Generac 005736-0, 005732-0, 005623-1, 005622-1 User Manual
Owner’s Manual
• SAFETY
• ASSEMBLY
• OPERATION
• TROUBLESHOOTING
GP Series
Portable Generator
• WARRANTY
AUTHORIZED DEALER SUPPORT:
www.generac.com
or
1-888-436-3722
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODELS: 005622-1, 005623-1,
005732-0, 005736-0
Table of Contents
Portable Generator System
Owner's Manual
Introduction ..................................................................................... 1
Read this Manual Thoroughly ....................................................... 1
Safety Rules .................................................................................... 2
Standards Index .............................................................................. 3
Section 1 – General Information ................................................... 4
1.1 Unpacking ....................................................................................... 4
1.2 Assembly ......................................................................................... 4
Section 2 – Operation .................................................................... 4
2.1 Know the Generator ........................................................................ 4
2.2 Hourmeter ....................................................................................... 5
2.3 Cord Sets and Connection Plugs .................................................... 6
2.4 How to Use the Generator .............................................................. 6
2.5 Don’t Overload the Generator ......................................................... 7
2.6 Wattage Reference Guide ............................................................... 7
2.7 Before Starting the Generator ......................................................... 7
2.8 To Start the Engine ......................................................................... 8
2.9 Stopping the Engine ........................................................................ 9
2.10 Low Oil Level Shutdown System ..................................................... 9
Section 3 – Maintenance ............................................................... 9
3.1 Maintenance Schedule .................................................................... 9
3.2 Product Specifications ..................................................................... 9
3.3 General Recommendations........................................................... 10
3.4 Service Air Filter ............................................................................ 11
3.5 Valve Clearance ............................................................................ 11
3.6 General .......................................................................................... 11
3.7 Long Term Storage ........................................................................ 11
3.8 Other Storage Tips ........................................................................ 11
Section 4 – Troubleshooting ........................................................ 12
4.1 Troubleshooting Guide .................................................................. 12
Section 5 – Notes ......................................................................... 13
Section 6 – Warranty .................................................................... 14
Manual del propietario ............................................... 15
Introducción .................................................................................. 17
Lea este manual atentamente ..................................................... 17
Reglas de seguridad .................................................................... 18
Índice de normas........................................................................... 19
Sección 1 – Información general ................................................ 20
1.1 Cómo desempacar ........................................................................ 20
1.2 Ensamblaje .................................................................................... 20
Sección 2 – Funcionamiento ....................................................... 20
2.1 Conozca el generador ................................................................... 20
2.2 Contador horario ........................................................................... 21
2.3 Juegos de cables y enchufes de conexión ................................... 22
2.4 Cómo utilizar el generador ........................................................... 22
2.5 No sobrecargue el generador ....................................................... 23
2.6 Guía de referencia del vataje ........................................................ 23
2.7 Antes de arrancar el generador .................................................... 23
2.8 Cómo arrancar el motor ................................................................ 24
2.9 Cómo parar el motor ..................................................................... 25
2.10 Sistema de apagado por bajo nivel de aceite ............................... 25
Sección 3 – Mantenimiento ......................................................... 25
3.1 Programación de mantenimiento .................................................. 25
3.2 Especificaciones del producto ....................................................... 25
3.3 Recomendaciones generales ........................................................ 26
3.4 Servicio del filtro de aire ............................................................... 27
3.5 Abertura de la válvula ................................................................... 27
3.6 General .......................................................................................... 27
3.7 Almacenaje por períodos largos ................................................... 27
3.8 Otros consejos útiles para el almacenaje ..................................... 27
Sección 4 – Solución de problemas ........................................... 28
4.1 Guía para la solución de problemas ............................................. 28
Sección 5 – Notas ........................................................................ 29
Sección 6 – Garantía .................................................................... 30
Guide du propriétaire ................................................. 31
Introduction ................................................................................... 33
