Generac GP6500-5940-1, 5941-2, 5941-1, 5940-1, 005939-2 Owner’s Manual

GENERAC _

Owner'sM

GPSeriesPortableGenerator

introduction.............................................................1

Maintenance.........................................................13

ReadthisManual Thoroughly.................................1

Safety Rules...........................................................1

StandardsIndex.............................................................3

Generalinformation................................................4

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

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

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

1.2.1 Assemblingthe Accessory Kit............................4

1.2.2 BatteryCableConnection(ElectricStart Only)....5

Operation................................................................5

2.1 Knowthe Generator.......................................................5

2.2 Hourmeter......................................................................7

2.3 CordSets andConnectionPlugs....................................7

2.3.1 120 VAC,20 Amp, DuplexReceptacle...............7

2.3.2 120/240VAC,30 Amp, Receptacle....................7

2.3.3 120 VAC,20 Amp, GFCIDuplexReceptacle.......7

2.3.4 120/240VAC,30 Amp Receptacle.....................8

2.4 Howto Usethe Generator..............................................8

2.4.1 Groundingthe GeneratorWhenUsed

asa Portable.....................................................8

2.4.2 Connectingthe Generatorto a Building's

ElectricalSystem...............................................9

2.5 Don'tOverloadthe Generator..........................................9

2.6 WattageReferenceGuide...............................................9

2.7 BeforeStartingthe Generator.......................................10

2.7.1 Adding EngineOil............................................10

2.7.2 Adding Gasoline...............................................10

2.8 Starting Pull Start Engines............................................11

2.9 Starting ElectricStart Engines......................................11

2.9.1 ManualStart....................................................12

2.10 Stoppingthe Engine.....................................................12

2.11 Low Oil Level ShutdownSystem..................................12

2.11.1 SensingLow Oil Level......................................12

2.12 Chargingthe Battery(Electric Start Units Only).............12

3.1 PerformingScheduledMaintenance.............................13

3.2 MaintenanceSchedule.................................................13

3.3 ProductSpecifications..................................................13

3.3.1 GeneratorSpecifications..................................13

3.3.2 EngineSpecifications.......................................13

3.3.3 EmissionsInformation.....................................13

3.4 GeneralRecommendations...........................................13

3.4.1 GeneratorMaintenance....................................13

3.4.2 ToCleanthe Generator.....................................14

3.4.3 EngineMaintenance.........................................14

3.4.4 CheckingOil Level...........................................14

3.4.5 Changingthe Oil..............................................14

3.4.6 Replacingthe SparkPlug.................................14

3.4.7 BatteryReplacement(if applicable)..................14

3.5 ServiceAir Cleaner.......................................................15

3.5.1 CleanSparkArrestor Screen(CARDmodels)...15

3.6 ValveClearance............................................................15

3.7 General........................................................................15

3.8 Long TermStorage.......................................................16

3.9 OtherStorageTips.......................................................16

Troubleshooting....................................................17

4.1 TroubleshootingGuide..................................................17

Warranty...............................................................18

MANUALDELPROPIETARIO.............................23

MANUELD'ENTRETIEN......................................47

iNTRODUCTiON

Thankyou for purchasingthis model by GeneracPowerSystems, Inc. This model is a compact, high performance, air-cooled, engine driven generatordesigned to supply electrical power to

operateelectrical loads where no utility power is available or in placeof utility dueto a poweroutage.

BEADTHISMANUALTHOROUGHLY

If anyportion ofthis manualis not understood,contactthenearest AuthorizedDealerfor starting, operatingandservicingprocedures.

The operator is responsiblefor proper and safe use of the equipment.We strongly recommend that the operator read this manualandthoroughlyunderstandallinstructions beforeusingthe equipment.Wealsostronglyrecommendinstructingother usersto

properlystart andoperatethe unit.This preparesthemifthey need to operatetheequipmentin an emergency.Savetheseinstructions for future reference.Ifyou loanthis unitto someone,ALWAYSloan

these instructionsto the individualas welt.

Thegeneratorcan operatesafely,efficiently and reliablyonly if it

is properlylocated, operatedandmaintained.Before operatingor

servicingthe generator:

• Becomefamiliarwith and strictly adhereto alt local, state and nationalcodes and regulations.

• Study all safety warnings in this manual and on the product carefully.

• Becomefamiliarwith this manualandthe unit beforeuse.

Themanufacturercannot anticipateevery possible circumstance that might involvea hazard.The warnings inthis manual,and on tags and decals affixedto the unit are, therefore,not all inclusive.

If using a procedure,work method or operatingtechniquethat the

manufacturerdoes not specifically recommend,ensurethat it is

safe for others. Also make sure the procedure,work method or

operatingtechniqueutilizeddoes not renderthe generatorunsafe.

THE INFORMATIONCONTAINEDHEREIN WAS BASED ON

MACHINESIN PRODUCTIONAT THE TIME OF PUBLICATION.

GENERACRESERVESTHERIGHTTOMODIFYTHISMANUALAT

ANYTIME.

SAFETYRULES

Throughoutthis publication,and on tags and decals affixedto the

generator,DANGER,WARNING,CAUTIONand NOTEblocks are

usedto alert personnelto special instructionsabout a particular

operation that may be hazardous if performed incorrectly or

carelessly.Observethem carefully.Their definitionsareasfollows:

INDICATES A HAZARDOUS SITUATION OR ACTION

WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH

OR SERIOUS INJURY.

Indicates a hazardous situation or action which, if

not avoided, could result in death or serious injury.

_,CAUTION!

Indicates a hazardous situation or action which,

if not avoided, could result in minor or moderate injury.

NOTE:

Notes containadditional informationimportantto a procedure and will be found withinthe regulartextbody of thismanual.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliancewith the special instructionswhile performing the action or serviceareessentialto preventingaccidents.

Four commonly used safety symbols accompany the BANGER, WARNINGand CAUTIONblocks. The type of information each

indicatesis 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.

i/_This symbol points out potential fire hazard.

This symbol points out potential electrical shock hazard.

GENERAL HAZARDS

• NEVERoperatein an enclosed area, in a vehicle, or indoors EVENIFdoors and windows areopen.

• For safety reasons, the manufacturer recommends that the maintenanceof this equipmentis carried out by an Authorized Dealer.Inspectthe generatorregularly,and contactthe nearest AuthorizedDealerfor parts needingrepairor replacement.

• Operategeneratoronly on levelsurfacesandwhereit will notbe exposedto excessivemoisture,dirt, dust or corrosivevapors.

• Keephands, feet, clothing, etc., awayfrom drive belts, fans, and othermoving parts. Neverremoveany fan guardor shield whilethe unit is operating.

• Certain parts of the generator get extremely hot during operation. Keep clear of the generator until it has cooled to

avoidsevereburns.

• Do NOToperategeneratorinthe rain.

• Do not alter the construction of the generator or change controlswhich might createan unsafeoperatingcondition.

• Neverstart or stop the unit with electrical loads connected to receptaclesAND with connecteddevices turned ON. Start the engine and let it stabilize before connecting electrical loads. Disconnectall electricalloads beforeshutting down the

generator.

• Do not insert objectsthrough unit's cooling slots.

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

• Neverusethe generatoror anyof its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerousoperating conditions from leaking exhaust gases,

fuel leakage,oil leakage,etc.

• Onelectricstart models, disconnectthe POSITIVE(+) battery cable from the engine starter ORthe NEGATIVE(=) battery cable from the battery terminal, whichever is easier, before

transportingthe generator.

EXHAUST& LOCATIONHAZARDS

• Never operate in an enclosed area or indoors!NEVERuse in the home, in a vehicle,or in partlyenclosed areassuch

as garages,evenif doors and windowsare open! ONLYuse outdoors and far from openwindows,doors, vents,andinan

areathat will notaccumulatedeadly exhaust.

