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.

Generator

					RAN
			SU			CE	PR
			S
		A						O
	Y							G
T								R
I				Need				A
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Q

Assistance?

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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.

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! THE PRODUCT TO

THE RETAILER!

READ & FOLLOW ALL INSTRUCTIONS

SAVE THESE INSTRUCTIONS

DO NOT DISCARD

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]

REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

© 2012 Campbell Hausfeld/Scott Fetzer	For parts, product & service information	IN954800AV 3/12
	visit www.chpower.com or call 1-800-803-1436

Operating Instructions and Parts Manual

	Safety Guidelines			• Be sure that the generator is placed
	This manual contains information			on a flat level surface prior to and
				during operation. The generator
	that is very important to know and
				must not slide or shift during
	understand. This information is
				operation.
	provided for SAFETY and to PREVENT
	EQUIPMENT PROBLEMS. To help			• Keep all persons away from the
	recognize this information, observe the			generator during operation.
	following symbols.			• Do not allow persons wearing
	Danger indicates
				loose clothing or jewelry to start
	an imminently	• NEVER use inside a house or		or operate the generator. Loose
	hazardous situation which, if not
		garage, EVEN IF doors and windows		clothing or jewelry may become
	avoided, WILL result in death or serious
		are open.		entangled in moving components,
	injury.
	Warning indicates	• Only use OUTSIDE and far away		causing equipment damage and or
				personal injury.
	a potentially	from windows, doors and vents.
	hazardous situation which, if not	GENERAL SAFETY		• Keep all persons away from parts
	avoided, COULD result in death or			that move or become hot during
	serious injury.	• Before starting or
				operation.
	Caution indicates
		servicing any generator,		• Be sure all powered devices are
	a potentially
		read and understand all	MANUAL
	hazardous situation which, if not			shut off prior to connecting them
		instructions. Failure to
	avoided, MAY result in minor or			to the generator.
		follow safety precautions
	moderate injury.			• Keep the generator clean and well
	Notice indicates	or instructions can cause equipment
				maintained at all times.
	important	damage and/or serious personal
	information, that if not followed, may	injury or death. Engine instructions		• Be sure that all tools and appliances
	cause damage to equipment.	for these units are contained in		are in good repair and are properly
	NOTE: Information that requires special	a separate manual. Retain all		grounded. Use devices that have
	attention.	manuals for future reference.		three prong power cords. If an
		FUEL AND		extension cord is used, be sure
	General Safety Information	VAPORS		that it has three prongs for proper
		ARE EXTREMELY FLAMMABLE!		grounding.
	CALIFORNIA PROPOSITION 65
		Allow engine to cool at		Do not operate this
	The engine exhaust	least two (2) minutes before		generator on wet
	from this product	refueling. Do not use gasoline/ethanol		surfaces or in the rain.
	contains chemicals known to the State	blends with greater than 15% ethanol.		Shut off the engine
	of California to cause cancer, birth	Never
				and disconnect the
	defects, or other reproductive harm.	operate		spark plug wire before performing any
	You can	this generator in an explosive		service or maintenance to the unit.
	create	or flammable atmosphere or		• Use only unleaded fuel. Do not
	dust when you cut, sand, drill	poorly ventilated area.		refill the fuel tank while the engine
	or grind materials such as
		• Never use this generator for		is running. Use precautions to
	wood, paint, metal, concrete,
		any application other than that		prevent fuel spillage during refills.
	cement, or other masonry. This dust
		specified by the manufacturer.		Be sure the fuel tank cap is securely
	often contains chemicals known to
		Never operate this generator under		in place before starting the engine.
	cause cancer, birth defects, or other
	reproductive harm. Wear protective	conditions not approved by the		Clean up any spilled fuel before
	gear.	manufacturer. Never attempt to		starting the engine. Allow engine
	EMISSIONS	modify this generator to perform		to cool for at least two minutes
		in any manner not intended by the		before refueling. Do not add fuel
	Engines that are
		manufacturer.		while smoking or if unit is near
	certified to comply
		• For maintenance and repairs,		any sparks or open flames. Do not
	with U.S. EPA emission regulations for
				overfill tank - allow room for fuel
	SORE (Small Off Road Equipment), are	use only products and parts
				to expand. Always keep nozzle in
	certified to operate on regular unleaded	recommended by the manufacturer.
				contact with tank during fueling.
	gasoline, and may include the following	• Be sure that the generator is
	emission control systems: (EM) Engine			• This generator may be used for
		properly grounded to an external
	Modifications and (TWC) Three-Way			emergency stand-by service. In
		ground path prior to operation.
	Catalyst (if so equipped).			such cases, a manual transfer
		Refer to the section entitled
	Using a generator
				switch must be installed between
		"Grounding Instructions" for
	indoors CAN KILL			the electric utilities meter and the
		proper grounding procedures.
	YOU IN MINUTES. Generator exhaust			electrical distribution box. This
	contains carbon monoxide. This is a	• Be sure that the generator is
				switch should be installed by a
	poison you cannot see or smell.	operated only by persons who