Lire soigneusement ce manuel ................................................... 33
Consignes de sécurité. ................................................................ 34
Répertoire-type ............................................................................. 35
Section 1 – Généralités ................................................................ 36
1.1 Déballage ...................................................................................... 36
1.2 Montage ........................................................................................ 36
Section 2 – Fonctionnement ....................................................... 36
2.1 Connaître la génératrice ................................................................ 36
2.2 Horamètre ..................................................................................... 37
2.3 Cordons électriques et fiches de branchement ............................ 38
2.4 Mode d'emploi de la génératrice ................................................... 38
2.5 Ne pas surcharger la génératrice .................................................. 39
2.6 Guide de référence de puissance ................................................. 39
2.7 Avant la mise en route de la génératrice. ...................................... 39
2.8 Démarrage du moteur ................................................................... 40
2.9 Arrêt du moteur ............................................................................. 41
2.10 Système d'arrêt en cas de faible niveau d'huile ............................ 41
Section 3 – Entretien .................................................................... 41
3.1 Calendrier d'entretien .................................................................... 41
3.2 Spécifications de l'appareil ............................................................ 41
3.3 Recommandations générales........................................................ 42
3.4 Entretien du filtre à air ................................................................... 43
3.5 Jeu de soupape ............................................................................. 43
3.6 Généralités .................................................................................... 43
3.7 Rangement à long terme .............................................................. 43
3.8 Autres conseils sur le rangement .................................................. 43
Section 4 – Dépannage ................................................................ 44
4.1 Guide de dépistage des pannes ................................................... 44
Section 5 – Remarques ................................................................ 45
Section 6 – Garantie ............................................Couvercle arrière
INTRODUCTION
DANGER
Thank you for purchasing this model of the GP Series portable
generator 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 on job sites, or
remote locations where no utility power is available or in place of utility
power due to a power outage.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest
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 personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or carelessly.
Observe them carefully. Their definitions are as follows:
DANGER
After this heading, read instructions that, if
not strictly complied with, will result in serious
personal injury, including death and/or property
damage.
After this heading, read instructions that, if not
strictly complied with, may result in serious
personal injury and/or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, 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 is as follows:
This symbol points out important safety
information that, if not followed, could endanger
personal safety and/or property of 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
manual and thoroughly understand all instructions before using
the 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.
DANGER
Using a generator indoors WILL KILL YOU IN
MINUTES. Exhaust contains carbon monoxide, a
poison gas you cannot see or smell.
NEVER use in the home or in partly enclosed
areas such as garages. ONLY use outdoors and
far from open windows, doors and vents.
DANGER
Using a generator indoors WILL KILL YOU IN MINUTES. Exhaust contains
carbon monoxide, a poison gas you cannot see or smell.
NEVER use in the home or in partly enclosed areas such as garages.
ONLY use outdoors and far from open windows, doors and vents.
Always disconnect the spark plug wire and
place the wire where they cannot contact the
spark plug to prevent accidental starting when
setting up, transporting, adjusting or making
repairs to the 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 the area.
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.
Allow generator and engine to cool entirely before adding fuel.
Never add fuel while unit is running.
Do not overfill the fuel tank. Always allow room
for fuel expansion. If tank is over-filled, 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 or 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.
1
IMPORTANT SAFETY INSTRUCTIONS
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.
DANGER
Allow at least five (5) feet, or greater, of clearance on all
sides of generator. Never operate the unit inside any room
or enclosure.
NEVER operate the generator indoors, in an attached garage
or near an open window.
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; indoors or 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.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this 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.
The engine exhaust from this product contains
chemicals known to the state of California to cause
cancer, birth defects or other reproductive harm.
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
The manufacturer cannot anticipate every possible circumstance that
might involve a hazard. The warnings in this manual, and on tags and
decals affixed to the unit are, therefore, not all inclusive. If using a
procedure, work method or operating technique that the manufacturer
does not specifically recommend, ensure that it is safe for others. Also
make sure the procedure, work method or operating technique utilized
does not render the generator unsafe.
2
WARNING:
WARNING:
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. Do not touch hot surfaces such as
the muffler. Severe burns can occur on contact.