Using a generator indoors CAN KiLL YOU IN MINUTES,

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

NEVER use inside a home

or garage, EVENIF doors and windows are open.

Only use OUTSIDE and far away from windows,

doors_ and vents,

ELECTRICALHAZARDS

• The generator produces dangerously high voltage when in

operation.Avoidcontactwith barewires,terminals,connections, etc., while the unit is running, even on equipmentconnected to the generator. Ensure all appropriate covers, guards and barriersarein placebeforeoperatingthe generator.

• Never handle any kind of electrical cord or device while standinginwater,while barefootorwhile handsor feet arewet.

DANGEROUSELECTRICALSHOCKMAYRESULT.

• TheNationalElectricCode(NEC)requirestheframe andexternal

electrically conductive parts of the generator be properly connectedto an approvedearth ground.Local electricalcodes

may also require proper grounding of the generator.Consult with a localelectricianfor groundingrequirementsin the area.

• Use a ground fault circuit interrupter in any damp or highly conductivearea(such as metaldecking or steelwork).

• Do not useworn, bare,frayed or otherwisedamagedelectrical cord setswith the generator.

• Beforeperforminganymaintenanceonthegenerator,disconnect the enginestarting battery (if equipped)to prevent accidental start up. Disconnectthe cable from the batterypost indicated by a NEGATIVE,NEGor (-) first. Reconnectthatcable last.

• In caseof accident causedby electricshock, immediatelyshut down the source of electrical power. If this is not possible,

attempt to free the victim from the live conductor. AVOID DIRECTCONTACTWITHTHEVICTIM. Use a non-conducting

implement,such asa rope or board,to free thevictim from the live conductor.If the victim is unconscious, applyfirst aid and getimmediatemedical help.

• The engine exhaustfumes contain carbon monoxide, which you cannot see or smell. This poisonous gas, if breathedin

sufficientconcentrations,can causeunconsciousnessor even death.

• 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 operationof the generator.ThegeneratorMUSTbeoperatedoutdoors.

• Thisexhaustsystem must be properly maintained.Do nothing

that mightrendertheexhaustsystemunsafeorinnoncompliance

with any localcodes and/orstandards.

• Alwaysusea batteryoperatedcarbonmonoxidealarmindoors, installedaccordingto themanufacturersinstructions.

• If you start to feet sick, dizzy,or weak after the generatorhas beenrunning,moveto fresh air IMMEDIATELYSeea doctor,as you couldhave carbonmonoxidepoisoning.

FIREHAZARDS

• Gasolineishighly FLAMMABLEand itsvaporsare EXPLOSIVE. Do not permit smoking,open flames, sparksor heat in the

vicinitywhile handling gasoline.

• Neveraddfuel while unit isrunning or hot.Allow engineto cool

completelybeforeaddingfuel.

• Never fill fuel tank indoors, Comply with all laws regulating storageand handlingof gasoline.

• Do not overfill the fuel tank. Always allow room for fuel expansion.If tank is over=filled,fuel can overflow onto a hot

engineandcauseFIREor an EXPLOSION.Neverstoregenerator with fuel in tank where gasolinevapors might reachan open flame, spark or pilot light (as on a furnace, water heateror clothes dryer). FIREor EXPLOSIONmay result. Allow unit to cool entirelybeforestorage.

• Wipe up any fuel or oil spills immediately.Ensure that no combustiblematerialsareleft on or nearthe generator.Keepthe areasurroundingthe generatorcleanandfree from debrisand keepa clearanceof five (5) feet on all side to allow for proper ventilationof the generator.

* Do notinsert objectsthrough unit's cooling slots. * Do not operate the generator if connected electrical devices

overheat,if electricaloutputislost, if engineor generatorsparks or if flames or smoke are observedwhile unit is running.

* Keepafire extinguishernearthe generatorat all times.

STANDARDS/NDEZ

1. NationalFireProtectionAssociation(NFPA)70:TheNATIONAL ELECTRICCODE(NEC)availablefrom www.nfpa.org

2. NationalFire ProtectionAssociation (NFPA)5000: BUILDING CONSTRUCTIONAND SAFETYCODEavailable from www.

nfpa.org

3. InternationalBuildingCodeavailablefrom www.iccsafe.org

4. Agricultural Wiring Handbookavailablefrom www.rerc.org , Rural ElectricityResourceCouncil RO.Box 309 Wilmington,

OH45177-0309

5. ASAEEP-364.2Installationand Maintenanceof FarmStandby Electric Power available from www.asabe.org, American Society of Agricultural & Biological Engineers 2950 Niles Road,St. Joseph,MI 49085

This list is not all inclusive.Checkwith theAuthority HavingLocal Jurisdiction (AHJ)for any localcodes or standardswhich maybe applicableto your jurisdiction.

MODELNO: SERIALNO:

Unit ID Location

DECAL

DATA

CALIFORNIAPROPOSITION65 WARNING

Engineexhaustandsomeof its constituentsareknown

to theStateof Californiato causecancer,birth defects

andotherreproductiveharm.

CALIFORNIAPROPOSITION65 WARNING

This productcontainsor emitschemicalsknown tothe

Stateof Californiato causecancer,birth defectsand

otherreproductiveharm.

1.1 UNPACKING

• Removeall packagingmaterial.

• Removeseparateaccessorybox.

• Removethegeneratorfrom carton.

1.1.1 ACCESSORYBOX

• 1-Owner's manual

• 1-Bottleof OilSAE30

• 3-ProductRegistrationCards (English,Spanish,French)

• 1-BatteryCharger(electricstart only)

• 1-HandleAssembly

• 1-FrameFoot(E)

• 2-Never-FlatWheels(H)

• 1-Hardwarebag(containingthefollowing):

- 2-LongCurvedHeadBolts(A)

- 2-AcornNuts(B)

- 4-Flangednuts(C)

- 2-RubberFeet(D)

- 2-ShortBolts(F)

- 2-AxlePins(G)

- 2-Washers(1)

- 2-CotterPins(J)

- 2-FlangeNuts(electricstartonly)

1.2 ASSEMBLY

The generator requires some assembly prior to using it. If problems arise when assemblingthe generator,please call the GeneratorHetplineat 1-888-436-3722.

6. Usea pliersandbendonetab of cotterpin (J)outwardto lock into place.

7. Repeatsteps5, 6, & 7 for other wheel.

Figure 1A- Handle Assembly

Figure 1B - Foot Assembly

1.2.1 ASSEMBLINGTHEACCESSORYKIT

Refer to the instructions below and Figures 1A, 1B, and 1C to installthe handle,feet, and wheels. Note:the handlecomponents

are already pre-assembledfrom the factory. The wheels are designedto greatly improve the portability of the generator.You

will needthefollowing tools to properlyinstallthe accessorykit:

• Ratchetanda 13mm [1/2"] socket

• 13mm [1/2"] boxwrench

• Needlenosepliers

Handle

1. Installthe handleassemblyto theframeby usingbolts (A) and nuts (B).

Feet

2. Use nuts (C) to mount the rubberfeet (D)to the foot bracket (E).

3. Mountthefoot bracket(E)to the framewith two bolts (F) and nuts (C).

Wheels

4. Slideaxlepin (G)through wheel(H), washer (I), andthrough thebracket on the frame.

5. Secureaxle pin (G)to the frame with the cotterpin (J).

Figure lC - Wheel Assembly

BEND ONETAB

AFTERAXLE

PIN(G)IS

THROUGH

THEFRAME

INSERTED _

1.2.2 BATTERYCABLECONNECTION(ELECTRICSTART

ONLY)

The unit has been deliberately shipped with the battery cables disconnected.Youwill needa lOmm wrenchto securethe battery

cables. Toconnect the battery(seeFigure17 for connectiondetails):

1. Cut off cable ties securing battery cables and remove red coversfrom batteryterminals.

2. First,connectthe redcableto the positive(+) batteryterminal with the bolt, lock washer andnut supplied.

3. Connectthe black cable to the negative(-) batteryterminal with the bolt, lock washer andnut supplied.

4. Make sureall connectionsare secure. Slidethe rubber boots overthe terminalsand connectionhardware.

NOTE:

if the battery is unable to start the engine,charge it with the 12V chargerincludedinthe accessory box (seethe "Charginga Battery"sectionfor details).

