Generac 004451, 004582 User Manual

FOR YOUR NEAREST AUTHORIZED SERVICE CENTER 1-800-333-1322

Owner’s Manual

UULLTTRRAA SSOOUURRCCEE

Commercial, Industrial, Residential

Portable Generator

MODELS: 004451 (12,500 Watt) 004582 (15,000 Watt)

• Safety

• Assembly

• Operation

• Maintenance

• Troubleshooting

• Electrical Data

• Parts

• Warranty

by Generac Power Systems, Inc

Commercial-Industrial-Residential Portable Generator System

Safety Rules ..............................................1-3

Section 1 – General Information ................4

1.1 Unpacking ............................................................................4

1.1.1 Accessory Box ........................................................4

1.2 Assembly ..............................................................................4

1.2.1 Assembling the Wheel Kit ......................................4

1.2.2 Assembling the Handle ..........................................5

1.2.3 Battery Connection..................................................5

Section 2 – Operation ..................................6

2.1 Know The Generator ............................................................6

2.2 Cord Sets and Connector Plugs ..........................................7

2.2.1 120V AC, 20 A, Duplex Receptacle ........................7

2.2.2 120V AC, 20 A, GFCI Receptacle ..........................7

2.2.3 120V AC, 30 A Receptacle ..................................7-8

2.2.4 120/240V AC, 30 A, Receptacle ............................8

2.2.5 12 VDC, 10 Amp Receptacle ..................................8

2.2.6 120/240V AC, 50 A, Receptacle ............................8

2.3 How To Use The Generator ..................................................9

2.3.1 Grounding The Generator ......................................9

2.3.2 Connecting Electric Loads ......................................9

2.4 Don’t Overload The Generator..............................................9

2.5 Wattage Reference Chart ..................................................10

2.6 Before Starting The Generator............................................10

2.6.1 Adding Engine Oil ................................................10

2.6.2 Adding Gasoline ....................................................11

2.7 To Start The Engine ............................................................11

2.8 Stopping The Engine ..........................................................12

2.9 Automatic Idle Control ........................................................12

2.10 Cold Weather Operation/De-Icer ........................................12

2.11 Low Oil Pressure Shutdown................................................12

2.11.1 Initial Start-up ........................................................12

2.11.2 Sensing Low Oil Pressure ....................................12

2.11.3 Restarting ..............................................................12

2.12 Charging a Battery ..............................................................13

Section 3 – Maintenance............................14

3.1 Maintenance Schedule........................................................14

3.2 Product Specifications ........................................................14

3.2.1 Generator Specifications ......................................14

3.2.2 Engine Specifications ............................................14

3.3 General Recommendations ................................................15

3.3.1 General Maintenance ............................................15

3.3.2 To Clean The Generator........................................15

3.3.3 Engine Maintenance..............................................15

3.3.4 Checking Oil Level ................................................15

3.3.5 Changing The Oil & Oil Filter ................................15

3.3.6 Replacing The Spark Plug ..............................15-16

3.4 Service Air Cleaner ............................................................16

3.5 Clean Spark Arrestor Screen ..............................................16

3.6 Adjusting Valve Clearance ..................................................17

3.7 General ..............................................................................18

3.8 Long Term Storage..............................................................18

3.9 Other Storage Tips..............................................................18

Section 4 – Troubleshooting......................19

4.1 Troubleshooting Guide ........................................................19

Section 5 – Notes ..................................20-21

Section 6 – Electrical Data ..................22-23

Section 7 – Exploded Views and

Parts Lists..........................24-33

Section 8 – Warranty ............................34-36

INTRODUCTION

Thank you for purchasing this model of the GUARDIAN®product line by Generac Power Systems, Inc. This model is a compact, high performance, air-cooled, engine driven generator designed to supply electrical power to operate electrical loads where no utility power is available.

READ THIS MANUAL THOROUGHLY

If you do not understand any portion of this manual, contact your nearest GENERAC/GUARDIAN

Authorized Dealer for starting,

operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

After this heading, you can read instructions that, if not strictly complied with, will result in personal injury or property damage.

After this heading, you can read instructions that, if not strictly complied with, may result in personal injury or property damage.