Allow generator to cool before touching.
GENERAL HAZARDS
Never operate in an enclosed area or indoors.•
For safety reasons, the manufacturer recommends that the •
maintenance of this equipment is carried out by an 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 properly maintained. Do nothing that
might render the exhaust system unsafe or in noncompliance with
any local codes and/or standards.
Keep hands, feet, clothing, etc., away from drive belts, fans, and •
other moving or hot parts. Never remove any 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 be operated outdoors.
When working on this equipment, remain alert at all times. Never •
work on the equipment when physically or mentally fatigued.
Inspect the generator regularly, and contact the nearest Authorized •
Dealer for parts needing repair or replacement.
Before performing any maintenance on the generator, disconnect •
its battery cables (if equipped) 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.
Do NOT operate generator in the rain.•
IMPORTANT SAFETY INSTRUCTIONS
Portable Generator System
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 work must be done 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.
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 vapors are extremely FLAMMABLE and 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. Always reference the latest revision
available for the standards listed.
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.
FIRE HAZARDS
For fire safety, the generator must be operated and maintained •
properly. Operation must always 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 the 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 portable generator electric system. Keep
the extinguisher properly charged and be familiar with its use. If
there are any questions pertaining to fire extinguishers, consult the
local fire department.
Avoid spilling gasoline on a hot engine. Allow generator and engine •
to cool entirely before adding fuel. NEVER add fuel while the unit
is running. DO NOT overfill the fuel tank. Always allow room for
fuel expansion.
3
Section 1 – General Information
Portable Generator System
1.1 UNPACKING
Remove all packaging material.•
Remove separate accessory box.•
Remove the generator from carton.•
1.1.1 ACCESSORY BOX
Check all contents. If any parts are missing or damaged locate an
authorized dealer at 1-888-436-3722.
Contents Include:
1 – Owner’s Manual • 1 - Left Handle Assembly•
1 - Quart Oil SAE 30 • 1 - Right Handle Assembly•
2 - Never-Flat Wheels • 1 - Frame Foot•
1 - Foot Support•
1 - Hardware Bag (containing the following):•
2 - Rubber Feet 2 - 5/16” Bolts
2 - 5/16” Flat Washers 4 - 5/16” Locking Flange Nuts
4 - 5/16” Carriage Bolts 2 - 5/16” Locking Cap Nuts
2 - 1/2” Axle Bolts 2 - 1/2” Locking Flange Nuts
2 - 1/2" Flat Washers
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 1-888-436-3722.
Figure 1 – Wheel Assembly
FOOT
FOOT SUPPORT
Figure 2 – Install Handle Kit
1.2.1 ASSEMBLING THE ACCESSORY KIT
The wheels are designed into the unit to greatly improve the portability
of the generator.
NOTE:
The wheels are not intended for over-the-road use.
1. Refer to Figure 1 and install Wheels as follows:
• Slide the 1/2” Axle Bolt through the 1/2" Flat Washer, the Wheel
and Wheel bracket on frame.
• Install 1/2” Locking Flange Nuts onto 1/2” Flange Bolt.
2. Refer to Figure 1 and install Frame Foot, Foot Support, and
Rubber Feet as shown.
• Slide Rubber Bumper stud through the Foot Support and
Frame Foot. Install the 5/16" Locking Flange Nuts. Slide 5/16”
Bolt through 5/16” Flat Washer and then through holes in Frame
Rail.
• Slide Frame Foot onto 5/16” Bolts; Install 5/16” Locking Flange
Nuts.
3. Refer to Figure 2 and install Handles as shown.
• Remove top Curved Head Bolts and Cap Nuts (Cap Nuts will
be re-used).
• Slide Handle Assembly over Frame Tube, aligning 2 holes.
• Slide 5/16” Carriage Bolts through; Install 5/16” Cap Nuts.
2.1 KNOW THE GENERATOR
Read the Owner’s Manual and Safety Rules before operating this
generator.
