GP9500E TF - Generator Generac - Free user manual and instructions

Product Type	Portable Generator (Tri Fuel)
Fuel Types	Gasoline, LPG, Natural Gas
Rated Power (Gasoline)	9.5 kW
Rated Power (LPG)	8.55 kW
Rated Power (Natural Gas)	7.0 kW
Surge Power (Gasoline)	12.5 kVA
Rated AC Voltage	120/240V
Rated AC Load Current (240V)	39.6A
Rated Frequency	60 Hz @ 3600 RPM
Phase	Single Phase
Engine Displacement	500 cc
Fuel Tank Capacity	7.5 US gal (28.4 L)
Oil Capacity	1.16 qt (1.1 L)
Run Time at 50% Load (Gasoline)	10.5 hours
Run Time at 50% Load (LPG, 20 lb tank)	4.75 hours
Starting Method	Electric Start with Recoil Backup
CO Detection	COsense® Automatic Shutoff
GFCI Protection	Yes (120V duplex receptacle)
Receptacles	1x 120V 20A GFCI, 1x 120/240V 30A (L14-30R), 1x 120/240V 50A (NEMA 14-50R)
Hour Meter	Yes, with maintenance reminders
Weight (dry)	215.8 - 220.7 lb (97.9 - 100.1 kg)
Spark Plug	Bosch F7TC or equivalent, gap 0.028-0.031 in
Recommended Oil	SAE 30 or Synthetic 5W-30 (see temperature chart)
Battery (Electric Start)	12V Lead-Acid (replaceable)

Frequently Asked Questions - GP9500E TF Generac

What type of fuel can the GP9500E TF use?

The Generac GP9500E TF is a tri-fuel generator, meaning it can operate on gasoline, LPG (propane), or natural gas. Use the fuel selector dial to choose the desired fuel source.

How do I start the generator on gasoline?

First, ensure the generator is on a level surface outdoors, away from windows and doors. Turn the fuel selector to GAS. If using electric start, press and hold the START position until the engine starts, then release to RUN. For recoil start, pull the starter handle firmly after turning the switch to RUN.

What is the COsense system and how does it work?

The COsense system monitors for dangerous levels of carbon monoxide (CO) in the exhaust. If it detects accumulating CO, it automatically shuts off the engine and blinks a red light. Move the generator to an open outdoor area and restart after ventilating the area.

What is the recommended oil type and capacity?

Use SAE 30 or synthetic 5W-30 oil depending on temperature (see chart in manual). Oil capacity is 1.16 quarts (1.1 liters). Check oil level before each use and change after first 30 hours, then every 100 hours.

Can I run the generator indoors or in a garage?

NEVER run the generator indoors or in a garage, even with doors open. Generator exhaust contains carbon monoxide, a colorless, odorless poison that can kill you in minutes. Only operate outdoors, far from windows, doors, and vents.

How do I connect the generator to my house?

Use a manual transfer switch installed by a qualified electrician. The generator's neutral is bonded to the frame, so the transfer switch must switch the neutral as well (3-pole switch). This prevents hazardous back-feeding and protects utility workers.

What is the maintenance schedule?

Check oil level at each use. Change oil every 100 hours (first change at 30 hours). Inspect/clean air filter every 200 hours. Replace spark plug yearly. Check valve clearance after first 50 hours, then every 300 hours. Clean spark arrestor every 100 hours.

What does a blinking yellow light on the COsense badge mean?

A blinking yellow light indicates a system fault. The generator will shut off. This fault must be diagnosed by an Authorized Service Dealer. You may restart, but it may continue to shut off.

Why does my generator bog down when I add a load?

This could be due to overloading (connected devices exceed capacity), a short circuit in a connected device, a clogged spark arrestor, or engine speed issues. Reduce the load and check for shorted devices. Clean the spark arrestor screen if needed.

How do I store the generator long-term?

Change the oil, add fuel stabilizer and run for 10-15 minutes, then drain carburetor or run until fuel is gone. Remove spark plug, add a tablespoon of oil into cylinder, and pull recoil to distribute. Store in a clean, dry area with the cover on.

USER MANUAL GP9500E TF Generac

GP Series Multi-Fuel Portable Generator

Owner's Manual

Technical line drawing of a portable gas generator with visible cooling pipes and wheels (no text or labels)

MODEL:

SERIAL:

DATE PURCHASED:

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. (000209b)

Register your Generac product at:

www.generac.com

1-888-GENERAC

(1-888-436-3722)