After this heading, you can read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, you can read explanatory statements that require special emphasis. These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER,

WARNING

and

CAUTION

blocks. The type of information each

indicates follows:

 This symbol points out important safety

information that, if not followed, could endanger personal safety and/or property of you and others.

 This symbol points out potential explosion hazard.  This symbol points out potential fire hazard.  This symbol points out potential electrical shock

hazard.

The operator is responsible for proper and safe use of the equipment. We strongly recommend that the operator read this

Owner’s Manual

and thoroughly

understand all instructions before using this equipment. We also strongly recommend instructing other users to properly start and operate the unit. This prepares them if they need to operate the equipment in an emergency.

CAUTION!

Always disconnect spark plug wire and place the wire where it cannot contact the spark plug to prevent accidental starting when setting up, transporting, adjusting or making repairs to your generator.

• The generator produces dangerously high voltage that can cause

extremely hazardous electrical shock. Avoid contact with bare wires, terminals, etc. Never permit any unqualified person to operate or service the generator.

• Never handle any kind of electrical cord or device while standing in

water, while barefoot or while hands or feet are wet. Dangerous electrical shock will result.

• The National Electric Code 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 your area.

• Use a ground fault circuit interrupter in any damp or highly

conductive area (such as metal decking or steel work).

• Do not use worn, bare, frayed or otherwise damaged electrical cord

sets with the generator.

• Operate generator only on level surfaces and where it will not be

exposed to excessive moisture, dirt, dust or corrosive vapors.

• Gasoline is highly

FLAMMABLE

and its vapors are

EXPLOSIVE

. Do not permit smoking, open flames, sparks or heat in the vicinity while handling gasoline. Avoid spilling gasoline on a hot engine. Comply with all laws regulating storage and handling of gasoline.

• Never add fuel while unit is running.

• Do not overfill the fuel tank. Always allow room for fuel expansion. If tank is overfilled, fuel can overflow onto a hot engine and cause

FIRE

or an

EXPLOSION.

• Never store generator with fuel in tank where gasoline vapors might reach an open flame, spark or pilot light (as on a furnace, water heater or clothes dryer).

FIRE

EXPLOSION

may result.

• Generator exhaust gases contain

DEADLY

carbon monoxide gas.This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Operate this equipment only in the open air where adequate ventilation is available.

• Allow at least 2 feet of clearance on all sides of generator or you could damage the unit. Never operate the unit inside any room or enclosure where the free flow of cooling air into and out of the unit might be obstructed. Review “Cold Weather Operation” on page 12.

-------------



DANGER



-------------



WARNING



-------------



CAUTION



-------------

• Never start or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON. Start the engine and let it stabilize before connecting electrical loads. Disconnect all electrical loads before shutting down the generator.

• Do not insert objects through unit's cooling slots.

•

Never operate generator:

in rain; in any enclosed compartment; if connected electrical devices overheat; if electrical output is lost; if engine or generator sparks; if flames or smoke are observed while unit is running; if unit vibrates excessively.

Note:Your generator is equipped with a spark arrestor muffler. The spark arrestor must be maintained in effective working order by the owner/ operator. In the State of California, a spark arrestor is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.

Study these

SAFETY RULES

carefully before installing, operating or

servicing this equipment. Become familiar with this

Owner’s Manual

and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

GENERAC

cannot possibly anticipate every possible

circumstance that might involve a hazard. The warnings in this

manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique GENERAC

does not specifically recommend, you must satisfy yourself that it is safe for you and others. You also must make sure the procedure, work method or operating technique that you choose does not render the generator unsafe.



Despite the safe design of this generator, operating this

equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to operate or maintain this equipment.

 Potentially lethal voltages are generated by these

machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

 Parts of the generator are rotating and/or hot during

operation. Exercise care near running generators.

 GENERAL HAZARDS 

• For safety reasons, GENERAC®recommends that the installation, initial start-up and maintenance of this equipment is carried out by a GENERAC

/GUARDIAN®Authorized Dealer.

• The engine exhaust fumes contain carbon monoxide, which can be

DEADLY

. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must be installed properly, in strict compliance with applicable codes and standards. Following installation, you must do nothing that might render the system unsafe or in noncompliance with such codes and standards.

• Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

• Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator. The generator

MUST

operated outdoors.

• When working on this equipment, remain alert at all times. Never work on the equipment when you are physically or mentally fatigued.

• Inspect the generator regularly, and contact your nearest GENERAC

/GUARDIAN®Authorized Dealer for parts needing repair

or replacement.

• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

IMPORTANT SAFETY INSTRUCTIONS

Commercial-Industrial-Residential Portable Generator System

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's installation site. Safety should be stressed to all operators and potential operators of this equipment.

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

WARNING:

This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:

-------------



DANGER



-------------



 ELECTRICAL HAZARDS

• All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility

power delivers extremely high and dangerous voltages as does the generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is

running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If you must work

around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while standing in water,

while barefoot, or while hands or feet are wet.

DANGEROUS

ELECTRICAL SHOCK MAY RESULT.

• The National Electrical Code (NEC) requires the frame and external

electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electrical system.

• In case of accident caused by electric shock, immediately shut down

the source of electrical power. If this is not possible, attempt to free the victim from the live conductor.

AVOID DIRECT CONTACT

WITH THE VICTIM.

Use a non-conducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.

• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

 FIRE HAZARDS 

• For fire safety, the generator must be operated and maintained properly. Operation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has established. Also, ensure that the generator is operated in accordance with the manufacturer’s instructions and recommendations. Do not alter the construction of generator or change controls which might create an unsafe operating condition.

• Keep a fire extinguisher near the generator at all times. Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for use on the standby electric system. Keep the extinguisher properly charged and be familiar with its use. If you have any question pertaining to fire extinguishers, consult your local fire department.

 EXPLOSION HAZARDS 

• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.

• Gasoline is extremely

EXPLOSIVE.

STANDARDS INDEX

In the absence of pertinent standards, codes, regulations and laws, the published information listed below may be used as a guideline for operation of this equipment.

1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC CODE.

2. Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y. 10038.

3. AGRICULTURAL WIRING HANDBOOK, available from the Food and Energy Council, 909 University Avenue, Columbia, MO 65201.

4. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI

49085.

5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE.

IMPORTANT SAFETY INSTRUCTIONS

Commercial-Industrial-Residential Portable Generator System

1.1 UNPACKING

• Set the palleted carton on a rigid flat surface.

• Remove staples along bottom of carton that fasten carton to pallet. Open carton from top.

• Remove all packaging material.

• Remove separate accessory box.

• Lift carton off the generator.

• Remove generator from shipping pallet by removing bolts through the shipping brackets.

Figure 1 - Bracket Removal

1.1.1 ACCESSORY BOX

Check all contents. If any parts are missing or damaged locate an authorized dealer at 1-800-333-1322.

Contents include:

• Owner’s Manual

• Bolt-on tubular handle

• Wheel Axle

• 2 – Pneumatic Wheels

• 2 – Axle Bracket Assemblies

• 2 – Washers

• 2 – Wheel Spacers

• 2 – Cotter Pins

• Bolt-on Foot

• 6 – Carriage Bolts, Washers, Nuts

• Battery Charge Cable

• Spark Plug Wrench

• 2 Spark Plugs.

• Air Filter

• Pre-cleaner

1.2 ASSEMBLY

The generator requires some assembly prior to using it. If problems arise when assembling the generator, please call the Generator Helpline at 1-800-333-1322.

1.2.1 ASSEMBLING THE WHEEL KIT

The wheel kit is designed to greatly improve the portability of the generator. A socket wrench with a 9/16” socket, a 1/2” socket, a 1/2” wrench and a pair of pliers are the tools that will be needed for assembly of the wheel kit.

Note:The wheel kit is not intended for over-the-road use.

• Refer to

Figure 2

shown on opposite page and install the wheel kit

as follows:

• Place the generator on a hard flat surface.

• Stand at the engine end of the unit and gently tilt the generator forward, high enough to place wooden blocks beneath the cradle. This will allow space to install the wheel assemblies.

• Attach an axle bracket assembly with attached sleeve to either side of the frame. Ensure the sleeve faces outward.

• Slide the axle through the sleeves on the axle brackets.