Compare the generator to Figures 3 through 5 to become familiarized
with the locations of various controls and adjustments. Save this
manual for future reference.
1. 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.
2. 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.
3. Circuit Breakers (AC) – Each receptacle is provided with a
push-to-reset circuit breaker to protect the generator against
electrical overload.
4
Section 2 – Operation
Portable Generator System
Figure 3 - Control Panel
4. Hourmeter – Tracks hours of operation.
5. Air Filter – Filters intake air as it is drawn into the engine.
6. Choke Knob – Used when starting a cold engine.
7. Fuel Tank – Tank holds 6.6 U.S. gallons of fuel.
8. Grounding Lug – Ground the generator to an approved earth
ground here. See "Grounding the Generator" for details.
9. Run/Stop Switch – Controls the operation of the generator.
10. Muffler – Quiets the engine.
11. Handles – Pivot and retract for storage. Press the spring-loaded
button to move handles.
12. Gas Cap – Fuel fill location.
13. Fuel Gauge – Shows fuel level in tank.
14. Oil Fill – Add oil here.
15. Recoil Starter – Use to start engine manually.
16. Fuel Shut Off – Valve between fuel tank and carburetor.
17. Oil Drain – Use to drain engine oil.
Figure 4 - Generator Controls
Figure 5 - Generator Controls
2.2 HOURMETER
The Hourmeter tracks hours of operation for scheduled maintenance:
There will be a "CHG OIL" message every 100 hours. The message
will flash one hour before and one hour after each 100 hour interval,
providing a two hour window to perform service.
This message will actually begin flashing at 99 hours and disable
itself at 101 hours again, providing a two hour window to perform the
service.
Every 200 hours the "SVC" icon on the lower left hand corner of the
display will flash. The message will flash one hour before and one
hour after each 200 hour interval providing a two hour window to
perform service.
When the hour meter is in the Flash Alert mode, the maintenance
message will always alternate with elapsed time in hours and tenths.
The hours will flash four times, then alternate with the maintenance
message four times until the meter resets itself.
100 hours - CHG OIL — Oil Change Interval (Every 100 hrs)•
200 hours - SVC — Air Filter Interval (Every 200 hrs)•
5
Section 2 – Operation
Portable Generator System
2.3 CORD SETS AND CONNECTION PLUGS
2.3.1 120 VAC, 20 AMP, DUPLEX RECEPTACLE
This is a 120 Volt outlet protected against overload by a 20 Amp
push-to-reset circuit breaker (Figure 6). 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 6 - 120 Volt AC, 20 Amp, Duplex Receptacle
2.4 HOW TO USE THE GENERATOR
If there are any problems operating the generator, please call the
generator helpline at 1-888-436-3722.
2.4.1 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 (Figure 8). Local electrical
codes may also require proper grounding of the unit. For that purpose,
connecting a No. 10 AWG (American Wire Gauge) stranded copper
wire to the grounding lug 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 the area.
Figure 8 - Grounding the Generator
2.3.2 120/240 VAC, 30 AMP RECEPTACLE
Use a NEMA L14-30 plug with this receptacle (rotate to lock/unlock).
Connect a suitable 4-wire grounded cord set to the plug and to the
desired load. The cord set should be rated for 250 Volts AC at 30
Amps (or greater) (Figure 7).
Figure 7 - 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 25 Amp (5.0/5.5kW)
or two 30 Amp (6.5kW) push-to-reset circuit breakers.
6
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.
2.4.2 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".
10 W- 30
SA E 30
Sy nt he ti c 5W -3 0
Section 2 – Operation
Portable Generator System
2.5 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 label or decal affixed to the device.
If the appliance, tool or motor does not give wattage, multiply volts •
times ampere rating to determine watts (volts x amps = watts).
Some electric motors, such as induction types, require about three •
times more watts of power for starting than for running. This surge
of power lasts only a few seconds when starting such motors.
Make sure to allow for high starting wattage when selecting
electrical devices to connect to the 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 is provided to assist in determining
how many items the generator can operate at one time.