2.1 KNOWTHEGENERATOR

Read the Owner'sManual and Safety Rules before operating this generator.

Compare the generator to Figures 2 through 4 to become familiarizedwiththe locationsofvariouscontrols andadjustments.

Savethis manualfor future reference.

1. 120 Volt AC, 20 Amp, Duplex Receptacle - Supplies electrical power for the operationof 120 Volt AC, 20 Amp, single-phase,60 Hz electrical lighting, appliance, tool and motor loads. CARBmodels areequippedwith GFCIoutlets.

2. 120/240 Volt AC, 30 Amp LockingReceptacle - Supplies electricalpower for the operationof 120 and/or 240 VoltAC, 30 Amp, single-phase,60 Hz, electrical lighting, appliance,

tool andmotor loads.

3. Circuit Breakers(AC)- Eachreceptacleis provided with a push-to-reset circuit breakerto protectthe generatoragainst

electricaloverload.

4. Oil Drain- Useto drainengineoil.

5. Air Filter- Filters intakeair as it is drawn intothe engine.

6. ChokeKnob- Usedwhen startinga cold engine.

7. FuelTank- SeegeneratorSpecificationsfor tank capacity.

8. GroundingLug - Groundthe generatorto an approvedearth groundhere.See"Groundingthe Generator"for details.

g. Run/Stop Switch - Controls the operationof the generator

(pullstart models).

gA. Start Switch - Usedto start engine from the starter motor

(electricstart modelsonly).

10. Muffler - Quietsthe engine.

11. Handle - Pivot and retract for storage. Press the spring- loadedbuttonto move handles.

12. GasCap- Fuelfill location.

13. FuelGauge- Showsfuel levelin tank.

14. Oil Fill- Addoil here.

15. Recoil Starter - Useto start enginemanually.

15. FuelShut Off - Valve betweenfueltank and carburetor.

17. BatteryCharger Input -This receptacleallowsthe capability to recharge the 12 volt DO storage battery provided with the 12 Volt Adaptor Plug Chargerwhich is included in the

Accessory Box. Located behindthe battery chargerinput is a 1.50 Amp in-line fuse which is insidethe control panelto

protectthe battery (electricstart models only).

18. Battery - Powersthe electric starter (electric start models only).

lg. Hourmeter- Trackshoursof operation.

28. Spark Arrestor - Reducesfire hazardsby containing sparks

(CARBmodels only).

Figure2,4- Contro/Pane/(4g StateModels) Figure3 - Generator Controls

Figure2B - Contro/Panel (CARBModels)

Figure 2C - Contro/ Panel(CSAModels)

Figure4 - GeneratorControls

2.2 HOURIVIETER

TheHourmetertrackshoursofoperationfor scheduledmaintenance (Figure5):

Therewill be a "CHGOIL"messageevery100 hours.Themessage will flash one hour before and one hour after each 100 hour

interval,providing atwo hourwindow to perform service. This messagewill actuallybeginflashing at 99 hoursand disable

itselfat 101 hoursagain,providingatwo hourwindow to perform

the service.

Every200 hours the "SVC"icon on the lower left hand corner of

the display will flash. Themessagewill flash one hourbefore and

onehourafter each200 hourintervalprovidingatwo hourwindow

to perform service.

Whenthe hour meter is inthe FlashAlert mode, the maintenance message will always alternate with elapsed time in hours and

tenths. The hours wilt flash four times, then alternate with the

maintenancemessagefour timesuntil the meter resets itself.

• 100 hours- CHGOIL-- Oil ChangeInterval(Every100 hrs)

• 200 hours- SVC-- ServiceAir Filter(Every200 hrs) Note:

The hour glassgraphicwill flash on and off when the engine

is running.This signifiesthat the meter is tracking hours of

operation.

Figure 6 - 120 Volt AC, 20 Amp, Duplex Receptacle

2.3.2 120/240VAC,30 AMPRECEPTACLE

Use a NEMA L14-30 plug with this receptacle (rotate to lock! unlock). Connecta suitable4-wire groundedcord set to the plug

andto thedesiredtoad.Thecord set should be ratedfor 250 Volts ACat 30 Amps (or greater)(Figure7).

Figure 7 - 120/240 VAC,30 Amp Receptacle

Figure 5 - Hourmeter

0000.0

HOURGLASS RESETBUTTON GRAPHIC (IF EQUIPPED)

2.3 CORDSETSANDCONNECTIONPLUGS

2.3.1 120VAC,20 AMP,DUPLEXRECEPTACLE

This is a 120 Volt outlet protectedagainstoverloadby a 20 Amp push-to-resetcircuitbreaker (Figure6). Useeach socketto power

120 VoltAC, singlephase,60 Hzelectrical loadsrequiringupto a combined 2400 watts (2.4 kW) or 20 Ampsof current. Useonly high quality, well-insulated, 3-wire grounded cord sets ratedfor 125 Volts at 20 Amps (or greater).

Keep extensioncords as short as possible, preferablyless than 15 feet long, to preventvoltage drop and possibleoverheatingof

wires.

12OV/24OV

3CA

Use this receptacleto operate 120 Volt AC, 60 Hz, single phase loadsrequiringup to 3600 watts (3.6kW) of power at30 Amps or 240 VoltAC,60 Hz, singlephaseloadsrequiringup to 7200 watts

(7.2 kW) of power at 30 Amps. The outlet is protectedby two 30 Amp push-to-resetcircuit breakers.

2.3.3 120VAC,20AMP,GFC/OUPLEXRECEPTACLE

This is a 120 Volt outlet protectedagainstoverloadby a 20 Amp push-to=resetcircuit breaker(Figure8). Useeachsocketto power 120 VoltAC, singlephase,60 Hzelectrical loadsrequiringup to a combined 2400 watts (2.4 kW) or 20 Ampsof current.Use only high quality, well-insulated, 3-wire grounded cord sets ratedfor 125 Volts at 20 Amps (or greater).

Keepextensioncords as short as possibleto preventvoltagedrop and possibleoverheatingof wires.

Figure 8 - 120 Vo/t AC, 20 Amp, GFC/ Duplex Receptac/e

2.3.4 120/240VAC,30 AMPRECEPTACLE

Use a NEMA L14-30 plug with this receptacle (rotate to lock! unlock). Connecta suitable4-wire groundedcord set to the plug

andto thedesiredtoad.Thecord set should be ratedfor 250 Volts ACat 30 Amps (or greater)(Figure9).

Figure 9 - 120/240 VAC,30 Amp Receptac/e

_t he engine exhaust fumes contain carbon

monoxide, which can you cannot see or smell.

This poisonous gas, if breathed in sufficient concentrations, can cause unconsciousness Or even death.

_t 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.

_t 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.

_t Always use a battery operated carbon

monoxide alarm indoors, installed according to

the manufacturers instructions.

Using a generator indoors CAN KiLL YOU iN MINUTES.