• Slide one wheel with flat washer to the outside and a spacer to the inside onto each end of the axle. Make sure the air inflation valve on the wheel is facing outward.

• Insert retaining pins and using pliers, bend out the ends to prevent the pins from falling out of the axle. Remove the wooden blocks.

1.2.2 ASSEMBLING THE HANDLE

• Attach the handle by aligning one side of the handle on the cradle, then spread the handle around the cradle and let it spring into place. Secure the handle to the frame using the 5/16’ hex head bolts provided. Check each fastener to ensure that it is secure.

• Using the handle, lift the unit high enough to place wooden blocks under the unit. Attach the front support foot to the underside of the cradle using the 3/8” carriage bolts provided.

• Remove the shipping brackets from the cradle, if not already done so.

Section 1 – General Information

Commercial-Industrial-Residential Portable Generator System

Shipping

Bracket

(x4)

1.2.3 BATTERY CONNECTION

• The battery shipped with the generator has been provided fully charged. Caution must be taken when connecting the battery.

• Cut the tie wrap cable holding the RED and BLACK battery cables to the stator.

• Connect the RED battery cable to the battery Positive terminal (+). After making sure that the connection is tight, slip the rubber boot over the terminal connection.

• Connect the BLACK battery cable to the battery Negative terminal (–). Make sure the connection is tight.

• Double check all connections to ensure they are in the correct location and secure. See

Figure 3

at right.

Figure 3 - Battery Connections

CAPSCREW,

Section 1 - General Information

Commercial-Industrial-Residential Portable Generator System

Negative

Cable

Positive

Cable

Figure 2 - Handle Assembly

5/16 X 2-1/2

FLAT WASHER

LOCK WASHER

LOCK NUT

SPACER

WHEEL

FLAT WASHER

RETAINING PIN

AXLE

HANDLE

FRONT FOOT ASSEMBLY

LOCK NUT

CARRIAGE BOLT, 3/8 X 1

CAPSCREW, 5/16 X 1

LOCK WASHER

FLAT WASHER

Section 2 – Operation

Commercial-Industrial-Residential Portable Generator System

OPERATION

2.1 KNOW THE GENERATOR

Read the

Owner’s Manual

and

Safety Rules

before

operating this generator.

Compare the generator to this illustration to become familiarized with the locations of various controls and adjustments. Save this manual for future reference.

1) 12 Volt DC, 10 Amp Receptacle –

This receptacle allows the capability to recharge a 12 volt DC storage battery with provided battery charge cables.

2) 120 Volt AC, 20 Amp, Duplex Receptacle –

Supplies electrical power for the operation of 120 Volt AC, 20 Amp, single-phase, 60 Hz electrical lighting, appliance, tool and motor loads.

3) 120 Volt AC, 20A Duplex GFCI Receptacle – Supplies ground fault protected electrical power for operation of 120 volt AC 20 amp, single-phase, 60 Hz electric lighting, appliances, tools and motor loads.

4) 120 Volt AC, 30 Amp Locking Receptacle –

Supplies electrical power for the operation of 120 Volt AC, 30 Amp, singlephase, 60 Hz electrical lighting, appliance, tool and motor loads.

5) 120/240 Volt AC, 30 Amp Locking Receptacle – Supplies electrical power for the operation of 120 and/or 240 Volt AC, 30 Amp, single-phase, 60 Hz, electrical lighting, appliance, tool and motor loads.

6) 120/240 Volt AC, 50 Amp Receptacle –

Supplies electrical power for the operation of 120/240 Volt AC, 50 Amp, single-phase, 60 Hz, welder or motor loads.

7) Air Cleaner –

Filters intake air as it is drawn into the engine.

8) Choke Knob –

Used when starting a cold engine.

9) Winter / Summer Valve –

See “Cold Weather Operation.”

(Section 2, page 12.)

10) Circuit Breakers

(AC) – Each receptacle is provided with a push-to-reset circuit breaker to protect the generator against electrical overload.

11) Fuel Tank –

Tank holds 16 U.S. gallons of fuel.

12) Grounding Lug –

Ground the generator to an approved earth ground here. See page 9 for details.