NOTE:
All figures are approximate. See data label on appliance for
wattage requirements.
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100
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.
2.6 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
2.7 BEFORE STARTING THE GENERATOR
Prior to operating the generator, engine oil and gasoline will need to
be added, as follows:
2.7.1 ADDING ENGINE OIL
All oil should meet minimum American Petroleum Institute (API)
Service Class SJ, SL or better. Use no special additives. Select the
oil's viscosity grade according to the expected operating temperature
(also see chart).
Above 40° F, use SAE 30•
Below 40° F and down to 10° F, use 10W-30•
Below 10° F, use synthetic 5W-30•
SAE 30
10W-30
Synthetic 5W-30
7
Section 2 – Operation
Portable Generator System
Any attempt to crank or start the engine before
it has been properly serviced with the
recommended oil may result in an engine
failure.
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. Stop filling occasionally to check oil level. Be
careful not to over fill.
Install oil fill cap and finger tighten securely.•
Check engine oil level before starting each time thereafter.•
2.7.2 ADDING GASOLINE
DANGER
Never fill fuel tank indoors. Avoid spilling
gasoline on hot engine. Allow engine/unit to
cool entirely before adding fuel. Never fill fuel
tank when engine is running or hot. DO NOT
light a cigarette or smoke when filling the fuel
tank. Gasoline is highly flammable and its
vapors are explosive.
IMPORTANT: It is important to prevent gum deposits from forming
in fuel system parts such as the carburetor, fuel hose or tank during
storage. Alcohol-blended fuels (called gasohol, ethanol or methanol)
can attract moisture, which leads to separation and formation of acids
during storage. Acidic gas can damage the fuel system of an engine
while in storage. To avoid engine problems, the fuel system should
be emptied before storage of 30 days or longer. See the "Storage"
section. Never use engine or carburetor cleaner products in the fuel
tank as permanent damage may occur.
2.8 TO START THE ENGINE
Never start or stop engine with electrical
devices plugged into the receptacles AND
devices turned on.
Unplug all electrical loads from the unit's receptacles before •
starting the engine.
Make sure the unit is in a level position.•
OPEN• the Fuel Shut-off Valve (Figures 10 and 11).
Figure 10 - Fuel Shut-off Valve
Do not overfill the fuel tank. Always leave room
for fuel expansion. If the fuel tank is over-filled,
fuel can over flow onto hot engine and cause an
explosion.
Use regular UNLEADED gasoline with the generator engine. Do •
not use any gasoline with more than 10% added ethanol. Do not
use E85 gasoline. Do not mix oil with gasoline.
Clean area around fuel fill cap, remove cap.•
Slowly add unleaded regular gasoline to fuel tank. Fill to bottom of •
screen filter. Be careful not to overfill (Figure 9).
Install fuel cap and wipe up any spilled gasoline. •
Figure 9 - Fuel Tank
Fuel Tank
Fuel
DO NOT Fill Above Lip
Figure 11 - Fuel Shut-off Decal
8
Section 3 — Maintenance
Portable Generator System
Turn engine RUN/STOP switch to • ON position (Figure 12).
Pull engine CHOKE knob outward to • FULL CHOKE position
(Figure 12).
To start engine, firmly grasp the recoil handle and pull slowly until •
increased resistance is felt. Pull rapidly up and away.
When engine starts, move choke knob to • 1/2-CHOKE position until
engine runs smoothly and then fully into RUN position. If engine
falters, move choke back out to 1/2-CHOKE position until engine
runs smoothly and then to RUN position.
NOTE:
If engine fires, but does not continue to run, move choke lever to
FULL CHOKE and repeat starting instructions.
Figure 12 - Choke Position
IMPORTANT: Do not overload the generator. Also, do not overload
individual panel receptacles. These outlets are protected against
overload with push-to-reset-type circuit breakers. If amperage rating
of any circuit breaker is exceeded, that breaker opens and electrical
output to that receptacle is lost. Read “Don’t Overload the Generator”
carefully.