Section 1 Introduction and Safety 1

Introduction 1

Safety Rules 1

Safety Symbols and Meanings ..... 1

Exhaust and Location Hazards ..... 2

Electrical Hazards 3

Fire Hazards 3

Standards Index 3

Replacement Hazard Labels ...... 3

UL 4200A Warning 5

Section 2 General Information and

Setup 6

Know Your Generator 7

Emissions 7

Hour Meter 8

Connection Plugs 8

120/240 VAC, 50 Amp receptacle ... 9

COsense® 9

Remove Contents from Carton ..... 10

Assembly 10

Battery Cable Connection (electric start only) 11

Add Engine Oil 11

Fuel - Gasoline 12

Fuel - LP Requirements 12

Fuel Requirements and Recommendations - Natural Gas 13

Installing and Connecting Fuel Lines 14

Section 3 Operation ...... 16

Operation and Use Questions ..... 16

Before Starting Engine 16

Prepare Generator for Use 16

Grounding the Portable Generator 16

Know Generator Limits 17

Transporting/Tipping of the Unit .... 18

Starting Gasoline Pull Start Engines -

50 State Models ....18

Starting Gasoline Pull Start Engines -

49 State Models ....18

Starting Gasoline Electric Start Engines - 50 State Models ....19

Starting Gasoline Electric Start Engines - 49 State Models ....19

Starting LP Pull Start Engines - 49 and

50 State Models ....19

Starting LP Electric Start Engines - 49

and 50 State Models .....20

Starting Natural Gas Electric Start Engines - 49 and 50 State Models .....20

Section 4 Maintenance and

Troubleshooting ......21

Maintenance 21

Maintenance Schedule ......21

Preventive Maintenance ....21

Engine Maintenance ....21

Battery Replacement (if applicable) 23

Inspect Muffler and Spark Arrester 23

Valve Clearance 24

Storage 24

Troubleshooting 25

Wiring Diagram 27

Notes 31

CALIFORNIA WARNING

This product can expose you to chemicals including benzene, a carcinogen and reproductive toxicant, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

For more information, go to:

www.P65Warnings.ca.gov/

(W000808)

Section 1 Introduction and Safety

Introduction

Read This Manual Thoroughly

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. (000100a)

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-GENERAC), or visit www.generac.com for starting, operating, and servicing procedures. The owner is responsible for proper maintenance and safe use of the unit.

SAVE THESE INSTRUCTIONS for future reference. 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 emergency.

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 inclusive. 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, WARNING, CAUTION, and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Alert definitions are as follows:

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

(000001)

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

(000002)

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

(000003)

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 hazards 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

DANGER

Using 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.

000657

DANGER

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

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. (00017)

- 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 poisoning.

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000104)

DANGER

Electrocution. Turn utility and emergency power supplies to OFF before connecting power source and load lines. Failure to do so will result in death or serious injury. (000116)

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. (000146)

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. (000178a)

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

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury. (000111)

WARNING

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustables during use. Hot surfaces could result in severe burns or fire. (000108)

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. (000142a)

WARNING

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

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)

CAUTION

Hearing protection recommended.

PRECAUCIÓN

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

Exhaust and Location Hazards

DANGER

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

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)

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. (000178a)

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. (000146)

WARNING

Personal injury. Hot exhaust gasses. Do not attempt to move unit while running.

(000806)

WARNING

Personal injury. Excessive weight. Two person lift. Use only appropriate techniques when lifting equipment. Improper lifting techniques could result in equipment damage, death or serious injury (000805)

• 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 poisoning.
• NEVER run a generator indoors or in a partly enclosed area such as garages.
• ONLY use outdoors and far away from windows, doors, vents, crawl spaces and in an

area where adequate ventilation is available 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 provide sufficient ventilation.

Electrical Hazards

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000144)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000104)

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. (000)

• National Electric Code (NEC) requires the frame and external electrically conductive parts of the generator be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of the generator. Consult with a local electrician for grounding requirements in the area.
• Use a ground fault circuit interrupter (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

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.(000105)

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. (000166b)

DANGER

Risk of fire. Allow fuel spills to completely dry before starting engine. Failure to do so will result in death or serious injury.

(000174)

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. (000142a)

• 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 output 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

1. National Fire Protection Association (NFPA) 70: The NATIONAL ELECTRIC CODE (NEC) available from www.nfpa.org
2. National Fire Protection Association (NFPA) 5000: BUILDING CONSTRUCTION AND SAFETY CODE available from www.nfpa.org
3. International Building Code available from www.iccsafe.org
4. Agricultural Wiring Handbook available from www.rerc.org, Rural Electricity Resource Council P.O. Box 309 Wilmington, OH 45177-0309
5. ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power available from www.asabe.org, American Society of Agricultural & Biological Engineers 2950 Niles Road, St. Joseph, MI 49085
6. CSA C22.2 100-14 Electric motors and generators for installation and use, in accordance with the Rules of the Canadian Electrical Code
7. ANSI/PGMA G300 Safety and Performance 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:

• A0004473153-A

• A0004511103-A (Vertical CO Warning Decal)

DANGER

Using 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.

▲ PELIGRO

• INGESTION HAZARD: This product contains a button cell or coin battery.
• DEATH or serious injury can occur if ingested. A swallowed button cell or coin battery can cause Internal Chemical Burns in as little as 2 hours.
• KEEP new and used batteries OUT OF REACH of CHILDREN.
• Seek immediate medical attention if a battery is suspected to be swallowed or inserted inside any part of the body.

• Remove immediately recycle or dispose of used batteries according to local regulations and keep away from children. Do NOT dispose of batteries in household trash or incinerate.
  Even used batteries may cause severe injury or death.
  ◆ Call a local poison control center for treatment information.
  ◆ Battery type: CR2032
  ◆ Battery voltage: 3V
  Non-rechargeable batteries are not to be recharged.
  Do not force discharge, recharge, disassemble, heat above 104^ F or incinerate. Doing so may result in injury due to venting, leakage or explosion resulting in chemical burns.
  ◆ Product contains non-replaceable battery.