13) Idle Control Switch –

The idle control runs the engine at normal (high) speeds when there is an electrical load present and runs the engine at idle (low) speeds when a load is not present.

14) Start/Run/Stop Switch –

Controls the operation of the

generator.

15) Oil Fill –

Use this point to add oil to engine.

Figure 5 - Generator Controls

Figure 6 - Engine Control Panel

30A

120V

20A GFCI

120V

20A

120V

CIRCUIT BREAKERS - PUSH TO RESET

HOUR METER

10A

ON OFF

IDLE

CONTROL

12Vdc

120V/240V

50A

120V/240V

30A

50A

30A

TEST RESET

TESTRESET

30A

30A30A

20A

GFCI

120V

30A

1/10

HOURS

QUARTZ

Figure 4 - Control Panel

2.2 CORD SETS AND CONNECTION PLUGS

2.2.1 AC, 20 AMP, DUPLEX RECEPTACLE

This is a 120 Volt outlet protected against overload by a 20 Amp push-toreset circuit breaker. Use each socket to power 120 Volt AC, single phase, 60 Hz electrical loads requiring up to a combined 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).

Keep extension cords as short as possible, preferably less than 15 feet long, to prevent voltage drop and possible overheating of wires.

Figure 7 - 120 Volt AC, 20 Amp, Duplex Receptacle

2.2.2 120V AC, 20 AMP, GFCI RECEPTACLE

This unit is equipped with a ground fault circuit interrupter (GFCI). This device meets applicable federal, state and local codes.

A GFCI receptacle is different from conventional receptacles. In the event of a ground fault, a GFCI will trip and quickly stop the flow of electricity to prevent serious injury.

Definition: Instead of following its normal safe path, electricity passes through a persons body to reach the ground. For example, a defective appliance can cause a ground fault.

A GFCI receptacle does NO

T protect against circuit overloads, short circuits, or shocks. For example, electric shock can still occur if a person touches charged electrical wires while standing on a non-conducting surface, such as a wood floor.

Figure 8 - 120 VAC, 20 Amp GFCI Receptacle

Testing the GFCI: Test the GFCI outlet every month as follows:

• Plug a test lamp into the receptacle.

• Start the generator, the test lamp should be on.

• Press the “Test” button located on the front of the receptacle to trip the device.

• This should stop the flow of electricity making the lamp shut off. The yellow trip indicator should now be on.

• To restore the flow of electricity, press the “Reset” button on the front of the receptacle. If the GFCI does not perform in this manner, do not use the receptacle. Contact a local service dealer.

• This outlet is protected against overload by a 20A push-to-reset circuit breaker. Use the outlet to power 120V AC, single-phase, 60 Hz, electrical loads requiring up to a combined 2400 watts (2.4 kW) or 20 amps of current.

2.2.3 120V AC, 30 AMP RECEPTACLE

Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire cord set rated for 125 Volts AC at 30 Amps (or greater) to the plug.

Figure 9 - 120 VAC, 30 Amp Receptacle

Section 2 – Operation

Commercial-Industrial-Residential Portable Generator System

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. The outlet is protected by a 30 Amp push-to-reset circuit breaker.

2.2.4 120/240V AC, 30 AMP RECEPTACLE

Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4wire grounded cord set to the plug and to the desired load. The cord set should be rated for 250 Volts AC at 30 Amps (or greater).

Figure 10 - 120/240 VAC, 30 Amp Receptacle

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 two 30 Amp push-to-reset circuit breakers.

2.2.5 12 VOLT DC, 10 AMP RECEPTACLE

This receptacle allows you to recharge a 12 Volt automotive or utility style storage battery with the battery charge cables provided. This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery. See the section "Charging a Battery" (page 12) before attempting to recharge a battery.

Figure 11 - 12 Volt DC, 10 Amp Receptacle

2.2.6 120/240 VOLT AC, 50 AMP RECEPTACLE

Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire cord set rated for 250 Volts AC at 50 Amps to the plug.

Figure 12 - 120/240 VAC, 50 Amp Receptacle

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.

Section 2 – Operation

Commercial-Industrial-Residential Portable Generator System

120V

30A

120V/240V

30A

120V/240V

50A

2.3 HOW TO USE THE GENERATOR

If you have any problems operating your generator, please call the generator helpline at 1-800-333-1322.