2.9 STOPPING THE ENGINE
Shut off all loads, then unplug the electrical loads from generator •
panel receptacles. Never start or stop the engine with electrical
devices plugged in and turned on.
Let engine run at no-load for several minutes to stabilize the •
internal temperatures of engine and generator.
Move Run/Stop switch to • OFF position.
Close fuel valve.•
2.10 LOW OIL LEVEL SHUTDOWN SYSTEM
The engine is equipped with a low oil level sensor that shuts down the
engine automatically when the oil level drops below a specified level. If
the engine shuts down by itself and the fuel tank has enough gasoline,
check engine oil level.
2.10.1 SENSING LOW OIL LEVEL
If the system senses a low oil level during operation, the engine shuts
down. The engine will not run until the oil has been refilled to the
proper level.
3.1 MAINTENANCE SCHEDULE
Follow the calendar intervals. More frequent service is required when
operating in adverse conditions noted below.
Check Oil Level At Each Use
Change Oil ‡ *Every 100 hours or Every Season
Check Valve Clearance ***Every Season
Service Air Filter ** Every 200 hours or Every Season
Replace Spark Plug Every Season
‡ Change oil after first 30 hours of operation then every season.
* Change oil and oil filter every month when operating under heavy load or in high
temperatures.
** Clean more often under dirty or dusty operating conditions. Replace air filter parts
if they cannot be adequately cleaned.
*** Check valve clearance and adjust if necessary after first 50 hours of operation and
every 100 hours thereafter.
3.2 PRODUCT SPECIFICATIONS
3.2.1 GENERATOR SPECIFICATIONS
Rated. Power ........................................................................ 5.0/5.5/6.5 kW**
Surge Power ........................................................................ 6.25/6.88/8.0 kW
Rated AC Voltage .............................................................................. 120/240
Rated AC Load
Current @ 240V (5.0/5.5/6.5 kW) ............................ 20.8/22.9/27.1 Amps**
Current @ 120V (5.0/5.5/6.5 kW) ............................ 41.6/45.8/54.2 Amps**
Rated Frequency ............................................................ 60 Hz @ 3600 RPM
Phase ........................................................................................ Single Phase
** Maximum wattage and current are subject to, and limited by, such factors as fuel
Btu content, ambient temperature, altitude, engine condition, etc.. Maximum power
decreases about 3.5% for each 1,000 feet above sea level; and will also decrease
about 1% for each 6° C (10° F) above 16° C (60° F) ambient temperature.
3.2.2 ENGINE SPECIFICATIONS
Displacement ........................................................................................389 cc
Spark Plug Type ....................................NHSP F7RTC or Champion RN9YC
Spark Plug Gap ..................................... 0.028-0.031 inch or (0.70-0.80 mm)
Gasoline Capacity ................................................................. 6.6 U.S. gallons
Oil Type .......................See Chart in "Before Starting the Generator" Section
Oil Capacity .......................................................................... 1.1 L (1.16 Qts.)
Run Time at 50% Load (5.0/5.5/6.5 kW) ..................................10/10/9 Hours
Class II Emission Certified*
* The engine manufacturer must warrant the emission control system for a
period of two years. This warranty coverage is in addition to the warranty
provided by Generac, and may cover the engine even if Generac’s warranty
does not.
9
Section 3 — Maintenance
Portable Generator System
3.3 GENERAL RECOMMENDATIONS
The warranty of the generator does not cover items that have been
subjected to operator abuse or negligence. To receive full value from
the warranty, the operator must maintain the generator as instructed
in this manual.
Some adjustments will need to be made periodically to properly
maintain the generator.
All adjustments in the Maintenance section of this manual should
be made at least once each season. Follow the requirements in the
"Maintenance Schedule".
NOTE:
Once a year replace the spark plug and replace the air filter. A
new spark plug and clean air filter assure proper fuel-air mixture
and help the engine run better and last longer.
3.3.1 GENERATOR MAINTENANCE
Generator maintenance consists of keeping the unit clean and dry.