Section 2 General Information and Setup

Figure 2-1. Features and Controls

Generator Components

1 Frame	22 Engine Switch
2 Fuel Gauge	23 Hour Meter
3 R o l l O v e r	24 Circuit Breakers (AC)
4 Fuel Cap	25 AC Receptacle
5 Fuel Pump (if equipped)	26 COsense RED (Hazard)
6 Handle	27 COsense YELLOW (Fault)
7 Air Filter
8 Fuel Selector Dial
9 Recoil Starter
10 Foot
11 LPG / NG Regulator Inlet - QUICK DIS-CONNECT
12 Oil Drain
13 Oil Fill / Dipstick
14 Wheel
15 Battery
16 Fuel Tank
17 Grounding Lug
18 Muffler
19 Carbon Canister (if equipped)
20 Cylinder Head
21 Spark Plug

Figure 2-2. Control Panel (Electric Start) (if equipped)

Technical line drawing of a portable gas generator with visible internal components and mounting base (no text or labels)

015952

Figure 2-3. Unit Identification Label

Know Your Generator

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. (000100a)

Replacement owner's manuals are available at www.generac.com.

Product Specifications

Generator Specifications GP6700EDF	(Dual Fuel)	GP9500ETF (Tri Fuel)
Rated Power @1.0 Power Factor (Gasoline) 6.7 kW** 9.5 kW**
Rated Power @1.0 Power Factor (LPG) 6.0 kW** 8.55 kW**
Rated Power @1.0 Power Factor (NG) - 7.0 kW**
Surge Power (Gasoline) 8.25 KVA 12.5 KVA
Surge Power (LPG) 7.425 KVA 11.25 KVA
Surge Power (NG)	-9.0 KVA
Rated AC Voltage	120/240V
Rated AC LoadCurrent @ 240V**Current @ 120V**	27.9A55.8A	39.6A79.2A
Rated Frequency	60 Hz @ 3600 RPM
Phase	Single Phase
Weight (dry)Pounds (lb) (49ST / 50ST)Kilograms (kg) (49ST / 50ST)	174.2 / 180.179 / 81.71	215.8 / 220.797.9 / 100.1
** Operating Temperature Range: -18 °C (0 °F) to 40 °C (104 °F). When operated above 25 °C (77 °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.
6.7kW Engine Specifications
Displacement	340 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	28.4 L (7.5 US gal)

Emissions

The United States Environmental Protection Agency (US EPA) (and California Air Resources Board (CARB), for engines/equipment 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.

Product Specifications

Oil Type	See Chart in Add Engine Oil
Oil Capacity 0.9 L (0.95 qt.)
Run Time at 50% Load (Gasoline / LPG) 13 Hours / 6 Hours (20 lb Tank)
9.5kW Engine Specifications
Displacement 500cc
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 28.4 L (7.5 US gal)
Oil Type	See Chart in Add Engine Oil
Oil Capacity 1.1 L (1.16 qt.)
Run Time at 50% Load (Gasoline / LPG) 10.5 Hours / 4.75 Hours (20 lb Tank)
Fuel consumption (Natural Gas)	50% Load = 75ft^3/hr 100% Load = 101ft^3/hr
* Go to generac.com or contact an IASD for replacement parts.

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 perform 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 Interval (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.

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 provides protection with a Ground Fault Circuit Interrupter with a press to TEST and RESET button.

Pure electrical circuit lines without any symbols

000203

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.

Circular diagram with concentric rings and three black curved segments (no text or symbols)

Figure 2-6. 120/240 VAC, 30 Amp Receptacle NEMA L14-30R

120/240 VAC, 50 Amp receptacle

See Figure 2-7. Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire cord set rated for 250 Volts AC at 50 Amps to plug. Use this receptacle to operate 120/240 Volt AC, 60 Hz electrical loads requiring up to 12,000 watts (12.0 kW) of power. This receptacle is protected by a 50 Amp 2-pole circuit breaker.

Pure electrical circuit symbol diagram without any text or labels

Figure 2-7. 120/240 VAC, 50 Amp Receptacle NEMA 14-50

COsense®

Carbon Monoxide (CO) Detection and Shut-off System (if equipped)

The COsense module monitors for the accumulation 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 location that results in the accumulation of CO, like indoors or in a partially enclosed area, 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 2-8. 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 electrical 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 Carbon 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 2-8. Instruction Action Label

Remove Contents from Carton

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

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
Service Warranty 1
Emissions Warranty 1
3' Power Cord (if equipped)	1
LPG Hose and Regulator	1
Hardware Bag	Qty.
Rubber Feet (D) 2
1/2" Axle Pin (E)	2
Hitch 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

1. Call Generac Customer Service 1-888-GENERAC (1-888-436-3722) with the unit model and serial number for any missing carton contents.
2. Record model, serial number, and date of purchase on front cover of this manual.

Assembly

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. (000100a)

Call Generac Customer Service at 1-888-GENERAC (1-888-436-3722) for any assembly 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), 1/2" flat washer (G), and wheel bracket on frame.

