Campbell Hausfeld GN6575, GN5060 User Manual

See Warranty on page 16 for important information about commercial use of this product.

Operating Instructions and Parts Manual GN5060, GN6575

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Need

Assistance?

Generator

Call Us First!

1-800-803-1436

Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . .1

Unpacking . . . . . . . . . . . . . . . . . . . . . . .1

Specifications. . . . . . . . . . . . . . . . . . . . .1

Safety Guidelines . . . . . . . . . . . . . . . . .2

General Safety Information . . . . . . 2 - 3

Glossary of Terms . . . . . . . . . . . . . . . . .3

Pre-operation . . . . . . . . . . . . . . . . . 3 - 4

Operation . . . . . . . . . . . . . . . . . . . . 5 - 6

Maintenance . . . . . . . . . . . . . . . . . . . . .6

Storage . . . . . . . . . . . . . . . . . . . . . . . . .6

Troubleshooting Chart . . . . . . . . . . . . .7

Service Record . . . . . . . . . . . . . . . . . . . .8

Wiring Diagram. . . . . . . . . . . . . . . . . . .9

Generator Assembly . . . . . . . . . . 10 - 11

Alternator Assembly . . . . . . . . . . 12 - 13

Control Panel Assembly . . . . . . . 14 - 15

Warranty . . . . . . . . . . . . . . . . . . . . . . .16

Description

These Campbell Hausfeld generators are powered by gasoline engines. Each unit is equipped with 120V and 230V outlets which provide continuous smooth power for the task at hand. These outlets are protected by GFCI (Ground Fault Circuit Interrupters) and thermal circuit breakers.

READ & FOLLOW ALL INSTRUCTIONS

SAVE THESE INSTRUCTIONS

DO NOT DISCARD

REMINDER: Keep your dated proof of purchase for warranty purposes!

Attach it to this manual or file it for safekeeping.

Unpacking

When unpacking unit, inspect carefully for any damage that may have occurred during transit. Make sure any loose fittings, bolts, etc., are tightened before putting unit into service. In case of questions, damaged or missing parts, please call 1-800-803-1436 for customer assistance. Have the serial number, model number, and parts list (with missing parts circled) before calling.

DO NOT RETURN

STOP!

For parts, product & service information

visit www.chpower.com or call 1-800-803-1436

THE PRODUCT TO THE RETAILER!

Specifications

Model GN5060

Engine . . . . . . . . . . . Honda GX270

Valve Type . . . . . . . . . . . . . . .OHV

Engine Size / Type. . . . . . 270cc / 4 Stroke

Start Type. . . . . . . . . . Manual Recoil

Alternator Type . . . . . 2 Pole, Brushless

Phase / Frequency. . . . . . . . 1 PH / 60 Hz

Alternator Rating . . . . . . . . . 5.2 KVA

Fuel Tank Cap . . . . 6 Gallons [22.7 Liter]

Model GN6575

Engine . . . . . . . . . . . Honda GX390

Valve Type . . . . . . . . . . . . . . .OHV

Engine Size / Type. . . . . . 390cc / 4 Stroke

Start Type. . . . . . . . . . Manual Recoil

Alternator Type . . . . . 2 Pole, Brushless

Phase / Frequency. . . . . . . . 1 PH / 60 Hz

Alternator Rating . . . . . . . . . 6.8 KVA

Fuel Tank Cap . . . . 6 Gallons [22.7 Liter]

IN954800AV 3/12

Operating Instructions and Parts Manual

Safety Guidelines

This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

Danger indicates

hazardous situation which, if not avoided, WILL result in death or serious injury.

Warning indicates

hazardous situation which, if not avoided, COULD result in death or serious injury.

Caution indicates

hazardous situation which, if not avoided, MAY result in minor or moderate injury.

Notice indicates

information, that if not followed, may cause damage to equipment.

NOTE: Information that requires special attention.

General Safety Information

CALIFORNIA PROPOSITION 65

The engine exhaust

contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

You can

dust when you cut, sand, drill or grind materials such as wood, paint, metal, concrete, cement, or other masonry. This dust often contains chemicals known to cause cancer, birth defects, or other reproductive harm. Wear protective gear.

EMISSIONS

Engines that are

with U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certiﬁ ed to operate on regular unleaded gasoline, and may include the following emission control systems: (EM) Engine Modiﬁ cations and (TWC) Three-Way Catalyst (if so equipped).