Operate and store the unit in a clean dry environment where it will not
be exposed to excessive dust, dirt, moisture or any corrosive vapors.
Cooling air slots in the generator must not become clogged with snow,
leaves, or any other foreign material.
Check the cleanliness of the generator frequently and clean when
dust, dirt, oil, moisture or other foreign substances are visible on its
exterior surface.
Never insert any object or tool through the air
cooling slots, even if the engine is not running.
NOTE:
DO NOT use a garden hose to clean generator. Water can enter
the engine fuel system and cause problems. In addition, if water
enters the generator through cooling air slots, some water will
be retained in voids and crevices of the rotor and stator winding
insulation. Water and dirt buildup on the generator internal
windings will eventually decrease the insulation resistance of
these windings.
3.3.2 TO CLEAN THE GENERATOR
Use a damp cloth to wipe exterior surfaces clean.•
A soft, bristle brush may be used to loosen caked on dirt, oil, etc.•
A vacuum cleaner may be used to pick up loose dirt and debris.•
Low pressure air (not to exceed 25 psi) may be used to blow away •
dirt. Inspect cooling air slots and openings on the generator. These
openings must be kept clean and unobstructed.
3.3.4 CHECKING OIL LEVEL
See the “Before Starting the Generator” section for information on
checking the oil level. The oil level should be checked before each
use, or at least every eight hours of operation. Keep the oil level
maintained.
3.3.5 CHANGING THE OIL
Change the oil after every 100 hours. If running this unit under dirty
or dusty conditions, or in extremely hot weather, change the oil more
often.
Hot oil may cause burns. Allow engine to cool
before draining oil. Avoid prolonged or repeated
skin exposure with used oil. Thoroughly wash
exposed areas with soap.
NOTE:
Whenever possible, run engine for approximately five (5) minutes
to get the engine oil hot. This will aid in draining the oil.
Use the following instructions to change the oil while the engine
is still warm:
Clean area around oil drain plug.•
Remove oil drain plug from engine and oil fill plug to drain oil •
completely into a suitable container.
When oil has completely drained, install oil drain plug and tighten •
securely.
Fill oil sump with recommended oil. (See “Before Starting the •
Generator” for oil recommendations).
Wipe up any spilled oil.•
Dispose of used oil at a proper collection center.•
3.3.6 REPLACING THE SPARK PLUG
Use Champion RN9YC spark plug or equivalent. Replace the plug
once each year. This will help the engine start easier and run better.
1. Stop the engine and pull the spark plug wire off of the spark
plug.
2. Clean the area around the spark plug and remove it from the
cylinder head.
3. Set the spark plug's gap to 0.70-0.80 mm (0.028-0.031 in.).
Install the correctly gapped spark plug into the cylinder head
(Figure 13).
Figure 13 - Spark Plug Gap
3.3.3 ENGINE MAINTENANCE
DANGER
When working on the generator, always
disconnect negative cable from battery. Also
disconnect spark plug wires from spark plug
and keep wire away from spark plug.
10
Section 3 — Maintenance
Portable Generator System
3.4 SERVICE AIR FILTER
The engine will not run properly and may be damaged if using a dirty
air filter. Clean the air filter every 200 hours or once a year (Figure 14).
Clean or replace more often if operating under dusty conditions.
Remove air • filter cover.
Wash in soapy water. Squeeze filter dry in clean cloth (DO NOT •
TWIST).
Clean air • filter cover before re-installing it.
NOTE:
To order a new air filter, please contact the nearest authorized
service center at 1-888-436-3722.
Figure 14 - Air Filter
3.7 LONG TERM STORAGE
It is important to prevent gum deposits from forming in essential fuel
system parts such as the carburetor, fuel hose or tank during storage.
Also, experience indicates that alcohol-blended fuels (called gasohol,
ethanol or methanol) can attract moisture, which leads to separation
and formation of acids during storage. Acidic gas can damage the fuel
system of an engine while in storage.