2. Insert Hitch pin (F) through axle pin (E). Install frame foot and rubber bumpers as follows:

3. Slide hex head bolts (L) through rubber bumper (D), then through frame foot (C) (if not pre-assembled) and install nut (H).

4. Slide hex head bolts (K) through frame foot (C) and holes in frame rail.

5. 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 mounting bracket of generator frame, nylon washer (M), handle (A), and nylon washer (M). 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.

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 terminal.
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 (+) battery terminal and connection hardware.
4. Connect the black cable to the negative (-) battery terminal with the bolt and nut supplied. Slide rubber boot over the negative (-) battery terminal and connection hardware.
5. Make sure all connections are secure.

Add Engine Oil

CAUTION

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

(000135)

1. Place generator on a level surface.
2. Verify oil fill area is clean.
3. See Figure 2-11. Remove oil fill cap and wipe dipstick clean.

Illustration of a mechanical device with a rotating arrow and a boat (no text or symbols)

000115

Figure 2-11. Remove Dipstick

1. Add recommended engine oil as shown in the following chart.

NOTE: Use petroleum based oil (supplied) for engine break-in before using synthetic oil.

000399

NOTE: Some units have more than one oil fill location. It is only necessary to use one oil fill point.

1. Thread dipstick into oil filler neck. Oil level is checked with dipstick fully installed.

2. See Figure 2-12. Remove dipstick and verify oil level is within safe operating range.

Technical line drawing of a mechanical component with threaded end and threaded shaft (no text or symbols)

000116

Figure 2-12. Safe Operating Range

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

Fuel - Gasoline

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. (000105)

WARNING

Fluid Injection. This machine produces high-pressure fluid streams that can pierce skin. Fluid injection could result in death or serious injury. (000106b)

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 recommended).
  • DO NOT use E85.
  • DO NOT use a gas oil mix.
• DO NOT modify engine to run on alternate fuels. Stabilize fuel prior to storage.
• Verify unit is OFF and cooled for a minimum of two minutes prior to fueling.
• Place unit on level ground in a well ventilated area.
• Clean area around fuel cap and remove cap slowly.
• See Figure 2-13. Slowly add recommended fuel (A). Do not overfill (B).
• Install fuel cap.

Figure 2-13. Add Recommended Fuel

NOTE: Allow spilled fuel to evaporate before starting unit.

IMPORTANT NOTE: It is important to prevent gum deposits from forming in fuel system parts such as the carburetor, fuel hose or tank during storage. Alcohol-blended fuels (called gasohol, ethanol or methanol) can attract moisture, which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. See the Storage section. Never use engine or carburetor cleaner products in the fuel tank as permanent damage may occur.

Fuel - LP Requirements

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. (00020)

WARNING

Personal injury. Keep out of reach of children. Failure to do so could result in death or serious injury.

(000128a)

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.

Line drawing of a gas cylinder with attached pipe and valve (no text or symbols)

Figure 2-14. Connect Hose Assembly to LP Tank

1. See Figure 2-15. Connect opposite regulator connecting hose end to generator at the LP connection point on the front of the generator.

QUICK DISCONNECT - Pull back on the collar as the hose connector engages the fuel inlet fitting on the generator. When fully engaged, release the collar to lock connector onto fitting.

Technical line drawing of a mechanical assembly with no visible text or symbols

Figure 2-15. Connect Hose to Regulator

1. 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 connection between the valve and regulator won't cause sharp bends or kinks in hose.

Line drawing of a hand holding a coiled cable or wire, with no visible text or symbols

002606

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.

Fuel Requirements and Recommendations - Natural Gas

DANGER

Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000192)

NOTE: NG is lighter than air and will collect in high areas. LP gas is heavier than air and will settle in low areas.

LP gas should only use a vapor withdrawal system. This type of system uses vapors formed above liquid propane in the storage tank.

BTU Content

Recommended fuels should have a BTU content of at least 1,000 BTU/ft ^3 (37.26 MJ/m ^3 ) for NG; or at least 2,500 BTU/ft ^3 (93.15 MJ/m ^3 ) for LP gas.

NOTE: BTU fuel content information is available from fuel supplier.

Fuel Pressure

Required fuel pressure for NG is 3.5–7.0 in water column (0.87–1.74 kPa) at generator fuel inlet. Required fuel pressure for LP gas is 10–12 in water column (2.49–2.99 kPa) at generator fuel inlet.

NOTE: All pipe sizing, construction, and layout must comply with NFPA 54 for NG applications and NFPA 58 or ICC IFGC for LP gas applications. Verify fuel pressure NEVER drops below required specification once gen-

erator is installed. See the NFPA website at www.nfpa.org for further information regarding NFPA requirements.

Always contact local fuel suppliers or fire marshal to verify codes and regulations for correct installation. Local codes will mandate correct routing of gaseous fuel line piping around gardens, shrubs, and other landscaping.

Piping strength and connections should be given special consideration for installations in areas at risk for flooding, tornadoes, hurricanes, earthquakes, and unstable ground.

IMPORTANT NOTE: Use an approved pipe sealant or joint compound on all threaded NPT fittings.

