7686 - Generator Generac - Free user manual and instructions

USER MANUAL 7686 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

Section 4 Maintenance and

• Troubleshooting p. 16
• Maintenance p. 16
• Maintenance Schedule p. 16
• Preventive Maintenance p. 16
• Engine Maintenance p. 16
• Battery Replacement (if applicable) 18 Inspect Muffler and Spark Arrester 18 Valve Clearance p. 19
• Storage p. 19
• Troubleshooting (000393) WARNING Operating, servicing and maintaining this equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing your equipment. For more information go to www.P65Warnings.ca.gov.Owner’s Manual for Portable Generator 1 p. 20

Section 1 Introduction and Safety

Introduction Thank you for purchasing a Generac Power Systems Inc. product. This unit has been designed to provide high-performance, effi- cient operation, and years of use when main- tained properly. If any section of the manual is not understood, contact your nearest Independent Authorized Service Dealer (IASD), or contact Generac Customer Service at 1-888-GENERAC (1- 888-436-3722), or www.generac.com with any questions or concerns. The owner is responsible for proper mainte- nance and safe use of the equipment. Before operating, servicing or storing this generator:

• Study all warnings in this manual and on the product carefully.

• Become familiar with this manual and the unit before use.

• Refer to the Assembly section of the man- ual for instructions on final assembly proce- dures. Follow the instructions completely. Save these instructions for future reference. ALWAYS supply this manual to any individual that will use this machine. 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 warnings in this manual, and on tags and decals affixed to the unit are, there- fore, not all inclusive. If using a procedure, work method or operating technique that the manufacturer does not specifically recom- mend, verify that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the equipment unsafe. 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 haz- ardous if performed incorrectly or carelessly. Observe them carefully. Their 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 warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instruc- tions 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) WARNING Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and productcould result in death or serious injury. (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.

• 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. (000179b) DANGER 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. (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) 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 (000250) 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. (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) 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. WARNING WARNING Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to service this equipment and could result in death or serious injury. (000215) 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. (000216)

(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. (000179b) DANGER 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. (000178a) 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 (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 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 inclu- sive. 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 to do 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) 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. WARNING4 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 that this engine/equipment complies with exhaust and evaporative emissions stan- dards. Locate the emissions compliance decal on the engine to determine applicable stan- dards. For emissions warranty information, please reference the included emissions war- ranty. It is important to follow the maintenance specifications in the manual to ensure that the engine complies with the applicable emissions standards for the duration of the product’s life.

(000100a) WARNING Consult Manual. Read and understand manualcompletely before using product. Failure to completely understand manual and productcould result in death or serious injury. Product Specifications Generator Specifications GP6500 / GP6500E GP8000E Rated Power @1.0 Power Factor 6.5 kW** 8.0 kW** Surge Power 8.125 KVA 10.0 KVA 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) 174.8-186 79.3-84.4

** 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, ambient temperature, altitude, engine condition, etc. Maximum power decreases about 3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16° C (60° F) ambient temperature. 6.5kW Engine Specifications Displacement 389 cc Spark Plug Part No. 0J00620106 Spark Plug Gap 0.028-0.031 inch or (0.70-0.80 mm) Gasoline Capacity 26 L (6.9 gal) Oil Type See Chart in Add Engine Oil Oil Capacity 1.0 L (1.06 qt.) Run Time at 50% Load 10.5 HoursOwner’s Manual for Portable Generator 7 Hour Meter The Hour Meter tracks hours of operation for scheduled maintenance. See Figure 2-4.

• 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 The 120 Volt outlet is overload protected by a 20 Amp push-to-reset circuit breaker. See Fig- ure 2-5. 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 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). See Figure 2-6. 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. 8.0kW Engine Specifications Displacement 420ccSpark Plug Part No. 0J00620106Spark Plug Gap 0.028-0.031 inch or (0.70-0.80 mm)Gasoline Capacity 28.4 L (7.5 gal)Oil TypeSee Chart in Add Engine Oil Oil Capacity 1.0 L (1.06 qt.)Run Time at 50% Load 11 Hours* Go to Generac.com or contact an IASD for replacement parts. Product Specifications