licensed electrician.

have read and understand these instructions.

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2

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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3

Operating Instructions and Parts Manual

Pre-Operation (Continued)	1-3/8 inch [3.5 cm or 35 mm]
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			Gasoline Fill Level
washer and wing nut on top of the
ground wire end terminal.

Figure 1

2.The ground wire should be made

of #8 gauge wire. Do not use wire

FUELING AND REFUELING

6.

After each start up, allow the

with a higher gauge number.

(SEE FIGURE 1)

engine to run for 2-3 minutes with

Higher gauge numbers indicate

1.

Shut-off engine and wait 2 minutes

no load.

thinner wire, which may not

before filling fuel tank.

Engine speed is

provide an adequate ground path.

2.

Remove fuel cap and fill fuel tank

preset to provide

3. The other end of the ground wire

proper output voltage. Never attempt

to bottom of metal filler neck;

to modify or adjust engine speed or

must be securely fastened to an

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

output voltage.

approved ground source.

from top of filler neck opening.

The following are ground sources

3.

Do not overfill fuel tank. Overfilling

ENGINE BREAK-IN

approved by the National Electric

may damage roll-over valve and

After initial start-up, the engine

Code. Other ground sources may be

carbon canister.

should be broken in according to the

acceptable. Refer to the National

4.

Reinstall fuel cap; make sure to

manufacturer's instructions. Refer to the

Electric Code and local regulations for

engine manual for the proper break-in

rotate cap clockwise unit it stops.

further ground source information. If

procedure.

not sure of regulations or procedures,

STARTING

SHUT-OFF

obtain assistance from a qualified

1.

Remove all electrical loads from the

(licensed or certified) electrical

1.

Shut off and remove all electrical

generators.

technician.

load devices from the generator.

2.

Rotate fuel petcock valve lever,

a. An underground water pipe at

2.

Allow the engine to run for 2-3

located on underside of fuel tank,

least ten feet in length

minutes with no electrical loads.

to the vertical position to open

b. A non-corrosive underground

3.

Flip the engine toggle switch (on

valve.

pipe at least eight feet in length

3.

Flip engine toggle switch (on

control panel) to the OFF position.

and 3/4 inch diameter

4.

Verify that the generator has

c. A steel or iron underground rod

control panel) to the ON position.

at least eight feet in length and

4.

The engine is equipped with an

completely stopped.

5.

Rotate fuel petcock valve lever,

5/8 inch diameter

automatic choke. However, the

d. A non-ferrous rod at least

choke mechanism has a manual

located on underside of fuel tank,

eight feet in length, 1/2 inch

override feature for extreme cold

to the horizontal position to close

in diameter, and approved for

weather starting. For extreme cold

valve.

grounding purposes

weather starting, pull choke wire;

6.