NOTE: All installed gaseous fuel piping must be purged and leak tested prior to initial startup in accordance with local codes, standards, and regulations.

Natural Gas Pipe Sizing

To determine correct NG pipe size, find the kW rating of generator in the left column, and trace to the right. The number to the right is maximum length (measured in ft / m) allowed for the pipe sizes on top. Pipe sizes are measured by trade size diameter to include any fittings, valves (must be full flow), elbows, tees, or angles.

NOTE: See Table B.3.2 in NFPA 54 or Table A.2.2 in the ICC IFGC, Equivalent Lengths of Pipe Fittings and Valves for the correct values to be added to overall fuel piping length. Tables are based on schedule 40 black pipe. If installing any other piping system, follow pipe sizing charts for selected piping system.

Table 2-1. NG Pipe Sizing

Pipe Size (in / mm)	For 5–7 in Water Column (1.24–1.74 kPa)					For 3.5–5 in Water Column (0.87–1.24 kPa)
	Allowable Pipe Distances (ft/m)
	0.5/13	0.75/19	1/25	1.25/32	1.5/38	0.75/19	1/25	1.25/32	1.5/38
9.5 kW	10/3.1	60/18.3	200/61	750/228.6	—	20/6.1	60/18.3	175/53.3	—

Installing and Connecting Fuel Lines

DANGER

Explosion and fire. Fuel and vapors are extremely flammable and explosive. No leakage of fuel is permitted. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000192)

IMPORTANT NOTE: NG and LP gas are highly volatile substances. Strictly adhere to all safety procedures, codes, standards, and regulations.

Fuel line connections should be made by a certified contractor familiar with local codes. Always use AGA-approved gas pipe and a quality pipe sealant or joint compound.

Verify capacity of NG meter or LP tank to provide sufficient fuel for both the generator and other operating appliances.

Fuel Shutoff Valve

See Figure 2-17. The generator will require an external manual fuel shutoff valve (A) on the fuel line.

NOTE: Fuel shutoff valve must be installed at a readily accessible location, and within six (6) ft (1.8 m) of generator fuel inlet.

Technical line drawing of a mechanical connector assembly (no text or symbols)

Figure 2-17. QUICK DISCONNECT, Fuel Shutoff Valve with Manometer Port, and Flexible Fuel Line

Figure 2-18 illustrates a fuel shutoff valve with a manometer port for making fuel pressure checks. This optional accessory fuel shutoff valve permits making pressure checks for diagnostic purposes without going into the generator enclosure.

Technical line drawing of a valve assembly (no text or labels)

000743

Figure 2-18. Fuel Shutoff Valve with Manometer Port

Fuel shutoff valves available through an IASD:

• 1/2 in ball valve, part number 0K8752
• 3/4 in ball valve, part number 0K8754
• 1 in ball valve, part number 0K8184
• 1-1/4 in ball valve, part number 0L2844
• 1-1/2 in ball valve, part number 0L2845

NOTE: QUICK DISCONNECT size: 1/2" QDD (Female).

See Figure 2-19. The slidable sleeve on the quick connector (4) of LP hose has two states, Release state (1), Compressed state (2).

020033

Figure 2-19. Slidable Sleeve

Section 3 Operation

Operation and Use Questions

Call Generac customer service at 1-888-GENERAC (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

DANGER

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

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)

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.

(000178a)

WARNING

Risk of fire. Do not use generator without spark arrestor installed. Failure to do so could result in death or serious injury.

(000118a)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

(000110)

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. (000108)

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)

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 generator 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).

• NEUTRAL BONDED TO FRAME
- THERE IS A PERMANENT CONDUCTOR BETWEEN THE GENERATOR (STATOR WINDING) AND FRAME

See Figure 3-1. Where the generator is connected to a manual transfer switch, the transfer 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 properly ground the generator. The ground wire 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.

Mechanical assembly diagram showing a wheel and gear assembly with no visible text or symbols

Figure 3-1. Grounding the Generator

Special Requirements

Review all Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator.

Consult a qualified electrician, electrical inspector, or the local agency having jurisdiction:

• 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 utility 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 generator'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 connect to the generator:

• Calculate the watts needed to start the largest motor.

• Add to that figure the running watts of all other connected loads.

The Wattage Reference Guide is provided to assist in determining how many items the generator can operate at one time.

NOTE: All figures are approximate. See data label on appliance for wattage requirements.

Wattage Reference Guide

Device Running	Watts
*Air Conditioner (12,000 Btu) 1700
*Air Conditioner (24,000 Btu) 3800
*Air Conditioner (40,000 Btu) 6000