0002038 Owner’s Manual for Portable GeneratorFigure 2-6. 120/240 VAC, 30 Amp Receptacle NEMA L14-30R CO-SENSE™ Carbon Monoxide (CO) Detection and Shut-off System (if equipped) The CO-SENSE module monitors for theaccumulation of poisonous CO gas found inengine exhaust when the generator is running.If CO-SENSE detects increasing levels of COgas, it automatically shuts off the engine. CO-SENSE only monitors when the engine is run-ning. Generators are intended to be used out-doors, far from occupied buildings and theexhaust pointed away from personnel andbuildings. However, if mis-used and operatedin a location that results in the accumulation ofCO, like a house or even a garage with par-tially opened door, CO-SENSE shuts off theengine, notifies the user of what has hap-pened and directs the user to read the instruc-tion action label for steps to take. See Figure2-7. CO-Sense is not a substitute for an indoorcarbon monoxide alarm.See Figure 2-8. As the user approaches thegenerator to investigate a shut-off, a blinkingRED light in the CO-SENSE badge on theside of the generator provides notification thatthe generator was shut off due to an accumu-lating CO hazard. The RED light will blink forat least five minutes after a CO shut-off. Movethe generator to an open, outdoor area andpoint the exhaust away from people and occu-pied buildings. Once relocated to a safe area,the generator can be restarted and the properelectrical connections made to supply electri-cal power. The RED light will stop blinkingautomatically upon engine re-start. Introducefresh air and ventilate the location where thegenerator had shut down.See Figure 2-8. If a CO-SENSE system faulthas occurred and no longer provides protec-tion, the portable generator is shut off auto-matically and the YELLOW light will blink for atleast five minutes in the CO-SENSE badge tonotify the user of the fault. The CO-SENSEmodule can only be diagnosed and repairedby a trained technician at the dealer. The gen-erator can be re-started, but may continue toshut-off.CO-SENSE will detect the accumulation ofCarbon Monoxide from other fuel burningsources such as engine powered tools or pro-pane heaters used in the area of operation.For example, if another generator is used andthe exhaust is pointed at a CO-SENSEequipped generator, CO-SENSE may initiatea shut-off due to rising CO levels. This is notan error. Hazardous Carbon Monoxide hasbeen detected. The user must take action tomove and re-direct these devices to better dis-sipate Carbon Monoxide far away from per-sonnel and occupied buildings.Figure 2-7. Instruction Action Label

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 NOTE: The generator is shipped with only one (1) hardware bag, assembly A or B.

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. Needle Nose Pliers Ratchet Wrench 8mm Socket 12mm Socket 13mm Socket 10mm Wrench 13mm Wrench 8mm Wrench (2) (electric start only) 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).

Battery Charger (electric start models)

Hardware Bag Qty. Assy. A Qty. Assy. B Rubber Feet (D) 2 0 1/2” Axle Pin (E) 2 2 Cotter Pin (F) 2 2 1/2” Flat Washer (G) 2 2 Hex Flanged M6 Nut (H) 2 0 Hex Flanged M8 Nut (J) 6 6 M8 Bolt (Long) (K) 6 6 M6 Bolt (Long) (L) 2 0 M8 Nylon Flat Washer (M) 4 4 (000100a) WARNING Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.10 Owner’s Manual for Portable Generator 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

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). Figure 2-10. Handle Assembly Battery Cable Connection (electric start only) The unit has been shipped with the battery cables disconnected. You will need two 8mm box wrenches to con- nect the battery cables. See Figure 4-5.

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. Remove oil fill cap and wipe dipstick clean.

See Figure 2-11. 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.

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.

(000135) CAUTION Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage. SAE 3010W-30Synthetic 5W-30000399Owner’s Manual for Portable Generator 11 Figure 2-12. Safe Operating Range

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

Fuel 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-premium fuel is recommended).

• 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

4. Slowly add recommended fuel (A). Do not

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.

(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 to do so will 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

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

1. Verify engine oil level is correct.

2. Verify fuel level is correct.

3. Verify unit is secure on level ground, with

proper clearance and is in a well ventilated area. Prepare Generator for Use Grounding the Generator When Used as a Portable The generator is equipped with an equipment ground connecting the generator frame and the ground terminals on the AC output recep- tacles (see NEC 250.34 (A). This allows the generator to be used as a portable without grounding the frame of the generator as spec- ified in NEC 250.34. See Figure 3-1.

• Neutral Bonded to Frame. 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. Connecting a portable gen- erator to a building electrical system must be made in strict compliance with all national and local electrical codes and laws, and be com- pleted 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 up 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. Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.(000103) DANGER (000178a)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 (000179b) DANGER 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. 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. 000227Owner’s Manual for Portable Generator 13

• 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 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 select- ing electrical devices to connect to the gen- erator:

1. Figure the watts needed to start the largest

2. Add to that figure the running watts of all

• Allow 3 times the listed watts for starting these devices.14 Owner’s Manual for Portable Generator Starting 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 3-2. Open the fuel shut-off

5. Slide engine choke (C) to Full Choke posi-

tion (left). See Figure 3-3. Figure 3-3.Choke Position

6. Firmly grasp recoil handle and pull slowly

until increased resistance is felt. Pull rap- idly up and away.

7. When engine starts, move choke knob 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 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. Open the fuel shut-off valve. See Figure 3-

4. Move engine choke knob outward to Full

6. When engine starts, move choke knob to

1/2 choke position until engine runs smoothly, then fully to RUN position. If engine falters, move choke knob back to 1/2 choke position until engine runs smoothly, then move to RUN position. Manual Start The generator is equipped with a manual recoil starter which may be used if the battery is discharged. NOTE: The switch must be in the RUN/ON position. Use one of the generator’s recepta- cle outlets along with the included battery charger to charge the battery while the gener- ator is running. To start manually:

1. Firmly grasp the recoil handle and pull

slowly until increased resistance is felt.