Allow the unit to cool before

Any rod or pipe used for grounding

after engine warms, push choke in

installing any covers.

must be driven to eight feet deep or

to it's normal operating position.

buried in the deepest possible trench.

5.

Pull the starter rope with a brisk,

smooth motion.

TABLE 1 - ESTIMATED POWER USAGE (WATTS)

LOAD DEVICE

WATTS

LOAD DEVICE

WATTS

LOAD DEVICE

WATTS

LOAD DEVICE

WATTS

Air conditioner

2000-3000

Electric drill

500-1000

Radio

50-200

Toaster

900-1700

(large)

Automatic

150-1500

Fan

40-200

Refrigerator

190-2000

Vacuum cleaner

200-300

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

225-1000

Light bulb

AS RATED

Television

200-500

Large hand saw

1500-2500

(small)

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GN5060, GN6575

Pre-Operation (Continued)

3.

The 120 volt receptacles are rated

manuals and product tags to determine

AUTO-IDLE CONTROL (IF EQUIPPED)

for 20 amps and may be used in any

the wattage of all electrical load

combination of 120 volt loads and

devices.

Some units have an auto-idle control

also with 240 volt loads through

If actual watt ratings are not available,

that idles the engine when there is no

the 240 volt receptacles.

the Power Usage Chart, see Table 1, may

demand required of the generator.

The 240 volt receptacles, found

be used as a general guideline.

The control panel has an idle control

on some generators, are rated for

Remember that devices which generate

toggle switch to enable or disable this

20 amps and may be used in any

function.

heat during operation such as heaters,

combination of 240 volt loads and

1.

Idle Control Switch - ON enables

incandescent light bulbs, motors and

also with 120 volt loads through

hair dryers have a higher power draw

the auto-idle feature and the

the 120 volt receptacles.

than devices which generate little heat

engine will automatically idle when

The 120/240 volt twist lock

during operation such as florescent

not under load.

receptacle is rated for 20 amps and

bulbs, radios, and clocks.

2.

Idle Control Switch - OFF disables

may be used in any combination of

Long power cords and extension cords

the auto-idle feature and the

120 volt and 240 volt loads.

also draw additional power. Keep cords

engine will run at full throttle.

4.

Individual receptacles should not

at minimum possible length.

LOW OIL SHUTDOWN

be loaded beyond the amperage

Refer to Table 2 for maximum limits for

A low oil shutdown switch is provided

rating.

lengths of extension cords.

to protect the engine and generator

5. Total combined load through

8.

Circuit protection is provided by a

on most extended run models. When

any combination of receptacle

circuit breaker. The circuit breaker

engine oil level drops too low for

must not exceed the rated load

opens when the generator load

proper engine operation, the low oil

limits of the generator. Refer to

exceeds its maximum capacity

shutdown switch causes the engine

the identification plate on the

or a short circuit occurs. If the

to shut off. If oil level is low when

generators for amp and wattage

circuit breaker opens, perform the

attempting to start the generator

specifications.

following procedures to correct the

engine, the low oil level shutdown

6.

Always shut off and remove loads

problem:

switch prevents the engine from

before starting or shutting off the

starting. If engine does not start, check

a. Shut off and disconnect all

generator engine.

oil level.

electrical loads.

NOTE: It is important to keep the

7.

When plugging multiple electrical

b. Attempt to determine the cause

generator unit on a level surface. The

load devices into the generator

of the electrical problem -

oil level shutdown switch can prevent

receptacles, be sure to connect and

overloading or short circuit.

the engine from starting even if oil level

activate the highest power draw

c. Do not use any devices that have

item first. Allow the generator

is sufficient, when the generators unit is

short circuits. Avoid overloading

engine to stabilize, then connect

placed on an uneven surface.

the generator.

and activate the next highest power

d. Press the circuit breaker

draw device. The smallest power

Operation

pushbutton to reset the circuit

draw device should be connected to

breaker.