Battery Charger (20 Amp) 500
Belt Sander (3") 1000
Chain Saw 1200
Circular Saw (7-1/4") 1250 to 1400
*Clothes Dryer (Electric) 5750
*Clothes Dryer (Gas) 700
*Clothes Washer 1150
Coffee Maker	1750
*Compressor (1 HP) 2000
*Compressor (3/4 HP)	1800
*Compressor (1/2 HP)	1400
Curling Iron	700
*Dehumidifier	650
Disc Sander (9")	1200
Edge Trimmer	500
Electric Blanket	400
Electric Nail Gun 1200
Electric Range (per element)	1500
Electric Skillet	1250
*Freezer	700
*Furnace Fan (3/5 HP)	875
*Garage Door Opener 500 to 750
Hair Dryer 1200
Hand Drill	250 to 1100
Hedge Trimmer	450
Impact Wrench	500
Iron	1200
*Jet Pump	800
Lawn Mower	1200
Light Bulb (Incandescent) 100
Microwave Oven 700 to 1000
*Milk Cooler	1100
Oil Burner on Furnace	300
Oil Fired Space Heater (140,000 Btu)	400
Oil Fired Space Heater (85,000 Btu)	225
Oil Fired Space Heater (30,000 Btu)	150
*Paint Sprayer, Airless (1/3 HP)	600
Paint Sprayer, Airless (hand-held)	150
Radio	50 to 200
*Refrigerator	700
Slow Cooker	200
*Submersible Pump (1-1/2 HP)	2800
*Submersible Pump (1 HP)	2000
*Submersible Pump (1/2 HP)	1500
*Sump Pump 800 to 1050
*Table Saw (10") 1750 to 2000
Television 50 to 300
Toaster 1000 to 1650
Weed Trimmer 500
* Allow three (3) times the listed watts for starting these devices.

Transporting/Tipping of the Unit

WARNING

Personal injury. Excessive weight. Two person lift. Use only appropriate techniques when lifting equipment. Improper lifting techniques could result in equipment damage, death or serious injury. (000805)

• DO NOT store or transport the unit at an angle greater than 15 degrees.
• Two (2) people are needed to lift the unit.
• Allow the unit to cool before transporting or storing in an enclosed area.
  • DO NOT move unit during operation.

Starting Gasoline Pull Start Engines - 50 State Models

WARNING

Recoil Hazard. Recoil could retract unexpectedly. Kickback could result in death or serious injury.

(000183)

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)

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.

1. Unplug all electrical loads from the unit's receptacles before starting engine.
2. Place generator on a level surface.

3. Turn engine GAS/LP dial to GAS.

4. See Figure 2-2. Turn engine RUN/STOP/START switch to RUN/ON (manual start only).

5. Firmly grasp recoil handle and pull slowly until increased resistance is felt. Pull rapidly up and away.
6. Pull rapidly up and away to start engine.

IMPORTANT NOTE: Do not overload the generator. Also, do not overload individual panel receptacles. These outlets are protected against overload with push-to-reset-type circuit breakers. If amperage rating of any circuit breaker is exceeded, that breaker opens and electrical output to that receptacle is lost. Read Know Generator Limits carefully.

Starting Gasoline Pull Start Engines - 49 State Models

WARNING

Recoil Hazard. Recoil could retract unexpectedly. Kickback could result in death or serious injury.

(000183)

!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)

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

1. See Figure 2-2. Turn engine STOP/RUN/START switch to RUN (manual start only).

2. See Figure 3-4. Slide engine choke (C) to Full Choke position (left).

Figure 3-4. Choke Position

1. Brace one hand against the frame and firmly grasp recoil handle. Pull slowly until increased resistance is felt, then pull rapidly up and away.

2. 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 protected against overload with push-to-reset-type circuit breakers. If amperage rating of any circuit breaker is exceeded, that breaker opens and electrical output to that receptacle is lost. Read Know Generator Limits carefully.

Starting Gasoline Electric Start Engines - 50 State Models

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)

1. Unplug all electrical loads from the unit's receptacles before starting the engine.
2. Place generator on a level surface.
3. Turn engine GAS/LP dial to GAS.
4. Press and hold RUN/STOP/START switch in the START position. When engine starts, release the switch to the RUN position.

Starting Gasoline Electric Start Engines - 49 State Models

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)

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 valve.
4. Turn engine GAS/LP dial to GAS.
5. See Figure 3-4. Move engine choke lever outward to Full Choke.
6. Press and hold STOP/RUN/START switch in the START position. When engine starts, release the switch to the RUN position.
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 Pull Start Engines - 49 and 50 State Models

NOTE: Follow the start-up guide decal to pre-start the unit.

NOTE: 49 and 50 State models can only pull start on LP with a battery connected.

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.
4. Turn GAS/LP dial to LP. For 49 State Models, move engine choke lever to the RUN position (choke lever to the right).

Line drawing of a hand holding a tool above a cylindrical device with a coiled cable (no text or symbols)

002606

Figure 3-5.Fuel Shut-off Valve

1. Turn STOP/RUN/START switch to RUN (manual start only).
2. Brace one hand against the frame and firmly grasp recoil handle. Pull slowly until increased resistance is felt. Pull rapidly up and away two (2) to five (5) to PRIME fuel system.
3. Brace one hand against the frame and firmly grasp recoil handle. Pull slowly until increased resistance is felt.
4. 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.

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 protected against overload with push-to-reset-type circuit breakers. If amperage rating of any circuit breaker is exceeded, that breaker opens and electrical output to that receptacle is lost. Read Know Generator Limits carefully.

Starting LP Electric Start Engines - 49 and 50 State Models

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)

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 valve on cylinder.
4. Turn engine GAS/LP dial to LP.
5. See Figure 3-4. (49 State Model only) Move engine choke lever to the RUN position (choke lever to the right).
6. Press and hold STOP/RUN/START switch in the START position. When engine

starts, release the switch to the RUN position.

