless (hand-held) 150Radio 50 to 200*Refrigerator 700Slow 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*Table Saw (10") 1750 to 2000Television 50 to 300Toaster 1000 to 1650Weed Trimmer 500* Allow 3 times the listed watts for starting these devices. (000183) WARNING Recoil Hazard. Recoil could retract unexpectedly. Kickback could result in death or serious injury. (000136) CAUTION Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.

C16 Owner’s Manual for Portable Generator

7. Brace one hand against the frame and

firmly grasp recoil handle. Pull slowly until increased resistance is felt, then pull rap- idly up and away.

8. When engine starts, move choke lever to

1/2-choke position until engine runs smoothly, then fully into RUN position. If engine falters, move choke back to 1/2- choke position until engine runs smoothly, 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 NOTE: Do not overload the generator. Also, do not overload individual panel receptacles. These outlets are pro- tected 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 Know Generator Limits carefully. Starting LP Pull Start Engines

1. Unplug all electrical loads from the unit's

receptacles before starting engine.

2. Place generator on a level surface.

3. See Figure 3-5. Open fuel shut-off valve on

cylinder. Figure 3-5.Fuel Shut-off Valve

4. See Figure 3-3. Turn GAS/LP dial to LP

and move engine choke lever to the RUN position (choke lever to the right).

5. Turn STOP/RUN/START switch to RUN

(manual start only).

6. Firmly grasp recoil handle and pull slowly

until increased resistance is felt. Pull rap- idly up and away two (2) to five (5) to PRIME fuel system.

7. Firmly grasp recoil handle and pull slowly

until increased resistance is felt. Pull rap- idly up and away. NOTE: If engine fires, but does not continue to run, move STOP/RUN/START switch to STOP and repeat starting instructions. IMPORTANT NOTE: Do not overload the generator. Also, do not overload individual panel receptacles. These outlets are pro- tected 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 Know Generator Limits carefully. Starting Gasoline Electric Start Engines

1. Unplug all electrical loads from the unit's

receptacles before starting the engine.

2. Place generator on a level surface.

3. See Figure 3-2. Open the fuel shut-off

outward to Full Choke.

7. When engine starts, move choke lever to

1/2 choke position until engine runs smoothly, then fully to RUN position. If engine falters, move choke lever back to 1/2 choke position until engine runs smoothly, then move to RUN position. Starting LP Electric Start Engines

1. Unplug all electrical loads from the unit's

receptacles before starting the engine.

2. Place generator on a level surface.

3. See Figure 3-5. Open the fuel shut-off

to the RUN position (choke lever to the right).

1. Shut off all loads and unplug electrical

loads from generator panel receptacles.

(000136) CAUTION Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage. (000136) CAUTION Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage. (000136) CAUTION Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.Owner’s Manual for Portable Generator 17

2. Let engine run at no-load for several min-

utes to stabilize internal temperatures of engine and generator.

3. See Figure 3-2 for gasoline or Figure 3-5

for LP. Close fuel valve and allow unit to run until the fuel in the carburetor is used up.

4. Move STOP/RUN/START switch to STOP.

NOTE: Under normal conditions, close the appropriate fuel valve and allow generator to run carburetor bowl out of fuel. For emergen- cies, switch to STOP. Low Oil Level Shutdown System The engine is equipped with a low oil level sensor to shut down the engine automatically when the oil level drops below a specified level. The engine will not run until the oil has been filled to the proper level. IMPORTANT NOTE: Verify proper engine oil and fuel levels before use. Charging the Battery (electric start units only) Battery Recycling Always recycle batteries in accordance with local laws and regulations. Contact your local solid waste collection site or recycling facility to obtain information on local recycling pro- cesses. For more information on battery recy- cling, visit the Battery Council International website at: http://batterycouncil.org NOTE: The battery shipped with the generator has been fully charged. A battery may lose some of its charge when not in use for pro- longed periods of time. If the battery is unable to crank the engine, plug in the 12V charger included in the accessory box. RUNNING

THE GENERATOR DOES NOT CHARGE

THE BATTERY. Use battery charger plug to keep the battery charged and ready for use. Battery charging should be done in a dry location.