Using a generator

YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

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an imminently

a potentially

important

from this product

create

certiﬁ ed to comply

indoors CAN KILL

• NEVER use inside a house or garage, EVEN IF doors and windows are open.

• Only use OUTSIDE and far away from windows, doors and vents.

GENERAL SAFETY

• Before starting or servicing any generator, read and understand all instructions. Failure to follow safety precautions or instructions can cause equipment damage and / or serious personal injury or death. Engine instructions for these units are contained in a separate manual. Retain all manuals for future reference.

FUEL AND

ARE EXTREMELY FLAMMABLE! Allow engine to cool at least two (2) minutes before refueling. Do not use gasoline / ethanol blends with greater than 15% ethanol.

Never

this generator in an explosive or flammable atmosphere or poorly ventilated area.

• Never use this generator for any application other than that specified by the manufacturer. Never operate this generator under conditions not approved by the manufacturer. Never attempt to modify this generator to perform in any manner not intended by the manufacturer.

• For maintenance and repairs, use only products and parts recommended by the manufacturer.

• Be sure that the generator is properly grounded to an external ground path prior to operation. Refer to the section entitled "Grounding Instructions" for proper grounding procedures.

• Be sure that the generator is operated only by persons who have read and understand these instructions.

VAPORS

operate

MANUAL

• Be sure that the generator is placed on a flat level surface prior to and during operation. The generator must not slide or shift during operation.

• Keep all persons away from the generator during operation.

• Do not allow persons wearing loose clothing or jewelry to start or operate the generator. Loose clothing or jewelry may become entangled in moving components, causing equipment damage and or personal injury.

• Keep all persons away from parts that move or become hot during operation.

• Be sure all powered devices are shut off prior to connecting them to the generator.

• Keep the generator clean and well maintained at all times.

• Be sure that all tools and appliances are in good repair and are properly grounded. Use devices that have three prong power cords. If an extension cord is used, be sure that it has three prongs for proper grounding.

Do not operate this

generator on wet

surfaces or in the rain. Shut off the engine

and disconnect the spark plug wire before performing any service or maintenance to the unit.

• Use only unleaded fuel. Do not

refill the fuel tank while the engine is running. Use precautions to prevent fuel spillage during refills. Be sure the fuel tank cap is securely in place before starting the engine. Clean up any spilled fuel before starting the engine. Allow engine to cool for at least two minutes before refueling. Do not add fuel while smoking or if unit is near any sparks or open flames. Do not overfill tank - allow room for fuel to expand. Always keep nozzle in contact with tank during fueling.

• This generator may be used for

emergency stand-by service. In such cases, a manual transfer switch must be installed between the electric utilities meter and the electrical distribution box. This switch should be installed by a licensed electrician.

GN5060, GN6575

General Safety Information (Continued)

Never mix oil with

gasoline for this engine. This is a four cycle engine designed to run on pure gasoline. Oil is used for engine lubrication purposes only.

HOT SURFACES! Hot surfaces will severely burn flesh. Do not touch engine, muffler, and alternator until the unit has fully cooled.

Always

keep a fire extinguisher accessible while operating unit.

• All installation, maintenance, repair

and operation of this equipment should be performed by qualified persons only in accordance with national, state, and local codes.

Improper

use of electric generators can cause electric shock, injury, and death! Take all precautions described in this manual to reduce the possibility of electric shock.

• Verify that all components of

the generator are clean and in good condition prior to operating the generator. Be sure that the insulation on all cables and power cords is not damaged. Always repair or replace damaged components before operating the generator. Always keep panels, shields, etc. in place when operating the generator.

• Always wear dry protective

clothing, gloves, and insulated footwear.

• Always operate the generator in a

clean, dry, well ventilated area. Do not operate the generator in wet, rainy, or poorly ventilated areas.

• Never use the generator as a work

surface.

If the generator

becomes wet for any reason, be absolutely certain that it is completely clean and dry prior to attempting use!

• Always shut the equipment off

prior to moving the unit.

ADDITIONAL SAFETY STANDARDS

Safety and Health Standards

OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

National Electrical Code

NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

Glossary of Terms

CC (Cubic Centimeter) - measure of

the engine's cylinder volume above the piston when measured with the piston fully retracted by the crankshaft.

Four Stroke Engine - an internal combustion engine in which the piston completes four separate strokes; intake, compression, power, and exhaust during two separate revolutions of the engine's crankshaft.