LOAD DEVICES

the receptacle and activated last.

Repeated cycling of

1.

All load devices and extension cords NOTE: Power draw can be calculated

the circuit

should use three prong terminals.

by multiplying volts and amps. The

breaker indicates a problem and

Refer to Table 2 for extension cord

resulting number is wattage.

may cause damage to the generator

and cable size requirements.

Never exceed the posted maximum

or load devices. Do not operate the

2.

Allow the engine to run for 2-3

generatoreated cycling of the circuit

wattage for the generator or any

breaker occurs.

minutes before applying any

individual receptacle. Refer to owner's

electrical loads.

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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5

Operating Instructions and Parts Manual

	Operation (Continued)				Maintenance		5. Slowly pull the starter cord, until
	INSTALLATION FOR STAND-BY USE				INFREQUENT USAGE			resistance is felt. This indicates that
								the piston is moving upward on the
	Precautions must be taken to prevent				If the generator is used infrequently,
								compression cycle, and the intake
	electrical back feeding into utility				starting difficulty may occur. To help
								and exhaust valves are closed. (The
	systems. This requires isolation of				prevent this, the generators should be
								piston pushes a small amount of
	the electrical system. To isolate the				run for approximately 30 minutes per
								air from the spark plug hole on
	electrical system, perform the following				week.
								compression.)
	procedures:
					STORAGE		6. Use of fuel stabilizers or anti-
	1. Turn off the main electrical system
					If the generator is not to be used for			gumming agents in the fuel system
		switch prior to connecting the
					extended periods of time, the following			can help prevent the build up of
		generator.
					pre-storage procedures should be			gum and varnish.
	2. In accordance with national and
					performed:		Whenever the generator is stored, be
		local standards, a double throw
					1.	Make sure engine oil is filled to the	sure that the fuel shut-off valve is in the
		transfer switch must be installed in
						proper level.	closed position.
		the system.
					2.	Drain all fuel from the tank, lines,	Refer to the engine manual that
				Always shut off
						carburetor and fuel valve.	accompanies this unit for instructions
				main power prior to
					3. Remove the spark plug, and pour		regarding maintenance of engine
	temporary connection of the generator
							components.
	to a building electrical system.					approximately one teaspoon of oil
				Installation of the		into the spark plug hole.				Never tamper with
				generator as a	4.	Pull the starter cord several times				engine speed
	backup electrical source must be						settings. Any governor adjustments
						to spread the oil throughout the
	performed by a qualified (licensed or						should be made by qualified personnel
						cylinder.
	certified) electrical technician.						only.