1. See Figure 3-6. Plug charger into Battery

Charger Input jack, located on the control panel. Plug wall receptacle end of battery charger into 120 Volt AC wall outlet.

2. Unplug battery charger from wall outlet

and control panel jack when generator is to be in use. Figure 3-6. Battery Charger Input Jack (000137a) WARNING Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. (000138a)WARNINGRisk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. BATTERY CHARGER INPUT 00042318 Owner’s Manual for Portable Generator

Section 4 Maintenance and Troubleshooting

Maintenance Regular maintenance will improve perfor- mance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be performed by an IASD. See the emissions warranty. NOTE: Call 1-888-GENERAC (1-888-436- 3722) with questions about component replacement. Maintenance Schedule Follow maintenance schedule intervals, whichever occurs first according to use. NOTE: Adverse conditions will require more frequent service. NOTE: Go to Generac.com or contact an IASD for replacement parts. NOTE: All required service and adjustments should be each season as detailed in the fol- lowing chart. Preventive Maintenance Dirt or debris can cause improper operation and equipment damage. Clean generator daily or before each use. Keep area around and behind muffler free from combustible debris. Inspect all cooling air openings on generator.

• Use a damp cloth to wipe exterior surfaces clean.

• Use a soft bristle brush to loosen caked on dirt, oil, etc.

• Use a vacuum to pick up loose dirt and debris.

• Low pressure air (not to exceed 25 psi) may be used to blow away dirt. Inspect cooling air slots and openings on generator. These openings must be kept clean and unobstructed. NOTE: DO NOT use a garden hose to clean generator. Water can enter engine fuel system and cause problems. If water enters generator through cooling air slots, some water will be retained in voids and crevices of rotor and sta- tor winding insulation. Water and dirt buildup on generator internal windings will decrease insulation resistance of windings. Engine Maintenance Engine Oil Recommendations To maintain the product warranty, the engine oil should be serviced in accordance with the recommendations of this manual. For your convenience, maintenance kits designed and intended for use on this product are available from the manufacturer that include engine oil, oil filter, air filter, spark plug(s), a shop towel and funnel. These kits can be obtained from an Independent Authorized Service Dealer (IASD). At Each UseCheck engine oil levelEvery 100 Hours or Every Year*Change oil ǂInspect/clean spark arrestorEvery YearReplace Spark PlugCheck Valve Clearance***Every 200 Hours or Every YearInspect/clean air cleaner filter**ǂ Change oil after first 30 hours of operation,then resume maintenance schedule.* Change oil and oil filter every month whenoperating under heavy load or in high tem-peratures.** Clean more often under dirty or dusty oper-ating conditions. Replace air filter parts ifthey cannot be adequately cleaned.*** Check valve clearance and adjust if neces- sary after first 50 hours of operation and every 300 hours thereafter.(000142a)WARNING Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage. (000141) WARNING Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.Owner’s Manual for Portable Generator 19 Inspect Engine Oil Level Inspect engine oil level prior to each use, or every 8 hours of operation.

1. Place unit on a level surface.

2. Disconnect the spark plug wire from the

spark plug and place the wire where it cannot contact spark plug.

3. Clean area around oil fill.

4. See Figure 4-1. Remove oil fill cap/dipstick

and wipe dipstick clean. Figure 4-1.Engine Oil Fill

5. Thread dipstick into filler neck. Oil level is

checked with dipstick fully installed.

6. See Figure 4-2. Remove dipstick and verify

oil level is within safe operating range. Figure 4-2.Safe Operating Range

7. Add recommended engine oil as neces-

sary. See Add Engine Oil.

8. Install oil fill cap/dipstick and hand-tighten.

NOTE: Some units have more than one oil fill location. It is only necessary to use one oil fill point. Change Engine Oil When using generator under extreme, dirty, dusty conditions, or in extremely hot weather, change oil more frequently. NOTE: Don’t pollute. Conserve resources. Return used oil to collection centers. Change oil while engine is still warm from run- ning, as follows:

1. Place generator on a level surface.

2. Disconnect the spark plug wire from the

spark plug and place the wire where it cannot contact spark plug.