RPM - Revolutions per Minute. Typically this is for measuring engine crankshaft or alternator rotor speed.

EPA - United States Environmental Protection Agency.

CARB or ARB - California Environmental Protection Agency Air Resources Board.

NEC - National Electrical Code UL - Underwriters Laboratories CSA - Canadian Standards Association NEMA - National Electrical

Manufacturers Association Alternator - an electromechanical

device that converts mechanical energy to electrical energy in the form of alternating current.

Hertz (Hz) - a unit of frequency of alternating current measured in cycles per second.

Brushless - an alternator that creates a magnetic field in the rotor that induces electrical current in stationary conductors which are wound as coils. By contrast, brush type generators commute electrical current from the rotor to the stator through carbon spring loaded brushes that make electrical contact through commutator bars.

AC (Alternating Current) - an electrical current that reverses its direction periodically or at a frequency.

DC (Direct Current) - an electrical current that moves in one direction therefore having a polarity.

Volt (V) - a measurement unit of work needed to move an electric charge.

Ampere (A) or (I) - a unit to define the rate of flow of electrical current.

Watt (W) - a unit of electrical power calculated by W = V x I or W = volts x amps.

Kilowatt (KW) - a unit of watt measurement equal to W/1000. For example: 5000W = 5KW.

Power Factor (PF) - the ratio of the real power flowing to the load to the apparent power in the circuit.

Kilo Volt-Ampere (KVA) - the unit used for the apparent power in an electrical circuit. KVA = KW/PF.

GFCI (Ground Fault Circuit Interrupter) - a circuit breaker that

opens when leakage current is detected. Thermal Circuit Breaker (CB) - a

circuit breaker that opens when current exceeds the circuit breaker's current

limit.

Pre-Operation

LOCATION

Selecting the proper location can significantly increase performance, reliability and life of the generator.

For best results locate the generator in an environment that is clean and dry. Dust and dirt in the unit retain moisture and increase wear of moving parts.

INSTRUCTIONS

Check engine oil level. Oil is NOT mixed with the gasoline, however adequate oil supply is necessary for proper engine lubrication. Refer to the Engine Manual for SAE, API and fill quantity specifications. Unit is shipped without oil in engine.

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Operating Instructions and Parts Manual

Pre-Operation (Continued)

GROUNDING

1. Use the ground terminal and wing nut on the generator frame to connect the unit to a suitable ground source. Securely fasten the end terminal of the ground wire to the ground terminal on the generators frame. Tighten the washer and wing nut on top of the ground wire end terminal.

2. The ground wire should be made of #8 gauge wire. Do not use wire with a higher gauge number. Higher gauge numbers indicate thinner wire, which may not provide an adequate ground path.

3. The other end of the ground wire must be securely fastened to an approved ground source.

The following are ground sources approved by the National Electric Code. Other ground sources may be acceptable. Refer to the National Electric Code and local regulations for further ground source information. If not sure of regulations or procedures, obtain assistance from a qualified (licensed or certified) electrical technician.

a. An underground water pipe at

least ten feet in length

b. A non-corrosive underground

pipe at least eight feet in length and 3/4 inch diameter

c. A steel or iron underground rod

at least eight feet in length and 5/8 inch diameter

d. A non-ferrous rod at least

eight feet in length, 1/2 inch in diameter, and approved for grounding purposes

Any rod or pipe used for grounding must be driven to eight feet deep or

buried in the deepest possible trench.

Figure 1

FUELING AND REFUELING (SEE FIGURE 1)

1. Shut-off engine and wait 2 minutes before filling fuel tank.

2. Remove fuel cap and fill fuel tank to bottom of metal filler neck; about 1-3/8 inch [3.5 cm or 35 mm] from top of filler neck opening.

3. Do not overfill fuel tank. Overfilling may damage roll-over valve and carbon canister.

4. Reinstall fuel cap; make sure to rotate cap clockwise unit it stops.

STARTING

1. Remove all electrical loads from the generators.

2. Rotate fuel petcock valve lever, located on underside of fuel tank, to the vertical position to open valve.

3. Flip engine toggle switch (on control panel) to the ON position.

4. The engine is equipped with an automatic choke. However, the choke mechanism has a manual override feature for extreme cold weather starting. For extreme cold weather starting, pull choke wire; after engine warms, push choke in to it's normal operating position.