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6

GN5060, GN6575

Troubleshooting Chart

Symptom	Possible Cause(s)		Corrective Action
Engine will not	1.	Run switch is set to "OFF".	1.	Set run switch to "ON".
start	2.	Fuel valve is turned to "CLOSE".	2.	Turn fuel valve to "OPEN" position.
	3.	Choke is open.	3.	Close the choke.
	4.	Fuel tank is empty.	4.	Add gas.
	5.	Engine is filled with	5.	Change the gas in the engine.
		contaminated or old gas	6.	Clean spark plug.
	6.	Spark plug is dirty.
	7.	Spark plug is broken.	7.	Replace spark plug.
	8.	Unit is not on level surface.	8.	Move unit to a level surface to prevent low oil shutdown from
				triggering.
	9.	Oil is low.	9.	Add or replace oil.
Engine runs	1.	Main or secondary circuit	1.	Reset main or secondary circuit breaker(s).
but there is no		breaker(s) are tripped.
electrical output	2.	Bad connecting of wires/cables.	2.	If you are using an extension cord, try a different one.
	3.	Bad electrical device connected	3.	Try connecting a different device.
		to generator.
Generator runs	1.	Generator is overloaded	1.	Turn off all electrical devices. Unplug all electrical devices. Turn
but does not				off generator. Wait several minutes. Restart generator. Try
support all				connecting fewer electrical loads to the generator.
electrical devices	2.	Short in one of the connected	2.	Try disconnecting any faulty or short-circuited electrical loads.
connected.		devices.
	3.	Air cleaner is dirty.	3.	Clean or replace air cleaner.
No output	1.	Engine speed is too slow	1.	Adjust engine speed.
voltage	2.	Open, shorted, or incorrect	2.	Referring to the wiring diagram, clean and reconnect all
		wiring		wiring.
	3.	Faulty capacitor	3.	Replace capacitor.
	4.	Open or shorted field windings	4.	Test winding resistance, replace field winding if necessary.
	5.	Open diodes	5.	Test diodes, replace if necessary.
	6.	Circuit breaker tripped	6.	Reset circuit breaker.
Low output	1.	Engine speed is too slow	1.	Adjust engine speed.
voltage with no	2.	Open diodes	2.	Test diodes, replace if necessary.
load	3.	Faulty capacitor	3.	Replace capacitor.
	4.	Open or shorted field windings	4.	Test winding resistance, replace field winding if necessary.
High output	1.	Faulty capacitor	1.	Replace capacitor.
voltage with no	2.	Engine speed is too fast	2.	Adjust engine speed.
load
Low output	1.	Open diode	1.	Test diodes, replace if necessary.
voltage under	2.	Engine speed too slow at full	2.	Adjust engine speed.
load		load	3.	Reduce the applied load.
	3.	Excessive load applied
Erratic output	1.	Unbalanced engine	1.	Refer to engine manual.
voltage	2.	Dirty, corroded, or loose wiring	2.	Referring to the wiring diagram, clean and reconnect all
		connection		wiring.
	3.	Unstable load applied	3.	Remove all loads, then apply each one individually to
				determine which one is causing erratic function.
Noisy operation	1.	Loose generator or engine bolt	1.	Tighten all mountings.
	2.	Short circuit in generator field or	2.	Test winding resistance, replace field winding if necessary.
		load		Test load devices for shorts. Replace defective load device.
	3.	Faulty bearing	3.	Replace bearing.
Auto-Idle does	1.	Damaged or disconnect wire in	1.	Repair or replace wiring.
not work		idle control circuit.
	2.	Failed idle control circuit board.	2.	Replace idle control board.
	3.	Failed current sensing coil.	3.	Replace current sensing coil.

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

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7

Operating Instructions and Parts Manual

Service Record

Date	Maintenance performed			Repair components required

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8

GN5060, GN6575

Stranded Copper

Wire Lead

Wire Number

Specifications

per Schematic

8 AWG, SAE J1128,

Ground Wire at

ENGINE

GPTI

Generator Frame

CARBURETOR

12 AWG, UL 1015/

11, 12, 13, 14, 15,

SOLENOID

UL 1230

16, 17, 18, 19, 20,

41

25, 26, 27, 28, 29,

39

30, 31, 34, 35, 45

16 AWG, SAE

23, 24, 28, 32, 33,

42

J1128, Type TXL

36, 37, 38, 39, 40,

40

Ins.

42, 43, 44, 46

IGNITION MODULE

ROTOR	STATOR
	A	WINDING
	U
	12V		L2
					ORANGE
	MAIN WINDING				ORANGE
	120V		N
						WHITE
					TB1 43 11	WHITE
			N		12	BLUE
					13	BROWN
					14	BLACK
	MAIN WINDING				GREEN
	120V		L1			13		15
				30	GROUND SCREW IN
	EXCITATION				ALTERNATOR HOUSING	14		16
	WINDING
	CAPACITOR					WHITE GFCI WIRE	CB1
							2-POLE	32
							GFCI
							CIRCUIT
							BREAKER
ALTERNATOR					BLACK	32	BLACK
						33	BLACK	33
	GROUND SCREW AT				GROUND SCREW AT	IDLE CONTROL
	ALTERNATOR HOUSING				GENERATOR FRAME	SOLENOID
						GREEN
	XILLIARY