To avoid engine problems, the fuel system should be emptied before
storage of 30 days or longer, as follows:
Remove all gasoline from the fuel tank.•
DANGER
Drain fuel into approved container outdoors,
away from open flame. Be sure engine is cool.
Do not smoke.
Start and run engine until engine stops from lack of fuel.•
While engine is still warm, drain oil from crankcase. Refill with •
recommended grade.
Remove spark plugs and pour about 1/2 ounce (15 ml) of engine •
oil into the cylinders. Cover spark plug hole with rag. Pull the recoil
starter a couple times to lubricate the piston rings and cylinder
bore..
3.5 VALVE CLEARANCE
Intake — 0.15 ± 0.02mm (cold), (0.006" ± 0.0008" inches)•
Exhaust — 0.0020 ± 0.02mm (cold) (0.008" ± 0.0008" inches)•
After the first 50 hours of operation, check the valve clearance in
the engine and adjust if necessary.
Important: If feeling uncomfortable about doing this procedure or
the proper tools are not available, please take the generator to the
nearest service center to have the valve clearance adjusted. This is a
very important step to insure longest life for the engine.
3.6 GENERAL
The generator should be started at least once every seven days
and be allowed to run at least 30 minutes. If this cannot be done
and the unit must be stored for more than 30 days, use the following
information as a guide to prepare it for storage.
DANGER
NEVER store engine with fuel in tank indoors
or in enclosed, poorly ventilated areas where
fumes may reach an open flame, spark or pilot
light as on a furnace, water heater, clothes dryer
or other gas appliance.
Avoid spray from spark plug holes when
cranking engine.
Install and tighten spark plugs. Do not connect spark plug wires.•
Clean the generator outer surfaces. Check that cooling air slots •
and openings on generator are open and unobstructed.
Store the unit in a clean, dry place.•
3.8 OTHER STORAGE TIPS
Do not store gasoline from one season to another.•
Replace the gasoline can if it starts to rust. Rust and/or dirt in the •
gasoline will cause problems with the carburetor and fuel system.
If possible, store the unit indoors and cover it to give protection •
from dust and dirt. BE SURE TO EMPTY THE FUEL TANK.
If it is not practical to empty the fuel tank and the unit is to be stored •
for some time, use a commercially available fuel stabilizer added to
the gasoline to increase the life of the gasoline.
Cover the unit with a suitable protective cover that does not retain •
moisture.
DANGER
NEVER cover the generator while engine and
exhaust area are warm.
11
Section 4 — Troubleshooting
Portable Generator System
4.1 TROUBLESHOOTING GUIDE
PROBLEM CAUSE CORRECTION
Engine is running, but no AC
output is available.
1. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Fault in generator.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in good condition.
4. Contact Authorized Service Facility.
Engine runs good but bogs down
when loads are connected.
Engine will not start; or starts and
runs rough.
Engine shuts down during
operation.
Engine lacks power.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Fuel Shut-off is OFF.
2. Dirty air filter.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to spark plug.
6. Bad spark plug.
7. Water in gasoline.
8. Overchoking.
9. Low oil level.
10. Excessive rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator” .
3. Contact Authorized Service Facility.
4. Contact Authorized Service Facility.
1. Turn Fuel Shut-off ON.
2. Clean or replace air filter.
3. Fill fuel tank.
4. Drain fuel tank and fill with fresh fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain fuel tank; fill with fresh fuel.
8. Put choke knob to No Choke position.
9. Fill crankcase to proper level.
10. Contact Authorized Service Facility.
11. Contact Authorized Service Facility.
12. Contact Authorized Service Facility.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Authorized Service Facility.
1. Reduce load (see “Don’t Overload the Generator”).
2. Clean or replace air filter.
3. Contact Authorized Service Facility.
Engine “hunts” or falters.
12
1. Choke is opened too soon.
2. Carburetor is running too rich or too lean.
1. Move choke to halfway position until engine runs
smoothly.
2. Contact Authorized Service Facility.
Section 5 — Notes
13
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