5. Pull the starter rope with a brisk, smooth motion.

1-3/8 inch [3.5 cm or 35 mm]

Gasoline Fill Level

6. After each start up, allow the engine to run for 2-3 minutes with

no load.

Engine speed is

preset to provide proper output voltage. Never attempt to modify or adjust engine speed or output voltage.

ENGINE BREAK-IN

After initial start-up, the engine should be broken in according to the manufacturer's instructions. Refer to the engine manual for the proper break-in

procedure.

SHUT-OFF

1. Shut off and remove all electrical

load devices from the generator.

2. Allow the engine to run for 2-3

minutes with no electrical loads.

3. Flip the engine toggle switch (on

control panel) to the OFF position.

4. Verify that the generator has

completely stopped.

5. Rotate fuel petcock valve lever,

located on underside of fuel tank, to the horizontal position to close valve.

6. Allow the unit to cool before

installing any covers.

TABLE 1 - ESTIMATED POWER USAGE (WATTS)

LOAD DEVICE WATTS LOAD DEVICE WATTS LOAD DEVICE WATTS LOAD DEVICE WATTS

Air conditioner 2000-3000 Electric drill

(large)

Automatic washer

Brooder 100+ Freezer 300-500 Skillet 1200 Water pump 1000-3000 Clothes dryer 5000-10,000 Hot plate 330-1100 Space heater 600-4800 Water heater 1000-5000 Coffee maker 400-700 Iron 500-1500 Sump pump 400-3000 Small hand saw 1000-2000 Electric drill

(small)

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150-1500 Fan 40-200 Refrigerator 190-2000 Vacuum cleaner 200-300

225-1000 Light bulb AS RATED Television 200-500 Large hand saw 1500-2500

500-1000 Radio 50-200 Toaster 900-1700

GN5060, GN6575

Pre-Operation (Continued)

AUTO-IDLE CONTROL (IF EQUIPPED)

Some units have an auto-idle control that idles the engine when there is no demand required of the generator. The control panel has an idle control toggle switch to enable or disable this function.

1. Idle Control Switch - ON enables the auto-idle feature and the engine will automatically idle when not under load.

2. Idle Control Switch - OFF disables the auto-idle feature and the engine will run at full throttle.

LOW OIL SHUTDOWN

A low oil shutdown switch is provided to protect the engine and generator on most extended run models. When engine oil level drops too low for proper engine operation, the low oil shutdown switch causes the engine to shut off. If oil level is low when attempting to start the generator engine, the low oil level shutdown switch prevents the engine from starting. If engine does not start, check oil level.

NOTE: It is important to keep the generator unit on a level surface. The oil level shutdown switch can prevent the engine from starting even if oil level is sufficient, when the generators unit is

placed on an uneven surface.

Operation

LOAD DEVICES

1. All load devices and extension cords should use three prong terminals. Refer to Table 2 for extension cord and cable size requirements.

2. Allow the engine to run for 2-3 minutes before applying any electrical loads.

3. The 120 volt receptacles are rated for 20 amps and may be used in any combination of 120 volt loads and also with 240 volt loads through the 240 volt receptacles.

The 240 volt receptacles, found

on some generators, are rated for 20 amps and may be used in any combination of 240 volt loads and also with 120 volt loads through the 120 volt receptacles.

The 120/240 volt twist lock

receptacle is rated for 20 amps and may be used in any combination of 120 volt and 240 volt loads.

4. Individual receptacles should not be loaded beyond the amperage rating.

5. Total combined load through any combination of receptacle must not exceed the rated load limits of the generator. Refer to the identification plate on the generators for amp and wattage specifications.

6. Always shut off and remove loads before starting or shutting off the generator engine.

7. When plugging multiple electrical load devices into the generator receptacles, be sure to connect and activate the highest power draw item first. Allow the generator engine to stabilize, then connect and activate the next highest power draw device. The smallest power draw device should be connected to the receptacle and activated last.

NOTE: Power draw can be calculated by multiplying volts and amps. The resulting number is wattage.

Never exceed the posted maximum wattage for the generator or any individual receptacle. Refer to owner's

manuals and product tags to determine the wattage of all electrical load devices.

If actual watt ratings are not available, the Power Usage Chart, see Table 1, may be used as a general guideline.

Remember that devices which generate heat during operation such as heaters, incandescent light bulbs, motors and hair dryers have a higher power draw than devices which generate little heat during operation such as florescent bulbs, radios, and clocks.