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

12OV/24OV

3CA

Use this receptacleto operate120 Volt AC, 60 Hz, single phase loads requiringup to 3600 watts (3.6 kW) of powerat 30 Amps or 240 Volt AC, 60 Hz,single phase loads requiringup to 7200 watts (7.2 kW) of power at 30 Amps. The outlet is protectedby

two 25 Amp (5.0/5.5kW) or two 30 Amp (6.5kW) push-to-reset

circuit breakers.

2.4 H0WTOUSETHEGENERATOR

Seethe "ToStart the Engine"sectionfor howto safelystart and stop the generator and how to connect and disconnect loads. If

there are any problems operatingthe generator,please call the

generatorhelplineat 1-888-436-3722.

_t ever operate in an enclosed area or indoors!

NEVER use in the home, in a vehicle, or in partly enclosed areas such as garages, EVEN

IF doors and windows are open! ONLY use

outdoors and far from open windows, doors, vents, and in an area that will not accumulate

deadly exhaust.

NEVER use inside a home or garage, EVEN iF doors

and windows are open.

Only use OUTSIDE and

far away from windows, doors, and vents.

2.4.1 GROUNDINGTHEGENERATORWHENUSEDASA

PORTABLE

This generator has an equipment ground that connects the generatorframe componentsto the ground terminals on the AC output receptacles (see NEC 250.34 (A) for explanation). This allows the generatorto be used as a portablewithout grounding theframe ofthe generatoras specifiedin NEC250.34.

SpecialRequirements

There may be Federalor State OccupationalSafety and Health Administration(OSHA)regulations,localcodes, or ordinancesthat applyto the intendeduse ofthe generator.

Pleaseconsult a qualified electrician, electrical inspector, or the local agencyhavingjurisdiction:

* In some areas, generators are requiredto be registeredwith

local utilitycompanies.

* If the generatoris used at a construction site, there may be

additionalregulationswhich must be observed.

2.4.2 CONNECT/NGTHEGENERATORTOA BU/LD/NG'$ ELECTR/CALSYSTEM

Connectionsfor standby power to a building's electricalsystem must be made by a qualifiedelectricianand in strict compliance

with all national and local electrical codes and laws. The connectionmust isolatethe generatorpowerfrom utility poweror otheralternativepowersources.

NOTE:

Because the generatorequipmentground is bonded to the AC neutral wires in the generator(see Figure 8), either a 3-pole transferswitch or a 2 pole transferswitch with a switching neutral kit is requiredto connectthis generatorto a building load. in this application the generator becomes a separately derived system(see NEC250.20 (D)), and mustbe grounded

in accordance with the national or local electrical code requirements.

GroundingtheGeneratorina BuildingStandbyApplication

_ he 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 (Figure 10). For that purpose, connecting a No. 10 AWG (AmericanWire Gauge)strandedcopperwire to the groundinglug and to an earth=drivencopperor brass groundingrod (electrode) provides adequateprotection against electrical shock. However, local codes mayvary widely.Consultwith a local electrician for grounding requirementsinthe area.

Proper groundingof the generator will help preventelectrical shockintheeventof a groundfault condition inthe generatoror in connectedelectricaldevices.Propergroundingalsohelpsdissipate static electricity,which often buildsup in ungroundeddevices.

Figure 10- Grounding the Generator

2.5 DON'TOVEBLOADTHEGENEBATOB

Overloadinga generatorin excess of its rated wattage capacity can result in damageto the generatorand to connectedelectrical devices.Observethefollowing to preventoverloadingthe unit:

* Addupthe total wattageofall electricaldevicesto beconnected

at one time. This total should NOT be greater than the generator'swattagecapacity.

* Theratedwattage of lights can betaken from light bulbs. The

ratedwattage of tools, appliancesand motors can usually be

found on a data labelor decalaffixedto the device.

* Ifthe appliance,toot or motor does not give wattage,multiply

voltstimes ampereratingto determinewatts (volts x amps = watts).

* Someelectric motors, such as induction types, requireabout

threetimes more watts of powerfor startingthan for running.

This surge of power lasts only a few seconds when starting suchmotors. Makesureto allowfor high startingwattagewhen selectingelectrical devicesto connect to the generator:

1. Figurethe watts neededto start the largestmotor.

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

TheWattageReferenceGuideis providedto assist in determining how many itemsthegeneratorcanoperateat onetime.

NOTE:

All figures are approximate.See data label onappliancefor wattage requirements.

2.6 WATTAGEBEFEBENCEGUIDE

Device ................................... RunningWatts

*Air Conditioner (12,000 Btu).......................... 1700

*Air Conditioner (24,000 Btu).......................... 3800

*Air Conditioner (40,000 Btu).......................... 6000

BatteryCharger(20 Amp).............................. 500

BeltSander(3") .................................... 1000

ChainSaw ........................................ 1200

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

*Clothes Dryer (Electric) ............................. 5750

*Clothes Dryer (Gas) ................................. 700

*Clothes Washer ................................... 1150

CoffeeMaker ...................................... 1750

*Compressor (1 HP)................................. 2000

*Compressor (3/4 HP)............................... 1800

*Compressor (1/2 HP)............................... 1400

CurlingIron......................................... 700

*Dehumidifier....................................... 650

DiscSander(9").................................... 1200

EdgeTrimmer....................................... 500

Electric Blanket...................................... 400

Electric NailGun.................................... 1200

Electric Range(per element)........................... 1500

ElectricSkillet...................................... 1250

*Freezer............................................ 700

*FurnaceFan (3/5 HP) ................................ 875

*GarageDoor Opener............................ 500 to 750

HairDryer......................................... 1200

HandDrill .................................... 250 to 1100

HedgeTrimmer...................................... 450

ImpactWrench...................................... 500

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

*JetPump......................................... 800

LawnMower....................................... 1200

LightBulb.......................................... 100

MicrowaveOven............................... 700to1000

*MilkCooler....................................... 1100

OilBurneronFurnace................................. 300

OilFiredSpaceHeater(140,000Btu)..................... 400

OilFiredSpaceHeater(85,000Btu)...................... 225

OilFiredSpaceHeater(30,000Btu)...................... 150

*PaintSprayer,Airless(1/3HP)......................... 600

PaintSprayer,Airless(handheld)......................... 150

Radio......................................... 50to200

*Refrigerator........................................ 700

SlowCooker........................................ 200

*SubmersiblePump(1-1/2HP)........................ 2800

*SubmersiblePump(1HP)........................... 2000

*SubmersiblePump(1/2HP).......................... 1500

*SumpPump................................. 800to1050

*TableSaw(10")............................. 1750to2000

Television..................................... 200to500

Toaster..................................... 1000to1650

WeedTrimmer...................................... 500

*Allow3timesthelistedwattsforstartingthesedevices.

2.7 BEFORESTARTIN6THEGENERATOR

Priorto operatingthe generator,engineoil and gasolinewill need

to be added,asfollows:

2.7.1 AL}gitVGEtVGIflEO/L

All oil should meet minimum American PetroleumInstitute (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).

* Above40° F,useSAE30 * Below40° Fand downto 10° F,use10W-30 * Below10° F,usesynthetic 5W-30

1. Placegeneratoron a levelsurface (not to exceed15° in any direction).

2. Cleanareaaroundoil fill andremoveoil fill cap.

3. Slowly fill engine with oil until the dipstick readsfull. Stop filling occasionallyto checkoil level.

4. Installdipstick andfingertighten securely.

5. Checkengineoil levelbefore starting eachtimethereafter.

2.7.2 ADD/NGGASOLINE

NEVER fill fuel tank indoors. Avoid spilling gasoline on hot engine. Allow engine 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.

Do not overfill the fuel tank. Always leave room

for fuel expansion. If the fuel tank is overfilled, fuel can over flow onto a hot engine and cause fire or an explosion. Wipe up any spilled fuel

immediately.