2.3.1 GROUNDING THE GENERATOR

The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground.

Local electrical codes may also require proper grounding of the unit. For that purpose, generally, connecting a No. 10 AWG (American Wire Gauge) stranded copper wire to the grounding wing nut and to an earth-driven copper or brass grounding rod (electrode) provides adequate protection against electrical shock. However, local codes may vary widely.

Consult with a local electrician for

grounding requirements in your area.

Figure 13 - Grounding the Generator

Proper grounding of the generator will help prevent electrical shock

in the event of a ground fault condition in the generator or in connected electrical devices. Proper grounding also helps dissipate static electricity, which often builds up in ungrounded devices.

2.3.2 CONNECTING ELECTRICAL LOADS

DO NOT

connect 240 Volt loads to 120 Volt receptacles.

DO NOT

connect 3-phase loads to the generator.

DO NOT

connect 50 Hz

loads to the generator.

• Let engine stabilize and warm up for a few minutes after starting.

• Plug in and turn on the desired 120 or 240 Volt AC, single phase, 60 Hz electrical loads.

• Add up the rated watts (or amps) of all loads to be connected at one time. This total should not be greater than (a) the rated wattage/amperage capacity of the generator or (b) circuit breaker rating of the receptacle supplying the power. See "Don't Overload the Generator" below.

2.4 DON’T OVERLOAD THE

GENERATOR

Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and to connected electrical devices. Observe the following to prevent overloading the unit:

• Add up 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 usually be found on a data plate or decal affixed to the device.

• If the appliance, tool or motor does not give wattage, multiply volts times ampere rating to determine watts (volts x amps = watts).

• Some electric motors, such as induction types, require about three times more watts of power for starting than for running.This surge of power lasts only a few seconds when starting such motors. Make sure you allow for this high starting wattage when selecting electrical devices to connect to your generator:

1. Figure the watts needed to start the largest motor.

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

The Wattage Reference Guide on page 10 is provided to assist you in determining how many items your generator can operate at one time. (Note: All figures are approximate. See data plate on appliance for wattage requirements.)

Section 2 – Operation

Commercial-Industrial-Residential Portable Generator System

Generator Ground Lug

2.5 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 (6-1/2") . . . . . . . . . . . . . . . . . . . . . .800 to 1000

*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

Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Running Watts

Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450

Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500

Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200

*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800

Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200

Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 (handheld) . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500

Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650

Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500

*Allow 3 times the listed watts for starting these devices.

Section 2 – Operation

Commercial-Industrial-Residential Portable Generator System

2.6 BEFORE STARTING THE GENERATOR

Prior to operating the generator, engine oil and gasoline will need to be added, as follows:

2.6.1 ADDING ENGINE OIL

NOTE: When adding oil to the engine crankcase in the future, use only high quality detergent oil rated with API service classification SF or SG SAE 30 weight. Use no special additives.

Select the oil’s viscosity grade according to the expected operating temperature.

Do not use SAE 10W-40.

• Above 40°F

, use SAE 10W-30 or SAE 30.

• Below 40°F,

use synthetic 5W-20 or 5W-30.

Although multi-viscosity oils (5W-30, 10W-30, etc.) improve starting in cold weather, these multi-viscosity oils will result in increased oil consumption when used above 32°F. Check your engine oil level more frequently to avoid possible damage from running low on oil.

• Place generator on a level surface.

• Clean area around oil fill and remove oil fill cap and dipstick.

• Wipe dipstick clean.

• Slowly fill engine with oil through the oil fill opening until it reaches the full mark on the dipstick. Stop filling occasionally to check oil level. DO NOT OVERFILL.

• Install dipstick. Install oil fill cap and finger tighten securely.

• Check engine oil level before starting each time thereafter.

Synthetic 5W-20, 5W-30

10W-30, SAE 30

ºF -20 0 20 32 40 60 80

ºC -30 -20 -10 0

Synthetic 5W-20, 5W-30

Temperature Range of Expected Use

10W-30, SAE 30

20 30

100

+ 27 hidden pages

Generac 004451, 004582 User Manual

Table of Contents

INTRODUCTION