Long power cords and extension cords also draw additional power. Keep cords at minimum possible length.

Refer to Table 2 for maximum limits for lengths of extension cords.

8. Circuit protection is provided by a circuit breaker. The circuit breaker opens when the generator load exceeds its maximum capacity or a short circuit occurs. If the circuit breaker opens, perform the following procedures to correct the problem:

a. Shut off and disconnect all

electrical loads.

b. Attempt to determine the cause

of the electrical problem overloading or short circuit.

c. Do not use any devices that have

short circuits. Avoid overloading the generator.

d. Press the circuit breaker

pushbutton to reset the circuit breaker.

Repeated cycling of

the circuit breaker indicates a problem and may cause damage to the generator or load devices. Do not operate the generatoreated cycling of the circuit breaker occurs.

TABLE 2 - EXTENSION CORDS

Maximum Recommended Lengths (in feet)

Amps Watts 120 V Watts 240 V #8 Wire #10 Wire #12 Wire #14 Wire #16 Wire

2.5 300 600 1000 600 375 250 5 600 1200 500 300 200 125

7.5 900 1800 350 200 125 100

10 1200 2400 250 150 100 50 15 1800 3600 150 100 65 20 2400 4800 175 125 75 50 25 3000 6000 150 100 60 30 3600 7200 125 65 40 4800 9600 90

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Operating Instructions and Parts Manual

Operation (Continued)

INSTALLATION FOR STAND-BY USE

Precautions must be taken to prevent electrical back feeding into utility systems. This requires isolation of the electrical system. To isolate the electrical system, perform the following procedures:

1. Turn off the main electrical system switch prior to connecting the generator.

2. In accordance with national and local standards, a double throw transfer switch must be installed in

the system.

Always shut off

main power prior to temporary connection of the generator to a building electrical system.

Installation of the

generator as a backup electrical source must be performed by a qualified (licensed or certified) electrical technician.

Maintenance

INFREQUENT USAGE

If the generator is used infrequently, starting difficulty may occur. To help prevent this, the generators should be run for approximately 30 minutes per week.

STORAGE

If the generator is not to be used for extended periods of time, the following pre-storage procedures should be performed:

1. Make sure engine oil is filled to the proper level.

2. Drain all fuel from the tank, lines, carburetor and fuel valve.

3. Remove the spark plug, and pour approximately one teaspoon of oil into the spark plug hole.

4. Pull the starter cord several times to spread the oil throughout the cylinder.

5. Slowly pull the starter cord, until resistance is felt. This indicates that the piston is moving upward on the compression cycle, and the intake and exhaust valves are closed. (The piston pushes a small amount of air from the spark plug hole on compression.)

6. Use of fuel stabilizers or antigumming agents in the fuel system can help prevent the build up of gum and varnish.

Whenever the generator is stored, be sure that the fuel shut-off valve is in the closed position.

Refer to the engine manual that accompanies this unit for instructions regarding maintenance of engine

components.

Never tamper with

engine speed settings. Any governor adjustments should be made by qualified personnel only.

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Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

Engine will not start

Engine runs but there is no electrical output

Generator runs but does not support all electrical devices connected.

No output voltage

Low output voltage with no load

High output voltage with no load

Low output voltage under load

Erratic output voltage

Noisy operation 1. Loose generator or engine bolt

Auto-Idle does not work

★ These diagnostic and repair procedures should be performed by an authorized service center.