1. UseregularUNLEADEDgasolinewiththegeneratorengine.Do not usepremiumgasoline.Do not mix oilwith gasoline.

2. Cleanareaaroundfuel fill cap, removecap.

3. Slowly add unleaded regular gasoline to fuel tank. Fill to bottom of screenfilter. Be carefulnottooverfill (Figure11).

4. Installfuel cap andwipe up any spilled gasoline.

IMPORTANT:Itis importantto preventgum depositsfrom 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 leadsto separationand formationof acids duringstorage.Acidic gascan damagethefuel system of an enginewhile in storage.Toavoid engineproblems, the fuel system should be emptiedbefore storage of 30 days or longer.Seethe "Storage"section. Neveruseengineor carburetor cleanerproducts inthefueltank aspermanentdamagemay occur.

Figure 11 - Fuel Tank

mEm

°F -20 -10 0 10 20 32 40 60 80 100

oc-3'o -_o -lo o lo 2'0 3'o 4b

Temperature Range of Expected Use

_CAUTION!

Any attempt to crank or start the engine before it has been properly serviced with the

recommended oil may result in an engine failure.

FueJTank

Fuel/ Do NOTFillAboveLip

2.8 STARTINGPULLSTARTENGINES

Never start or stop engine with electrical devices plugged into the receptacles AND devices turned on.

1. Unplugall electrical loadsfrom the unit's receptaclesbefore startingthe engine.

2. Make surethe unitis in a levelposition (notto exceed15° in anydirection).

3. OPENthe FuelShut-offValve(Figure12).

4. TurnengineRUN/STOPswitch to ONposition (Figure13).

5. Slide engine choke to the LEFT to FULL CHOKEposition (Figure14).

Figure 13 - Engine ON/OFF Switch

ENGINE ON/OFF SWITCH

(PULL START ENGINES ONLY)

Figure 12- FuelShut-off Valve

FUEL SHUTOFF

Tostart engine,firmly graspthe recoil handleandpull slowly until increasedresistanceisfelt. Pullrapidly up and away.

Whenenginestarts, move chokeknob to 1/2-CHOKEposition until engine runs smoothly andthen fully into RUN position.

If enginefalters,move chokeback outto 1/2-CHOKEposition untilengine runssmoothly andthento RUNposition.

NOTE:

if enginefires, but does not continueto run,move chokelever to FULLCHOKEand repeatstarting instructions.

IMPORTANT:Donotoverloadthe generator.Also, do not overload individual panel receptacles.Theseoutlets are protected against overload with push-to-reset-type circuit breakers. If amperage rating of any circuit breakeris exceeded,that breaker opensand electricaloutputto that receptacleislost. Read"Don't Overloadthe Generator"carefully.

lllh

Figure 14 - Choke Position

CHOKELEVER

LEFT= CHOKE(START)

RIGHT= RUN

2.9 STARTINGELECTRICSTARTENGINES

Never start or stop engine with electrical devices plugged into the receptacles AND

devices turned on.

1. Unplugall electricalloads from the unit's receptaclesbefore startingthe engine.

2. Makesurethe unit is in a level position (not to exceed15° in anydirection).

3. Openthefuel shut-off valve (Figures12).

4. Move engineCHOKEknoboutward to FULLCHOKEposition

(Figure14).

5. Tostart engine, press and hold the Start/Run/Stopswitch in the"Start" position. Theenginewill crankandattemptto start. Whenthe enginestarts, releasethe switchto the run position.

Whenthe engine starts, move choke knob to "1/2 Choke" position untilthe engineruns smoothly andthen fully into the

"Run" position.If enginefalters,move chokeknob backoutto "1/2 Choke"position untilthe engineruns smoothly andthen

to "Run" position.

2.9.1 MANUALSTART

Thisgeneratoris also equippedwith amanualrecoil starterwhich may be used if the batteryis discharged.

NOTE:

The switch must be in the RUN position. Use one of the

generator's receptacle outletsalong with the includedbattery chargerto chargethe battery while the generator is running.

Tostart manually,firmly graspthe recoil handleand pull slowly

until increasedresistanceis felt. Pull rapidly up and away to start engine.Thenfollow the same choke sequence.

NOTE:

If enginefires, but does not continueto run, move chokelever to FULLCHOKEand repeatstarting instructions.

IMPORTANT:Donot overloadthe generator.Also, do not overload individual panel receptacles.Theseoutlets are protected against overload with push-to-reset-type circuit breakers. If amperage ratingof any circuit breaker is exceeded,that breakeropens and electricaloutputto that receptacleislost. Read"Don't Overloadthe Generator"carefully.

2.12 CHARGINGTHEBATTERY(ELECTRICSTART

UNITSONLY)

Storage batteries give off explosive hydrogen

gas while recharging. An explosive mixture will remain around the battery for a long time after it has been charged. The slightest spark can ignite the hydrogen and cause an explosion. Such an explosion can shatter the battery and cause blindness or other serious injury.

_tDo not permit smoking, flame, sparks

or any other source of heat around a battery. Wear protective goggles, rubber apron and

rubber gloves when working around a battery. Battery electrolyte fluid is an extremely

corrosive sulfuric acid solution that can cause severe burns, if spill occurs flush area with clear water immediately.

The battery shipped withthe generator hasbeen fully charged.

A battery may lose some of its chargewhen not in use for prolongedperiodsof time. If the battery is unable to crankthe engine,plugin the12V chargerincludedin the accessory box.

RUNNINGTHEGENERATORDOESNOTCHARGETHEBATTERY.

open

NOTE:

2.10STOPPINGTHEENGINE

1. Shut off all loads, then unplug the electrical loads from generatorpanel receptacles.Never start or stop the engine

with electricaldevicespluggedin andturnedon.

2. Let enginerun at no-load for severalminutesto stabilizethe internaltemperaturesof engineandgenerator.

3. Move Run/Stopswitch to OFFposition.

4. Closefuelvalve.

2.11LOW01LLEVELSHUTDOWNSYSTEM

Theengineis equippedwith a low oil levelsensorthat shuts down

the engineautomaticallywhenthe oil leveldropsbelowa specified

level. If the engine shuts down by itself and the fuel tank has enoughgasoline,check engineoil level.

2.11.1 SENSINGLOWOILLEVEL

If the system senses a low oil level during operation,the engine shuts down. Theenginewill not run until the oil has beenrefilled

to the proper level.

Usebatterychargerplugto keepthe batterychargedandreadyfor use. Batterychargingshouldbe done in a dry location.

1. Plugchargerinto "BatteryChargerInput" jack, locatedon the control panel.Plugwall receptacleendof the battery charger

into a 120 Volt ACwall outlet.

2. Unplugbattery chargerfromwall outletand control paneljack whengeneratoris goingto be in use.

NOTE:

Do not use the battery chargerfor more than 48 hoursat one charge.

Figure 15 - Battery Charger Jack

BATTERY

CHARGER

INPUT

3.1 PERFORMINGSCHEDULEDMAINTENANCE

It is important to perform serviceas specifiedin the Maintenance Schedulefor proper generator operation,and to ensurethat the

generatorcomplies with the applicableemissionstandardsfor the durationof its useful life.Serviceandrepairsmaybe performedby

any capableperson or repairshop.Additionally,emissionscritical maintenancemust be performed as scheduled in order for the Emissions Warrantyto be valid. Emissions critical maintenance consists of servicing the air filter and spark plugs in accordance

with the MaintenanceSchedule.

3.2 MAINTENANCESCHEDULE

Follow the calendar intervals. More frequent service is required whenoperatingin adverseconditions notedbelow.

CheckOil Level ChangeOil

*Every 100 hoursor EverySeason

CheckValveClearance ServiceAir Filter

** Every200 hoursor EverySeason

ReplaceSparkPlug

:i: Changeoil after first 30 hours of operationthenevery season. * Changeoiland oilfilter everymonth whenoperatingunderheavy load or in high

temperatures.