3. Clean area around oil fill, and oil drain

4. Remove oil fill cap/dipstick.

5. Remove oil drain plug and drain oil com-

pletely into a suitable container.

6. Install oil drain plug and tighten securely.

7. Add recommended engine oil as neces-

sary. See Add Engine Oil.

8. Install oil fill cap/dipstick and hand-tighten.

9. Wipe up any spilled oil.

10. Properly dispose of oil in accordance with

all applicable regulations. Air Filter Engine will not run properly and may be dam- aged if run with a dirty air filter. Service air fil- ter more frequently in dirty or dusty conditions. To service air filter:

2. Wash in soapy water. Squeeze filter dry in

clean cloth (DO NOT TWIST).

3. Clean air filter cover before re-installing it.

NOTE: To order a new air filter, contact the nearest authorized service center at 1-888- GENERAC (1-888-436-3722). SAE 3010W-30Synthetic 5W-30000399 (000139) WARNING Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

(000141) WARNING Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.20 Owner’s Manual for Portable Generator Figure 4-3. Air Filter Assembly Service Spark Plug To service spark plug:

1. Clean area around spark plug.

2. Remove and inspect spark plug.

3. See Figure 4-4. Inspect electrode gap with

feeler gauge and reset spark plug gap to

0.028 - 0.031 in (0.70 - 0.80 mm).

Figure 4-4. Spark Plug NOTE: Replace spark plug if electrodes are pitted, burned or porcelain is cracked. Use ONLY recommended replacement plug. See Specifications.

4. Install spark plug finger tight, and tighten

an additional 3/8 to 1/2 turn using spark plug wrench. Battery Replacement (if applicable) NOTE: The battery shipped with the generator has been fully charged. A battery may lose some charge when not in use for prolonged periods of time. If battery is unable to crank engine, plug in the 12V charger included in the accessory box (see the Charging a Battery section). IMPORTANT NOTE: Running the generator does not charge battery. See Figure 4-5.

2. Disconnect positive (+) battery terminal

SECOND (red wire). Figure 4-5. Battery Connection

3. Install new battery. Install hold down strap

4. Connect positive (+) battery terminal (red

6. Slide rubber boot over connection hard-

ware. Inspect Muffler and Spark Arrestor NOTE: It is a violation of California Public Resource Code, Section 4442, to use or oper- ate the engine on any forest-covered, brush- covered, or grass-covered land unless the exhaust system is equipped with a spark arrestor, as defined in Section 4442, main- tained in effective working order. Other states or federal jurisdictions may have similar laws. Contact original equipment manufacturer, retailer, or dealer to obtain a spark arrestor designed for exhaust system installed on this engine. NOTE: Use ONLY original equipment replace- ment parts. Inspect muffler for cracks, corrosion, or other damage. Remove spark arrestor, if equipped, inspect for damage or carbon blockage. Replace parts as required.

(000130)Accidental Start-up. Disconnect the negative battery cable, then the positive battery cable when working on unit. Failure to do so could result in death or serious injury. WARNING 000224Owner’s Manual for Portable Generator 21 Inspect Spark Arrestor Screen

forated or otherwise damaged. If screen is not damaged, clean with commercial sol- vent.

3. Replace spark arrestor cone (C) and

screen (B). Secure with clamp and screw. Figure 4-6. Spark Arrestor Screen Valve Clearance Important: Please contact an Independent Authorized Service Dealer for service assis- tance. Proper valve clearance is essential for prolonging the life of the engine. Check valve clearance after the first fifty-hours of operation. Adjust as necessary.

• Intake — 0.1 ± 0.02mm (cold), (0.004" ± 0.001" inches)

• Exhaust — 0.15 ± 0.02mm (cold) (0.006" ± 0.001" inches) Storage General It is recommended to start and run the genera- tor for 30 minutes, every 30 days. If this is not possible, refer to the following list to prepare unit for storage.

• DO NOT place a storage cover on a hot generator. Allow unit to cool to room tem- perature before storage.

• DO NOT store fuel from one season to another unless properly treated.

• Replace fuel container if rust is present. Rust in fuel will cause fuel system prob- lems.