YELLOW

YELLOW / WHITE

BLACK

PINK

							40	42
HOUR METER					37	RECTIFIER	RED
43		44	BLACK					41
						38	38
						AC	ENGINE
					39	46
							CONTROL
							SWITCH
									WHITE
									BLUE
						46
						FUSE - 15A
					ORANGE	36
				44			RECEPTACLE
							120 / 240 VOLT	25	WHITE
		TB2	37			ORANGE	NEMA L15-30R	28
							17		20
BROWN				36		BROWN			18
	15			17
							19		28
	16			18
BLACK						BLACK		45
			23	BLACK			BROWN
									BROWN
							BLACK
						CURRENT SENSING COIL
						BLACK WIRE HAS (2)
	TR2					LOOPS THROUGH COIL
						BROWN WIRE HAS (1)
	TR1
						LOOP THROUGH COIL
	AC1	BLACK 24
	AC2		IDLE CONTROL
IDLE CONTROL			SWITCH
CIRCUIT BOARD
		WHITE
		26

						31
					12
			34		11
		BLACK		RECEPTACLE		27
				20A DUPLEX
20	34
	CB2					29
	20A
	CIRCUIT					27
BREAKER
19	35			35		26
	CB3					25
	20A			20A DUPLEX
	CIRCUIT			RECEPTACLE
BREAKER
				GROUND SCREW AT
				CONTROL PANEL
	GREEN	45	29	GREEN
	GREEN			GREEN
		30	31

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9

GREEN

Figure 2 - Wiring Diagram

Operating Instructions and Parts Manual

Generator Assembly

27

32

28

26

2

25

23 22

14

	19	11
	18
14	12
13	16
24	17

15

9

10

30

4 3

8

29

1

31

20

21

7

6

5

Figure 3

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10

GN5060, GN6575

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

Please provide following information:	Address parts correspondence to:
- Model number	Campbell Hausfeld
- Serial number (if any)	Attn: Customer Service
- Part description and number as shown in parts list	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)		1
4	3/8 inch Constant tension hose clamp (GN5060 Only)	MJ111006AV	2
5	Hex Bolt, 3/8 - 16 UNC X 3 inch L		1
6	Fender Washer, 3/8 inch		3
7	ISO Mount Assembly	PM004290AV	3
8	Hex Nut, 3/8 - 16 UNC		2
9	Hex Bolt, 3/8 - 16 UNC X 2-1/2 inch L		1
10	Hex Bolt, M8 - 1.25 X 70		1
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		1
14	Flange Nut, 1/4 - 20 UNC		7
15	Hex Bolt, 5/16 - 18 UNC X 1-1/4 inch L		1
16	Star Washer - 5/16 inch Internal/External Tooth		1
17	Flange Nut, 5/16 - 18 UNC		1
18	Flat Washer - 0.344 X 0.688 X 0.065		2
19	Wing Nut, 5/16 - 18 UNC		1
20	600cc Carbon Canister	GN051031AV	1
21	Carriage Bolt - 1/4 - 20 UNC X 3/4 inch L		2
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		6
24	Conduit, 0.62 inch ID, 6 inch L		1
25	Conduit, 0.62 inch ID, 18 inch L		1
26	Fuel Tank	GN051030AV	1
27	Hex Bolt, 1/4 - 20 UNC X 1 inch L		4
28	Fender Washer - 1/4 inch		4
29	Grommet - 0.688 X 0.563 ID Hole X 0.063 Groove		1
30	1/4 inch ID Fuel Hose, 35 inch L (Tank to Carbon Canister)		1
31	1/2 inch ID Fuel Hose, 4 inch L (Carbon Canister to Engine)		1
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

Standard hardware item, available at local hardware stores

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11

Operating Instructions and Parts Manual

Alternator Assembly

					1
		3	4
14	6	7
5
10
8
13					23
				20
		15		18	22
11	2				19
5			17
9

16

21

12

8

24 25 26

21

Assembled muffler detail showing flange hex nut position.