Generator Shut Down

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)

1. Shut off all loads and unplug electrical loads from generator panel receptacles.
2. Let engine run at no-load for several minutes to stabilize internal temperatures of engine and generator.
3. See Figure 3-2 for gasoline or Figure 3-5 for LP. (For 49 State Generator) Close fuel valve and allow unit to run until the fuel in the carburetor is used up.
4. Move Run/Stop switch to Stop.

NOTE: (For 49 State Generator) Under normal conditions, close the appropriate fuel valve and allow generator to run carburetor bowl out of fuel. For emergencies, switch to STOP.

Starting Natural Gas Electric Start Engines - 49 and 50 State Models

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)

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 NG valve from hose supply.
4. Turn engine GAS/LP/NG dial to NG.
5. See Figure 3-4. (49 State Model only) Move engine choke lever to the RUN position (choke lever to the right).
6. Press and hold STOP/RUN/START switch in the START position. When engine starts, release the switch to the RUN position.

NOTE: Starting the generator with NG fuel for the first time once connected to fuel valve will take longer time to crank in order to purge air out of the fuel hose.

Section 4 Maintenance and Troubleshooting

Maintenance

Regular maintenance will improve performance 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 following chart.

At Each Use

Check engine oil level

Every 100 Hours or Every Year*

Change oil ‡

Inspect/clean spark arrestor

Every Year

Replace Spark Plug

Check Valve Clearance***

Every 200 Hours or Every Year

Inspect/clean air cleaner filter**

‡ Change oil after first 30 hours of operation, then every season.* Change oil and oil filter every month when operating under heavy load or in high temperatures.** Clean more often under dirty or dusty operating conditions. Replace air filter parts if they cannot be adequately cleaned.*** Check valve clearance and adjust if necessary after first 50 hours of operation and every 300 hours thereafter.

Preventive Maintenance

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.

(000142a)

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 stator winding insulation. Water and dirt buildup on generator internal windings will decrease insulation resistance of windings.

Engine Maintenance

!WARNING

Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.

(000141)

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).

000399

Inspect Engine Oil Level

WARNING

Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

(000139)

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/dipstick and wipe dipstick clean.

Diagram of a mechanical device with a rotating arrow and oil drop symbol (no text or labels)

000115

Figure 4-1. Engine Oil Fill

1. See Figure 4-2. Screw dipstick into filler neck. Oil level is checked with dipstick fully installed. Remove dipstick and verify oil level is within safe operating range.

Technical line drawing of a mechanical component with threaded end and textured base (no text or symbols)

000116

Figure 4-2. Safe Operating Range

1. Add recommended engine oil as necessary.
2. 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

WARNING

Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.

(000141)

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 running, 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 plug.
4. Remove oil fill cap/dipstick.
5. Remove oil drain plug and drain oil completely into a suitable container.
6. Install oil drain plug and tighten securely.
7. Add recommended engine oil as necessary. 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 damaged if run with a dirty air filter. Service air filter more frequently in dirty or dusty conditions. To service air filter:

1. See Figure 4-3. Turn knob (A) and remove air filter cover.
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).

Technical line drawing of a mechanical device with labeled component A (no text or symbols beyond label)

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).

Line drawing of hands holding a screwdriver (no text or symbols present)

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)

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. (000130)

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, use the Recoil Starter to run the generator and charge the battery.

See Figure 4-5.

1. Disconnect negative (-) battery terminal FIRST (black wire).
2. Disconnect positive (+) battery terminal SECOND (red wire).

Technical line drawing of a mechanical assembly with springs and bolts (no text or symbols)

Figure 4-5. Battery Connection

1. Install new battery. Install hold down strap on both hooks.
2. Connect positive (+) battery terminal (red wire) FIRST (red wire). Slide rubber boot over connection hardware.
3. Connect negative (-) battery terminal (black wire) SECOND.
4. Slide rubber boot over connection hardware.

Inspect Muffler and Spark Arrester

NOTE: It is a violation of California Public Resource Code, Section 4442, to use or operate 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, maintained 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 replacement 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

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. (000108)

1. See Figure 4-6. Loosen and remove screws (A).
2. Inspect screen (B) and replace if torn, perforated or otherwise damaged. If screen is not damaged, clean with commercial solvent.
3. Replace spark arrestor cone (C) and screen (B). Secure with screws.

Figure 4-6. Spark Arrestor Screen

Valve Clearance

Important: Please contact an Independent Authorized Service Dealer for service assistance. 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" ± 0.001" inches)
• Exhaust — 0.20 ± 0.02mm (cold) (0.008" ± 0.001" inches)

Storage

General

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.

(000143)

WARNING

Risk of Fire. Verify machine has properly cooled before installing cover and storing machine. Hot surfaces could result in fire.

(000109)

It is recommended to start and run the generator 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 temperature 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 problems.
  • Cover unit with a suitable protective, moisture 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

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.

(000181)

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, prepare and run engine for long term storage. Run engine for 10-15 minutes to circulate stabilizer 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 distribute 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.