• Cover unit with a suitable protective, mois- ture resistant cover.

• Store unit in a clean and dry area.

• Always store generator and fuel away from heat and ignition sources. Prepare Gasoline Fuel System for Storage Gasoline stored over 30 days can go bad and damage fuel system components. Keep fuel fresh, use fuel stabilizer. NOTE: LP fuel does not require storage treat- ment. If fuel stabilizer is added to fuel system, pre- pare and run engine for long term storage. Run engine for 10-15 minutes to circulate sta- bilizer throughout fuel system. Adequately prepared fuel can be stored up to 24 months. NOTE: If fuel has not been treated with fuel stabilizer, it must be drained into an approved container. Run engine until it stops from lack of fuel. Use of fuel stabilizer in fuel storage container is recommended to keep fuel fresh.

1. Change engine oil.

2. Remove spark plug.

3. Pour tablespoon (5-10cc) of clean engine

oil or spray a suitable fogging agent into cylinder.

4. Pull starter recoil several times to distrib-

ute oil in cylinder.

5. Install spark plug.

6. Pull recoil slowly until resistance is felt.

This will close valves so moisture cannot enter engine cylinder. Gently release recoil. Change Oil Change engine oil before storage. See Change Engine Oil. (000108) WARNING Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

(000143)Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Store fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury. DANGER (000200) WARNING Explosion and fire. The cylinder valve should be left off (closed) when generator is not in use. Failure to do so could result in death or serious injury. (000109) WARNING Risk of Fire. Verify machine has properly cooled before installing cover and storing machine. Hot surfaces could result in fire. (000181) WARNING Vision Loss. Eye protection is required to avoid spray from spark plug hole when cranking engine. Failure to do so could result in vision loss.22 Owner’s Manual for Portable Generator Drain Carburetor Gasoline Fuel

1. Close fuel valve.

2. Place carburetor drain hose into an

approved fuel container.

3. See Figure 4-7. Loosen screw (A) on the

carburetor and completely drain fuel.

4. Hand-tighten carburetor screw.

Engine is running, but AC output is not available.

1. Circuit breaker OPEN.

2. Poor connection or defective

3. Connected device is bad.

4. Fault in generator.

5. GFCI receptacle is OPEN (if

2. Check and repair.

3. Connect another device that is

5. Correct ground fault and press

reset button on GFCI recepta- cle (if equipped). Engine runs well at no-load, but bogs when load is applied.

1. Short circuit in a connected

2. Generator is overloaded.

3. Engine speed is too slow.

1. Disconnect shorted electrical

Engine will not start; or starts and runs rough.

1. Fuel shut-off is OFF.

nected to spark plug.

7. Water in fuel or cylinder over-

10. Excessive rich fuel mixture.

12. Engine lost compression.

13. Engine switch is OFF.

1. Turn fuel shut-off ON.

4. Drain fuel tank and fill with

5. Connect wire to spark plug.

6. Replace spark plug.

7. Drain fuel tank and fill with

9. Fill crankcase to correct level.

LP or Gas position. (If switch is defective, contact IASD.) Engine shuts down during operation.

4. COsense shut-off due to accu-

mulating carbon monoxide if a red light blinks on the side panel badge.

5. COsense shut-off due to a

system fault if a yellow light blinks on the side panel badge.

2. Fill crankcase to correct level.

4. Follow all safety instructions

and relocate generator to an open area outside, far away from windows, doors and vents.

5. Start to confirm yellow light

blinks when/if generator shuts- off. If COsense continues to fault and shut-off, contact IASD.24 Owner’s Manual for Portable Generator Engine lacks power. 1. Generator is overloaded.

2. Dirty air filter.

3. Engine needs to be serviced.

1. Choke is opened too soon.

2. Carburetor is running too rich

1. Set choke to halfway position

until engine runs smoothly.

Engine starts and shuts off right away.

1. COsense shut-off due to accu-

mulating carbon monoxide if a red light blinks on the side panel badge.

2. COsense shut-off due to a

system fault if a yellow light blinks on the side panel badge.

1. Follow all safety instructions

and relocate generator to an open area outside, far away from windows, doors and vents.

2. Start to confirm yellow light