1. Run switch is set to "OFF".

2. Fuel valve is turned to "CLOSE".

3. Choke is open.

4. Fuel tank is empty.

5. Engine is filled with contaminated or old gas

6. Spark plug is dirty.

7. Spark plug is broken.

8. Unit is not on level surface.

9. Oil is low.

1. Main or secondary circuit breaker(s) are tripped.

2. Bad connecting of wires / cables.

3. Bad electrical device connected to generator.

1. Generator is overloaded

2. Short in one of the connected devices.

3. Air cleaner is dirty.

1. Engine speed is too slow

2. Open, shorted, or incorrect wiring

3. Faulty capacitor

4. Open or shorted field windings

5. Open diodes

6. Circuit breaker tripped

1. Engine speed is too slow

2. Open diodes

3. Faulty capacitor

4. Open or shorted ﬁ eld windings

1. Faulty capacitor

2. Engine speed is too fast

1. Open diode

2. Engine speed too slow at full load

3. Excessive load applied

1. Unbalanced engine

2. Dirty, corroded, or loose wiring connection

3. Unstable load applied

2. Short circuit in generator field or load

3. Faulty bearing

1. Damaged or disconnect wire in idle control circuit.

2. Failed idle control circuit board.

3. Failed current sensing coil.

1. Set run switch to "ON".

2. Turn fuel valve to "OPEN" position.

3. Close the choke.

4. Add gas.

5. Change the gas in the engine.

6. Clean spark plug.

7. Replace spark plug.

8. Move unit to a level surface to prevent low oil shutdown from triggering.

9. Add or replace oil.

1. Reset main or secondary circuit breaker(s).

2. If you are using an extension cord, try a different one.

3. Try connecting a different device.

1. Turn off all electrical devices. Unplug all electrical devices. Turn off generator. Wait several minutes. Restart generator. Try connecting fewer electrical loads to the generator.

2. Try disconnecting any faulty or short-circuited electrical loads.

3. Clean or replace air cleaner.

1. Adjust engine speed. ★

2. Referring to the wiring diagram, clean and reconnect all wiring. ★

3. Replace capacitor. ★

4. Test winding resistance, replace field winding if necessary. ★

5. Test diodes, replace if necessary. ★

6. Reset circuit breaker.

1. Adjust engine speed. ★

2. Test diodes, replace if necessary. ★

3. Replace capacitor. ★

4. Test winding resistance, replace field winding if necessary. ★

1. Replace capacitor. ★

2. Adjust engine speed. ★

1. Test diodes, replace if necessary. ★

2. Adjust engine speed. ★

3. Reduce the applied load.

1. Refer to engine manual.

2. Referring to the wiring diagram, clean and reconnect all wiring. ★

3. Remove all loads, then apply each one individually to determine which one is causing erratic function.

1. Tighten all mountings.

2. Test winding resistance, replace ﬁ eld winding if necessary.

Test load devices for shorts. Replace defective load device.

3. Replace bearing.

1. Repair or replace wiring.

2. Replace idle control board.

3. Replace current sensing coil.

GN5060, GN6575

★

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Operating Instructions and Parts Manual

Service Record

Date Maintenance performed Repair components required

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J1128, Type TXL

Ins.

GN5060, GN6575

8 AWG, SAE J1128,

GPTI

12 AWG, UL 1015/

16 AWG, SAE

UL 1230

Stranded Copper

Wire Lead

Specifications

GREEN

ALTERNATOR HOUSING

GENERATOR FRAME

WHITE

GROUND SCREW AT

IDLE CONTROL

SOLENOID

IDLE CONTROL

CIRCUIT BOARD

ALTERNATOR

BLACK

AC2 AC1 TR1 TR2

IDLE CONTROL

SWITCH

ROTOR STATOR

EXCITATION

WINDING

CAPACITOR

BLACK

WHITE GFCI WIRE

BLACK

BREAKER

CIRCUIT

2-POLE

GFCI

CB1

BLACK

GROUND SCREW IN

ALTERNATOR HOUSING

120V

MAIN WINDING

GREEN

BLACK BLACK

BLACK

1311121443

BROWN

BLUE

361718

TB1

WHITE

TB2

MAIN WINDING

120V

ORANGE

WHITE

12V

AUXILLIARY WINDING

43 44

BLACK

HOUR METER

25, 26, 27, 28, 29,

30, 31, 34, 35, 45

23, 24, 28, 32, 33,

36, 37, 38, 39, 40,

42, 43, 44, 46

IGNITION MODULE

BLACK

PINK

per Schematic

Ground Wire at

Generator Frame

11, 12, 13, 14, 15,

16, 17, 18, 19, 20,

CARBURETOR

SOLENOID

ENGINE

YELLOW

YELLOW / WHITE

Wire Number

LOOP THROUGH COIL

GREEN GREEN

GREEN

30 31

GROUND SCREW AT

CONTROL PANEL

GREEN

Figure 2 - Wiring Diagram

BLACK WIRE HAS (2)

LOOPS THROUGH COIL

BROWN WIRE HAS (1)