** Clean more often under dirty or dusty operating conditions. Replaceair filter

parts ifthey cannot beadequatelycleaned.

*** Check valve clearance and adjust if necessary after first 50 hours of

operationand every 100 hours thereafter.

At EachUse

***Every Season

EverySeason

3.3 PRODUCTSPECIFICATIONS

3.3.1 GENERATORSPEC/F/CATiONS

RatedPower............................................................... 5.0/5.5/6.5 kW**

SurgePower............................................................... 6.25/6.88/8.0 kW

RatedACVoltage...................................................................... 120/240

RatedAC 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**

RatedFrequency.................................................... 60 Hz@ 3600 RPM

Phase................................................................................ SinglePhase

** Maximumwattageandcurrentaresubjectto,andlimitedby,suchfactors

asfuelBtucontent,ambienttemperature,altitude,enginecondition,etc.. Maximumpowerdecreasesabout3.5%foreach1,000feetabovesealevel;

andwillalsodecreaseabout1%foreach6° C (10° F)above16° C(60° F) ambienttemperature.

3.3.3 EM/SS/ONS/NFORIVIAT/ON

TheEnvironmentalProtectionAgency(and CaliforniaAir Resource Board for generators certified to CA standards) require(s)that this generator comply with exhaust and evaporative emission standards.Locate the emissions compliance decalon the engine to determinewhat standards the generatormeets.This generator is certified to operateon gasoline.The emission control system includesthefollowing components(if equipped):

Air Induction System • Ignition System

- IntakePipe/ Manifold -- SparkPlug

- Air Cleaner -- IgnitionModule Fuel System • Exhaust System

- Carburetor -- ExhaustManifold

- FuelTank/Cap -- Muffler

- FuelLines -- PulsedAir Valve

- EvaporativeVentLines -- Catalyst

- CarbonCanister

3.4 GENERALRECOMMENDATIONS

Thewarranty of thegeneratordoes notcover itemsthat havebeen subjectedto operator abuseor negligence.To receivefull value from the warranty, the operator must maintain the generatoras

instructed inthis manual. Some adjustmentswilt need to be made periodically to properly

maintainthegenerator. All adjustmentsin the Maintenancesectionof this manualshould

be madeat leastonce eachseason.Followthe requirementsinthe "MaintenanceSchedule".

NOTE: Once a year replace the spark plug and replace the air filter. A new spark plug and clean air filter assure properfuel-air

mixture andhelpthe engine runbetter andlast longer.

3.4.1 GENERATORMAINTENANCE

Generatormaintenanceconsistsof keepingthe unit cleanand dry. Operateandstorethe unit in a cleandry environmentwhereit will not be exposedto excessivedust,dirt, moistureor any corrosive vapors.Coolingair slotsin thegeneratormustnot becomeclogged with snow, leaves,or anyotherforeign material.

Checkthe cleanlinessof the generatorfrequentlyand cleanwhen dust, dirt, oil, moisture or otherforeign substancesarevisible on

its exteriorsurface.

3.3.2 ENGINESPECIFICATIONS

Displacement.............................................................................. 389 cc

SparkPlugType................................ NHSPLDF7TCor ChampionN9YC

SparkPlug Part No........................................................... 0G84420101

SparkPlug Gap.............................0.028-0.031 inch or (0.70-0.80 mm)

GasolineCapacity......................................................... 7.2 U.S. gallons

OilType.................. SeeChart in "Before Startingthe Generator"Section

OilCapacity.................................................................... 1 L (1.06 Qts.)

RunTimeat 50% Load (5.0/5.5/6.5 kW)..................................10 Hours

,ACAUTION!

,_ Never insert any object or tool through the air

cooling slots, even if the engine is not running.

NOTE: DONOTuse a gardenhoseto cleangenerator. Water canenter

the enginefuel systemand causeproblems.In addition,if water enters thegenerator throughcoolingair slots,some water will be retainedin voidsand crevicesof therotorand stator winding

insulation.Water and dirt buildup on the generator internal windingswill eventually decrease the insulationresistanceof

these windings.

3.4.2 TOCLEANTHEGENERATOR

• Usea damp cloth to wipe exteriorsurfaces clean.

• A soft, bristlebrush may be usedto loosen caked on dirt, oil, etc.

• Avacuumcleanermay be usedto pick up loosedirt anddebris.

• 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.

3.4.3 ENG/NEMA/NTENANCE

//_When working on the generator, always

disconnect negative cable from battery. Also disconnect spark plug wire from spark plug and

keep wire away from spark plug.

3.4.4 CNECK/NGO/LLEVEL

Seethe "BeforeStartingthe Generator"sectionfor informationon checkingthe oil level.Theoil levelshould be checkedbeforeeach

use, or at least every eight hours of operation. Keepthe oil level

maintained.

3.4.5 CNANG/NGTHEO/L

Changethe oil after the first 30 hours of operation. Changethe oil every 100 hours or every season thereafter. If running this

unit underdirty or dusty conditions, or in extremelyhot weather,

changethe oil moreoften.

,A CAUTION!

,l_ 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.

Usethe followinginstructionsto changetheoil aftertheengine

coolsdown:

1. Cleanareaaroundoil drain plug.

2. Removeoil drain plugfrom engineandoil fill plugto drainoil

completely intoa suitablecontainer.

3. When oil has completely drained, install oil drain plug and

tighten securely.

4. Filloil sumpwith recommendedoil. (See"BeforeStartingthe

Generator"for oil recommendations).

5. Wipeup any spilledoil.

6. Disposeof used oil ata propercollectioncenter.

3.4.6 REPLACINGTHESPARKPLUG

SeeEngineSpecificationsfor recommendedspark plug.Replace theplugonceeach year.This will helpthe enginestarteasierand

run better.

1. Stopthe engineand pull the spark plug wire off of the spark plug.

2. Cleanthe areaaroundthe spark plug and remove itfrom the cylinder head.

3. Setthe spark plug'sgapto 0.70-0.80 mm (0.028-0.031 in.). Installthe correctly gappedspark plug intothe cylinder head (Figure16).

Figure 16 - Spark Plug Gap

3.4.7 BATTERYREPLACEMENT{IFAPPLICABLE)_

NOTE:

Thebattery shippedwith the generator has been fully charged. A battery may lose some of its chargewhen not in use for prolongedperiodsof time. If the battery is unable to crank the engine,plugin the 12V chargerincludedin the accessory box (see the Charging a Battery section). RUNNINGTHE

GENERATORDOES NOT CHARGETHE BATTERY.The part numberfor this batteryis 0G9449.

,_ CAUTION!

,l_The NEGATIVE battery terminal should:

1. Always be DISCONNECTEDFIRST.

2. Alwaysbe CONNECTEDLAST.

Figure17 - Battery Connections

3.5 SERVICEAiRCLEANER

The engine will not run properly and may be damagedif using a dirty air cleaner.Clean or replacethe air cleaner paper filter once a year.Cleanor replacemore often if operatingunder dusty conditions(Figure18). Theair filter part numberis 0G84420151.

Tocleanor replacepaperair filter:

1. Removeair cleanercover andremove paperfilter.

2. Cleanpaperfilter bytapping it gently on a solid surface. If the filter is too dirty, replaceit with a newone. Disposeof the old

filter properly.

3. Cleanair cleanercover, then insert new paper filter into the baseof the air cleaner.Re-installair cleanercover.

Figure 18- Air Filter

Figure 19 - Spark Arrestor Screen

ARRESTDR

SPARK

ARRESTOR

SCREEN2

NOTE:

Toorder a newair filteror sparkarrestor screen,pleasecontact

the nearestauthorizedservice centerat 1-800-333-1322.