Troubleshooting

PROBLEM CAUSE	CORRECTION
Engine is running, but AC output is not available.	1. Circuit breaker OPEN.2. Poor connection or defective cord set.3. Connected device is bad.4. Fault in generator.5. GFCI receptacle is OPEN (if equipped).	1. Reset circuit breaker.2. Check and repair.3. Connect another device that is in good condition.4. Contact IASD.5. Correct ground fault and press reset button on GFCI receptacle (if equipped).
Engine runs well at no-load, but bogs when load is applied.	1. Short circuit in a connected load.2. Generator is overloaded.3. Engine speed is too slow.4. Shorted generator circuit.5. Clogged spark arrestor.	1. Disconnect shorted electrical load.2. Reduce load (see Know Generator Limits).3. Contact IASD.4. Contact IASD.5. Clean spark arrestor screen.
Engine will not start; or starts and runs rough.	1. Dirty air filter.2. Out of fuel.3. Stale fuel.4. Spark plug wire not connected to spark plug.5. Bad spark plug.6. Water in fuel.7. Low oil level.8. Excessive rich fuel mixture.9. Intake valve stuck open or closed.10. Engine lost compression.	1. Clean or replace air filter.2. Fill fuel tank, or replace LP cylinder.3. Drain fuel tank and fill with fresh fuel.4. Connect wire to spark plug.5. Replace spark plug.6. Drain fuel tank and fill with fresh fuel.7. Fill crankcase to correct level.8. Contact IASD.9. Contact IASD.10. Contact IASD.
Engine shuts down during operation.	1. Out of fuel.2. Low oil level.3. Fault in engine.4. COsense shut-off due to accumulating 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.	1. Fill fuel tank, or replace LP cylinder.2. Fill crankcase to correct level.3. Contact IASD.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.
Engine lacks power. 1. Generator is overloaded.2. Dirty air filter.3. Engine needs to be serviced.4. Clogged spark arrestor.		1. Reduce load (see Know Generator Limits).2. Clean or replace air filter.3. Contact IASD.4. Clean spark arrestor screen.
Engine surges or stumbles.		1. Contact IASD.
Engine starts and shuts off right away.	1. COsense shut-off due to accumulating 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 blinks when/if generator shuts-off. If COsense continues to fault and shut-off, contact IASD.

Wiring Diagram

GP6700EDF - 50 State Models

GP9500TF 495T

Notes

Part No. A0005966335 Rev. A 10/31/2024

©2024 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.com

Technical line drawing of a portable gas generator with visible cooling pipes and battery (no text or labels)

MODELO:

SERIE:

FECHA DE COMPRA:

ADVERTENCIA

www.P65Warnings.ca.gov/

(W000808)

Technical line drawing of a portable gas generator with visible engine, fan, and wheels (no text or labels)

015952

Pure electrical circuit lines without any symbols

Circular diagram with concentric rings and four black curved segments arranged in a cross pattern (no text or symbols)

000204
Figura 2-6. Tomacorriente de 120/240 VCA, 30 A NEMA L14-30R

Tomacorriente de 120/240 VCA, 50 A

Pure electrical circuit symbol diagram without any text or labels

000924
Figura 2-7. Tomacorriente de 120/240 VCA, 50 A NEMA 14-50

COsense®

Figura 2-10. Ensamblaje de la manija

Illustration of a hand turning a valve with a curved arrow indicating rotation (no text or symbols)

Technical line drawing of a mechanical connector or fitting (no text or symbols)

Line drawing of a gas stove burner with attached pipe and valve (no text or symbols)

Technical diagram showing mechanical components with an arrow indicating direction (no text or symbols present)

Figura 2-15. Conecte la manguera al regulador.

Line drawing of a hand holding a coiled cable or wire above a cylindrical container (no text or symbols)

002606

Figura 2-16. Abra la válvula de tanque de PL

Technical line drawing of a valve assembly (no text or labels)

Technical line drawing of a mechanical connector assembly (no text or symbols)

Technical line drawing of a mechanical assembly with a wheel and gear component (no text or symbols)

MOVING HANDLE CAN PINCH IF HAND PLACED ON CRADLE

LIFTING BY HANDLE WITHOUT PIN INSERTED CAN CAUSE PHYSICAL INJURY

ALWAYS INSERT LOCKING PIN TO SECURE HANDLE IN PLACE WHEN LIFTING OR MOVING UNIT

CAUTION

Two person lift

Line drawing of a hand holding a coiled cable or wire attached to a cylindrical container (no text or symbols)

002606
Figura 3-5. Válvula de corte del combustible

Illustration of a hand holding a tool with a curved arrow indicating rotation (no text or symbols)

000115
Figure 4-1. Llenado del aceite del motor

Technical line drawing of a mechanical component with threaded end and textured base (no text or symbols)

Technical line drawing of a mechanical device with labeled component A (no text or symbols beyond label)

000379
Figure 4-3. Ensamblaje del filtro de aire

Illustration of hands connecting a screw component to a pin (no text or symbols)

Figura 4-4. Bujía

Technical diagram of a mechanical assembly with springs, hoses, and connectors (no text or labels)

GP9500TF 495T

Notas

Pieza n." A0005966335 Rev. A 31/10/2024

©2024 Generac Power Systems, Inc.