CURRENT SENSING COIL

BREAKER

CIRCUIT

RECEPTACLE

BLACK

20A

CB3

20A DUPLEX

BROWN

19 35

BROWN

BLACK

BREAKER

CIRCUIT

BROWNBROWN

20A

ORANGE

CB2

ORANGE

RECEPTACLE

NEMA L15-30R

20 34

BLACK

RECEPTACLE

120 / 240 VOLT

WHITE

20A DUPLEX

GREEN

FUSE - 15A

39 46

RECTIFIER

RED

ENGINE

CONTROL

SWITCH

WHITE

BLUE

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Operating Instructions and Parts Manual

Generator Assembly

19 18

Figure 3

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For replacement parts or technical assistance, call 1-800-803-1436

GN5060, GN6575

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

Address parts correspondence to:

Campbell Hausfeld Attn: Customer Service 100 Mundy Memorial Dr. Mt. Juliet, TN 37122 USA

Replacement Parts List

Ref.

No. Description Part Number Qty.

1 Generator Frame GN051081SJ 1 2 Honda Engine and Sincro Alternator Assembly See Page 12 1 3 1/4 inch ID Fuel Hose, 8-1/4 inch L, Carb. to Petcock (GN5060 Only) 4 3/8 inch Constant tension hose clamp (GN5060 Only) MJ111006AV 2 5 Hex Bolt, 3/8 - 16 UNC X 3 inch L 6 Fender Washer, 3/8 inch 7 ISO Mount Assembly PM004290AV 3 8 Hex Nut, 3/8 - 16 UNC

9 Hex Bolt, 3/8 - 16 UNC X 2-1/2 inch L 10 Hex Bolt, M8 - 1.25 X 70 11 ISO Mount Spacer GN051065AV 1 12 Ground Cable, 8 AWG SAE GN052305AV 1 13 Hex Bolt, 1/4 - 20 UNC X 3/4 inch L 14 Flange Nut, 1/4 - 20 UNC 15 Hex Bolt, 5/16 - 18 UNC X 1-1/4 inch L 16 Star Washer - 5/16 inch Internal / External Tooth 17 Flange Nut, 5/16 - 18 UNC 18 Flat Washer - 0.344 X 0.688 X 0.065 19 Wing Nut, 5/16 - 18 UNC 20 600cc Carbon Canister GN051031AV 1 21 Carriage Bolt - 1/4 - 20 UNC X 3/4 inch L 22 Control Panel Assembly (Includes ALL parts listed on page 14, plus all wiring and conduit) GN051111SJ 1 23 Pan Head Screw, 1/4 - 20 UNC X 3/4 inch L 24 Conduit, 0.62 inch ID, 6 inch L 25 Conduit, 0.62 inch ID, 18 inch L 26 Fuel Tank GN051030AV 1 27 Hex Bolt, 1/4 - 20 UNC X 1 inch L 28 Fender Washer - 1/4 inch 29 Grommet - 0.688 X 0.563 ID Hole X 0.063 Groove 30 1/4 inch ID Fuel Hose, 35 inch L (Tank to Carbon Canister) 31 1/2 inch ID Fuel Hose, 4 inch L (Carbon Canister to Engine) 32 Roll-over Valve GN051032AV 1

Warning Decal - Frame DK667841AV 1 Warning Decal (CPSC) - Fuel Tank DK667848AV 1 Warning Decal (Earth Ground) - Frame DK667849AV 1 Warning Decal (Fueling Process) - Fuel Tank DK667850AV 1 Warning Decal (Not sold in California) - Fuel Tank DK667851AV 1 Warning Decal (Spark Warning) - Frame DK667155AV 1 Warning Decal (EPA Certification) - Frame DK667500AV 1

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Standard hardware item, available at local hardware stores

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Operating Instructions and Parts Manual

Alternator Assembly

Figure 4

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Assembled muffler detail

showing flange hex nut

position.

For replacement parts or technical assistance, call 1-800-803-1436

GN5060, GN6575

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

Address parts correspondence to:

Campbell Hausfeld Attn: Customer Service 100 Mundy Memorial Dr. Mt. Juliet, TN 37122 USA

Replacement Parts List

Ref.

No. Description Part Number Qty.