Figure 4

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12

GN5060, GN6575

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

Please provide following information:	Address parts correspondence to:
- Model number	Campbell Hausfeld
- Serial number (if any)	Attn: Customer Service
- Part description and number as shown in parts list	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
2	●	Sincro Alternator - 6.8 kVA, 60Hz	GN051001SJ	1
	■	Sincro Alternator - 5.2 kVA, 60Hz	GN051000SJ	1
3	■ ●	Sincro Engine Adapter	Not Available	1
4	■ ●	Hex Bolt, M8 x 25mm		4
5	■ ●	M8 NyLock Nut		5
6		Hex Bolt, 3/8 - 16UNC X 1.00L		4
7		3/8 inch Lock Washer		4
8	■ ●	Screw, Pan Head, M5 X 10mm		5
9	■ ●	Sincro Rear Shield	GN051016AV	1
10	■ ●	Capacitor - 35mf, 450V	GW001016SV	1
11	●	Sincro Threaded Rod (6.8 kVA Alt.)	GN051008AV	1
	■	Sincro Threaded Rod (5.2 kVA Alt.)	GN051025AV	1
12	■ ●	Sincro Rear Cover Kit	GN051002SJ	1
13	■ ●	Sincro Round Hole Plug	GN051009AV	1
14	■ ●	Sincro LH Louver	GN051018AV	1
15	■ ●	Sincro RH Louver	GN051017AV	1
16		Elbow ConnectorHEYCO 8425	GN051096AV	1
17		Honda Muffler	▲	1
18		Muffler Bracket - Honda GX390 Engine	GN051012KK	1
		Muffler Bracket - Honda GX270 Engine	GN051011KK	1
19		Flange Hex Nut, M8		2
20		Hex Bolt- 5/16 - 18 UNC X 0.75 L		2
21		Flange Hex Nut, 5/16 - 18 UNC		2
22		Hex Bolt, 3/8 - 16 UNC x 1-3/4 inch L		1
23		Flange Hex Nut, 3/8 -16 UNC		1
24		USDA Screen	GN051013AV ▲	1
25		Clamp, USDA Screen	GN051014AD ▲	1
26		Pan Head Self Tapping Screw (Muffler Clamp)	GN051015AV ▲	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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13

Operating Instructions and Parts Manual

Control Panel Assembly

5
4	12
	3
	6
	6
8
	1
26	26
	5
10	28
	29
	14
13	15
	2
	7
9
	11
22
18	26
17
30	25	16
19	27

21	24
	20
	23

Figure 5

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14

GN5060, GN6575

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

Please provide following information:	Address parts correspondence to:
- Model number	Campbell Hausfeld
- Serial number (if any)	Attn: Customer Service
- Part description and number as shown in parts list	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 PlatePainted	GN051024KK	1
5	Pan Head Screw, #6 - 32 X 3/8 inch L		8
6	Cover, Duplex Receptacle	GN051021AV	2
7	Duplex Receptacle120V, 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		3
11	Nylock Nut, #8 - 32		3
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		1
19	Terminal Block	GN051099AV	2
20	Tapping Screw, #10 X 1/2 inch L		4
21	Elbow ConnectorHeyco 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		4
27	Idle Control Current Sensing Coil	GN051075AV	1
28	Pan Head Screw, #8-32 X 3/4 inch L		1
29	#8 Lock Washer, Internal/External Tooth		1
30	Fuse Holder	HV010201AV	1
	Fuse, 1-1/4 inch x 1/4 inch, 15 Amp (not shown)		1

Standard hardware item, available at local hardware stores

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15