3.6 VALVECLEARANCE

* Intake-- 0.15 _ O.02mm(cold), (0.006" _ 0.0008" inches) * Exhaust-- 0.20 _ O.02mm(cold) (0.008" _ 0.0008" inches)

After the first 50 hoursof operation, checkthe valve clearance in the engineand adjustif necessary.

Important: If feelinguncomfortable aboutdoing this procedureor

the propertools are not available,pleasetakethe generatorto the

nearestservicecenterto havethevalveclearanceadjusted.Thisis a very important stepto ensure longestlifefor the engine.

8.5.1CLEANSPARKARRESTORSCREEN(CARB MOOELS

The engineexhaustmuffler has a spark arrestor screen. Inspect and cleanthe screenat leastonce eachyear (Figure19). If unit is usedregularly,inspect and clean moreoften.

i,_lf using the generator on any forest=covered,

brush=covered or grass=covered unimproved

land, it must equipped with a spark arrestor. The spark arrestor must be maintained in good condition by the owner/operator.

Cleanandinspectthe sparkarrestorwhenthe engineis at ambient temperatureasfollows:

1. Remove the spark arrestor screen from the muffler by looseningthe clamp andremovingthe screw.

2. Inspect screen and replace if torn, perforated or otherwise damaged. DONOTUSEa defective screen. If screen is not damaged,cleanit with commercialsolvent.

3. Replacethe spark arrestor and secure with the clamp and screw.

3.7 GENERAL

Thegeneratorshouldbestarted atleastonceeverythirty days and be allowedto run at least30 minutes.If this cannot be done and

the unitmust be stored for morethan 30 days, use the following

informationas a guideto prepareit for storage.

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.

,_AIIow unit to cool entirely before storage.

3.8 LONGTERMSTORAGE

It is importantto preventgum depositsfrom forming in essential fuel systemparts such asthe carburetor,fuel hoseor tank during storage. Also, experience indicates that alcohol-blended fuels

(calledgasohol,ethanol or methanol)can attract moisture,which

leadsto separationand formation of acids during storage.Acidic gas candamagethefuel system of an enginewhile in storage.

To avoid engine problems, the fuel system should be emptied

beforestorageof 30 days or longer,asfollows:

1. Addaqualitygasolinestabilizertothefuelperthemanufacturers specifications,and run theunitfor 10-15 minutes.

2. After enginecools down, removeall gasoline from the fuel tank. Usea commercially available,non-conductivevacuum siphon.

3.9 OTHERSTORAGETiPS

* Donot store gasolinefrom oneseasonto another. * Replacethe gasolinecan if it starts to rust. Rustand/or dirt in

the gasolinewill cause problems with the carburetorand fuel

system.

* Ifpossible, storethe unitindoorsandcover itto giveprotection

from dust and dirt. BESURETOEMPTYTHEFUELTANK,

, If it is not practical to emptythe fuel tank and the unit is to

be stored for some time, use a commercially availablefuel stabilizer added to the gasoline to increase the life of the gasoline.Runthe unitfor 10-15 minutes,turn off the fuel valve andallow to run until enginestopsfrom lack of fuel.

, Coverthe unit with a suitable protective cover that does not

retainmoisture.

Drain fuel into approved container outdoors,

away from open flame, Be sure engine is cool,

Do not smoke.

3. Start andrun engineuntilenginestops from lack offuel.

4. After engine cools down, drain oil from engine. Refill with

recommendedgrade.

5. Removespark plug and pour about 1/2 ounce (15 mt) of engine oil into the cylinder.Cover spark plug holewith rag.

Pull the recoil starter a coupletimes to lubricatethe piston ringsand cylinder bore.A fogging agentcan also be used in

the placeof oil.

• , CAUTION!

Avoid spray from spark plug hole when

cranking engine.

6. Installandtightensparkplug.Do notconnectsparkplugwire.

7. Cleanthe generatorouter surfaces. Check that cooling air slots and openingson generatorareopenand unobstructed.

8. Storethe unit in a clean,dry place.

_t NEVER cover the generator while engine and

exhaust areas are warm,

4.1 TROUBLESHOOTINGGUIDE

Engineis running,but noACoutput is available.

1. Circuit breakeris open.

2. Poorconnection or defectivecord set.

3. Connecteddevice is bad.

4. Faultingenerator.

1. Resetcircuit breaker.

2. Checkand repair.

3. Connectanotherdevicethat is ingood condition.

4. Contact AuthorizedServiceFacility.

Engine runs well hut bogs down 1. Short circuit in a connectedload. 1. Disconnectshorted electrical load. whenloads areconnected. 2. Generatoris overloaded. 2. See"Don't Overloadthe Generator".

3. Enginespeedis too slow. 3. ContactAuthorizedServiceFacility.

4. Shorted generatorcircuit. 4. Contact AuthorizedServiceFacility.

Enginewiil notstart;orstartsand

runsrough.

FuelShut-off is OFF. 1.

Dirtyair filter. 2.

Out of gasoline. 3.

Stale gasoline. 4.

Spark plugwire not connectedto spark plug. 5.

Badsparkplug. 6.

7. Water in gasoline.

8. Over-choking.

9. Lowoil level.

10. Excessiverich fuel mixture.

11. Intakevalvestuck open or closed.

12. Enginehas lost compression.

i i

TurnFuelShut-offto ON. Cleanor replaceair filter.

Fillfuel tank. Drainfuel tank and fill with fresh fuel.

Connectwireto spark plug. Replacespark plug.

7. Drainfuel tank; fill with fresh fuel.

8. Put choke knob to No Chokeposition.

9. Fill crankcaseto proper level.

10. ContactAuthorizedServiceFacility.

11. ContactAuthorizedServiceFacility.

12. ContactAuthorizedServiceFacility.

Engineshuts down during 1. Out of gasoline. 1. Fillfuel tank. operation. 2. Low oil level. 2. Fill crankcaseto proper level.

3. Faultin engine. 3. Contact AuthorizedServiceFacility.

Engine lacks power. 1. Loadis too high. 1. Reduceload (see"Don't OverloadtheGenerator").

2. Dirty air filter. 2. Cleanor replaceair filter.

3. Engineneedsto beserviced. 3. Contact AuthorizedServiceFacility.

Engine "hunts" orfalters. 1. Chokeis openedtoo soon. 1. Movechoke to halfway position until engineruns

smoothly.

2. Carburetoris runningtoo rich or too lean. 2. Contact AuthorizedServiceFacility.

1"7

U,S, EPA EMiSSiON CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLiGATiONS

TheUnited StatesEnvironmentalProtectionAgency (EPA)and GeneracPowerSystems, Inc. (Generac)are pleasedto explainthe EmissionControl

SystemWarranty (ECSWarranty) on your new 2011 andlater equipment.New equipmentthat use smallspark-ignited enginesmust bedesigned, built, andequipped to meet stringentanti-smog standardsfor the federalgovernment.Generacwill warrant the emission control system on your equipment

for the period of time listed belowprovidedthere has beenno abuse, neglect,unapprovedmodificationor improper maintenanceof your equipment. Theemission control system on this equipmentincludesall components whose failurewould increasethe emissionsof anyregulatedpollutant. These

componentsare listed in the Emissions Information section ofthis manual.

MANUFACTURER'S WARRANTY COVERAGE:

This ECSWarrantyis validfor two years,or for the same period as specifiedin the GeneracLimited Warranty,whicheveris longer.Forequipmentwith

hourmeters,the warranty period is anumber of hours equalto halfthe UsefulLifeto which the equipmentis certified, or the warrantyperiod specified abovein years, whicheveris less.TheUseful Life can befound on the EmissionControlLabelon the engine.If, during suchwarranty period,any

emission-relatedpart on your equipment isfound to be defectivein materials or workmanship, repairsor replacementwill be performedby aGenerac

AuthorizedWarrantyServiceDealer.