1 Honda GX390 Low Profile Engine GN060001AV 1

Honda GX270 Low Profile Engine GN060000AV 1

6 Hex Bolt, 3/8 - 16UNC X 1.00L

7 3/8 inch Lock Washer

9 10 11

12 13 14 15 16 Elbow Connector- HEYCO 8425 GN051096AV 1 17 Honda Muffler 18 Muffler Bracket - Honda GX390 Engine GN051012KK 1

19 Flange Hex Nut, M8 20 Hex Bolt- 5/16 - 18 UNC X 0.75 L 21 Flange Hex Nut, 5/16 - 18 UNC 22 Hex Bolt, 3/8 - 16 UNC x 1-3/4 inch L 23 Flange Hex Nut, 3/8 -16 UNC 24 USDA Screen GN051013AV ▲ 1 25 Clamp, USDA Screen GN051014AD ▲ 1 26 Pan Head Self Tapping Screw (Muffler Clamp) GN051015AV ▲ 1

●

Sincro Alternator - 6.8 kVA, 60Hz GN051001SJ 1

■

Sincro Alternator - 5.2 kVA, 60Hz GN051000SJ 1

■ ●

Sincro Engine Adapter Not Available 1

■ ●

Hex Bolt, M8 x 25mm

■ ●

M8 NyLock Nut

■ ●

Screw, Pan Head, M5 X 10mm

■ ●

Sincro Rear Shield GN051016AV 1

■ ●

Capacitor - 35mf, 450V GW001016SV 1

●

Sincro Threaded Rod (6.8 kVA Alt.) GN051008AV 1

■

Sincro Threaded Rod (5.2 kVA Alt.) GN051025AV 1

■ ●

Sincro Rear Cover Kit GN051002SJ 1

■ ●

Sincro Round Hole Plug GN051009AV 1

■ ●

Sincro LH Louver GN051018AV 1

■ ●

Sincro RH Louver GN051017AV 1

Muffler Bracket - Honda GX270 Engine GN051011KK 1

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▲

★

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2 2 2 1 1

REPLACEMENT PARTS KITS

▲

Honda Muffler Kit GN051010SJ

SYMBOLS DEFINED

■

Included with GN051000SJ - Sincro Alternator (5.2 kVA)

●

Included with GN051001SJ - Sincro Alternator (6.8 kVA)

★

Standard hardware item, available at local hardware stores

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Operating Instructions and Parts Manual

Control Panel Assembly

3 6

Figure 5

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For replacement parts or technical assistance, call 1-800-803-1436

GN5060, GN6575

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

Address parts correspondence to:

Campbell Hausfeld Attn: Customer Service 100 Mundy Memorial Dr. Mt. Juliet, TN 37122 USA

Replacement Parts List

Ref.

No. Description Part Number Qty.

1 Control Panel GN051093AD 1

2 GFCI Circuit Breaker GN051042AV 1

3 Cover, GFCI Circuit Breaker GN051022AV 1

4 GFCI Cover Plate- Painted GN051024KK 1

5 Pan Head Screw, #6 - 32 X 3/8 inch L

6 Cover, Duplex Receptacle GN051021AV 2

7 Duplex Receptacle- 120V, 20 Amp GN003403AV 2

8 Cover, Twist Lock Receptacle GN051020AV 1

9 Twistlock Receptacle, 125 - 250V, 30 Amp GW004255AV 1 10 Pan Head Screw, #8 - 32 X 1/2 inch L 11 Nylock Nut, #8 - 32 12 Digital Hour Meter GN051094AV 1 13 Thermal Circuit Protector - Pushbutton GN051041AV 2 14 Engine Run-Stop Switch GW004258AV 1 15 Idle Control Switch PM351124AV 1 16 Rear Control Panel Cover GN051023AV 1 17 Bridge Rectifier, 200V, 15 Amp GN006651AV 1 18 Pan Head Screw, 8 - 18 HiLo X 1 inch L 19 Terminal Block GN051099AV 2 20 Tapping Screw, #10 X 1/2 inch L 21 Elbow Connector- Heyco 8425 GN051096AV 1 22 Connector Nut GN051097AV 2 23 Straight Connector - Heyco 8402 GN051095AV 1 24 Control Panel Hole Plug, 7/8 inch ID MJ106807AV 1 25 Idle Control Circuit Board GN051070AV 1 26 Pan Head Screw, #8 - HiLo X 1/2 inch L 27 Idle Control Current Sensing Coil GN051075AV 1 28 Pan Head Screw, #8-32 X 3/4 inch L 29 #8 Lock Washer, Internal / External Tooth 30 Fuse Holder HV010201AV 1

Fuse, 1-1/4 inch x 1/4 inch, 15 Amp (not shown)

★

Standard hardware item, available at local hardware stores

★

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