2. Pull rapidly up and away to start engine.

3. Follow the same choke sequence.

NOTE: If engine fires, but does not continue to run, move choke lever to Full Choke and repeat starting instructions. IMPORTANT NOTE: Do not overload gener- ator or individual panel receptacles. These outlets are overload protected with push- to-reset circuit breakers. If amperage rat- ing of any circuit breaker is exceeded, that breaker opens and electrical output to that receptacle is lost. Read Know Generator Limits carefully. (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.

(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 15 Generator Shut Down

1. Shut off all loads and unplug electrical

loads from generator panel receptacles.

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

utes to stabilize internal temperatures of engine and generator.

3. Move Run/Stop switch to Stop.

4. Close fuel valve.

NOTE: Under normal conditions, close fuel valve and allow generator to run carburetor bowl out of fuel. For emergencies, 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) 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. Plug charger into Battery Charger Input

jack, located on the control panel. See Fig- ure 3-4. 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 3-4. Battery Charger Input Jack (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. (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) WARNING "!44%29 #(!2'%2 ).054

WARNING Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death or serious injury. (000228)16 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 Season*Change oil ǂInspect/clean spark arrestorEvery SeasonReplace Spark PlugCheck Valve Clearance***Every 200 Hours or Every SeasonInspect/clean air cleaner filter**ǂ Change oil after first 30 hours of operation,then every season.* 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 andevery 300 hours thereafter. (000142a)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. WARNING (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 17

Inspect Engine Oil Level Inspect engine oil level prior to each use, or every 8 hours of operation.

1. Place generator on a level surface.

2. Clean area around oil fill.

3. See Figure 4-1. Remove oil fill cap and

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

4. Screw dipstick into filler neck. Remove

dipstick and verify oil level is within safe operating range. See Figure 4-2. Figure 4-2. Safe Operating Range

5. Add recommended engine oil as neces-

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.

5. Remove oil drain plug and drain oil com-

pletely into a suitable container.

6. Install oil drain plug and tighten securely.

7. Slowly pour oil into oil fill opening until oil

level is between L and H marks on dip- stick. DO NOT overfill.

8. Install oil fill cap, and finger 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). Figure 4-3. Air Filter Assembly 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.

1. Clean area around spark plug.

2. Remove and inspect spark plug.

3. Inspect electrode gap with wire feeler

gauge and reset spark plug gap to 0.028 -

0.031 in (0.70 - 0.80 mm). See Figure 4-4.

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

bracket and tighten.

4. Connect positive (+) battery terminal (red

6. Slide rubber boot over connection hard-

ware. Inspect Muffler and Spark Arrester 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 arrester, 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 arrester 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 arrester, if equipped, inspect for damage or carbon blockage. Replace parts as required. Inspect Spark Arrester Screen

1. Loosen clamp (A) and remove screw. See

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.

(000130) WARNING 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 Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result inenvironmental damage, death or serious injury.(000228) (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.Owner’s Manual for Portable Generator 19Figure 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 — 0.15 ± 0.02mm (cold), (0.006" ± 0.0008" inches)

• Exhaust — 0.20 ± 0.02mm (cold) (0.008" ± 0.0008" 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 Fuel System for Storage Fuel stored over 30 days can go bad and damage fuel system components. Keep fuel fresh, use fuel stabilizer. 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.

(000143) DANGER 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. (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.20 Owner’s Manual for Portable Generator Troubleshooting

PROBLEM CAUSE CORRECTION

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.

5. Spark plug wire not connected

10. Excessive rich fuel mixture.

12. Engine lost compression.

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; fill with fresh

9. Fill crankcase to correct level.

Engine shuts down during operation.

4. CO-SENSE shut-off due to

accumulating carbon monox- ide if a red light blinks on the side panel badge.

5. CO-SENSE 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 CO-SENSE continues to fault and shut-off, contact IASD. Engine lacks power. 1. Load is too high.

2. Dirty air filter.

3. Engine needs to be serviced.

1. Choke is opened too soon.

2. Carburetor is running too rich

1. Set choke to halfway position

until engine runs smoothly.

2. Contact IASD.Owner’s Manual for Portable Generator 21

Engine starts and shuts off right away.

1. CO-SENSE shut-off due to

accumulating carbon monox- ide if a red light blinks on the side panel badge.

2. CO-SENSE 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

blinks when/if generator shuts- off. If CO-SENSE continues to fault and shut-off, contact IASD. PROBLEM CAUSE CORRECTIONPart No. 10000029705 Rev. A 04/02/2018 ©2018 Generac Power Systems, Inc. All rights reserved Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722) www.generac.comGenerador portátil serie GP Manual del usuario MODELO:

5. ASAE EP-364.2, Installation and