OWNER'S WARRANTY RESPONSiBiLiTiES:

Asthe equipmentowner,you are responsiblefor the completion of all requiredmaintenanceas listed in your factory suppliedOwner'sManual.For warranty purposes,Generacrecommendsthat you retainall receiptscovering maintenanceon your generator,butGeneraccannotdenywarranty

solelydueto the lack of receipts.

Youshould beaware that Generacmay denyany and/or all warrantycoverageor responsibility if your equipment,or apart!component thereof,has failed due to abuse,neglect, impropermaintenance,or unapprovedmodifications.

Youare responsiblefor contactinga GeoeracAuthorizedWarrantyDealer as soonas a problemoccurs.Thewarranty repairsshouldhe

completed in a reasonable amount of time, not to exceed 30 days.

Warrantyservice can bearrangedby contacting eitheryour sellingdealeror a GeneracAuthorizedWarrantyServiceDealer.Tolocate the Generac AuthorizedWarrantyServiceDealernearestyou, call our toll free numberbelow, or email emissions@generac.com.

1-800-333-1322

IMPORTANTNOTE:This warranty statementexplainsyour rights and obligationsunderthe EmissionControl SystemWarranty,which is providedto

you by Generacpursuantto federal law. Seealsothe "GeneracLimitedWarrantiesfor GeneracPowerSystems,Inc.," which is enclosedherewith on a

separatesheet,also providedto you byGenerac.Notethat this warranty shall not apply to any incidental,consequentialor indirect damagescaused bydefects in materials or workmanship or any delayin repairor replacementof the defectivepart(s). This warranty is in place of all other warranties,

expressedor implied.Specifically,Generacmakesno other warrantiesas to the merchantabilityor fitness for aparticular purpose.Any implied

warrantieswhich areallowed by law, shallbe limited in durationto the terms of the expresswarranty providedherein.Somestates do not allow

limitationson how long an implied warrantylasts, so the above limitation may not applyto you.

TheECSWarrantyappliesonly to the emission control system of your newequipment. Boththe ECSWarrantyandthe GeneracWarrantydescribe

importantrights and obligationswith respectto your new engine.

Warrantyservice can beperformed onlyby a GeneracAuthorizedWarrantyServiceFacility.When requestingwarranty service,evidencemust be

presentedshowingthe date ofthe saleto the originalpurchaser/owner.

Ifyou have any questionsregardingyour warranty rightsandresponsibilities,you should contact Generacatthe following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, Wi 53190

PartI of 2

PartNo. 0J3335 Rev.C 11/11

EMiSSiON CONTROL SYSTEM WARRANTY

EmissionControl SystemWarranty (ECSWarranty)for equipmentusing small spark-ignitedengines:

(a) Applicability:This warrantyshall applyto equipmentthat uses small off-road engines.TheECSWarrantyperiodshallbegin on the date the new

equipmentis purchasedby/deliveredto its original, end-usepurchaser/ownerandshall continue for the lesserof:

(1) The periodof time specified in the GeneracLimitedWarrantyenclosedherewith,but not less than 24 months,or (2) Forenginesequippedwith hour meters,a numberof operatinghours equalto half ofthe engine'suseful life. The usefullife is specifiedon the

EmissionsControl Labelon the engine.

(b) GeneralEmissionsWarrantyCoverage:Generacwarrantsto the original,end-usepurchaser/ownerof the new engineor equipment andto each

subsequentpurchaser/ownerthat the ECSwhen installed was:

(1) Designed,built and equippedso asto conform with all applicableregulations;and (2) Freefrom defectsin materialsand workmanship which causethe failureof a warrantedpart at anytime duringthe ECSWarranty Period.

(1) Any warranted part that is not scheduledfor replacementas requiredmaintenancein the Owner'sManualshall bewarrantedfor the ECS

WarrantyPeriod.If any such partfails duringthe ECSWarrantyPeriod, it shall be repairedor replacedby Generacaccordingto Subsection

(4) below. Any such part repairedor replacedunderthe EOSWarranty shall bewarrantedfor the remainderof the ECSWarranty Period.

(2) Any warranted part that is scheduled onlyfor regular inspection as specifiedin the Owner'sManualshall be warrantedfor the EOSWarranty

Period.A statementin the Owner's Manualtothe effect of "repair or replace as necessary"shall not reducethe ECSWarrantyPeriod.Any such part repairedorreplacedundertheECSWarranty shall bewarranted for the remainderofthe ECSWarrantyPeriod.

(3) Any warranted part that is scheduledfor replacementasrequired maintenancein the Owner'sManualshallbe warrantedfor the period of time

priorto first scheduledreplacementpointfor that part. Ifthe part fails prior to thefirst scheduledreplacement,thepart shall berepairedor replacedby Generacaccordingto Subsection (4) below.Any such emissions-relatedpart repairedorreplacedunderthe ECSwarranty shall bewarrantedfor the remainderof the period prior to thefirst scheduledreplacementpoint for that part.

(4) Repairor replacementof any warranted,emissions-relatedpart underthis ECSWarrantyshall be performedat no chargeto the owner at a

GeneracAuthorizedWarrantyService Facility.

(5) Notwithstandingthe provisions of subsection (4) above,warranty services or repairs must beprovidedat GeneracAuthorizedService

Facilities.

(6) Whenthe engineis inspectedby aGeneracAuthorizedWarrantyServiceFacility,the purchaser/ownershallnot beheld responsiblefor

diagnosticcosts if the repair is deemedwarrantable.

(7) Throughoutthe ECSWarrantyPeriod, Generacshall maintaina supply of warrantedemission-relatedparts sufficient to meetthe expected

demandfor such parts.

(8) Any Generacauthorizedand approvedemission-relatedreplacementparts may beused in the performanceof any ECSWarrantymaintenance

or repairs andwill beprovided without chargeto the purchaser/owner.Such useshall not reduce Generac'sEOSWarrantyobligations.

(9) No modifications,other than those explicitlyapprovedby Generac,may be madeto the generator.Unapprovedmodificationsvoid this ECS

Warrantyand shall be sufficientgroundfor disallowingan EOSWarrantyclaim.

(10) Generacshall not be heldliablehereunderfor failures of any non-authorizedreplacementparts, or failures of any authorizedparts causedby

the use of non-authorizedreplacementparts.

EMiSSiON RELATED PARTS MAY iNCLUDE THE FOLLOWING (iF EQUIPPED):

1) FUELMETERINGSYSTEM 3) IGNITIONSYSTEM

A. CARBURETORAND INTERNALPARTS A. SPARKPLUGS

B. FUELTANK/CAP B. IGNITIONCOILS/MODULE C. FUELLINES 4) AIR INJECTIONSYSTEM

D. EVAPORATIVEVENTLINES A. PULSEAIRVALVE E. REGULATOR(GASEOUSFUELS) 5) EXHAUSTSYSTEM

2) AIR INDUCTIONSYSTEM A. CATALYST

A. INTAKEMANIFOLD B. EXHAUSTMANIFOLD

B. AIRFILTER

Part2 of 2

PartNo. 0J3335 Rev.C 11/11

EM/$$/ONWARRANTYFORCARBCERT/F/EDEOU/PMENT

CALiFORNiA AND U.S, EPA EMiSSiON CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLiGATiONS

The California Air ResourceBoard (CARB) and the UnitedStates EnvironmentalProtectionAgency (EPA),together with GeneracPower Systems, Inc. (Generac)arepleasedto explainthe EmissionControlSystemWarranty (ECSWarranty)onyour new 2012 equipment.Newequipmentthat use smallspark-

ignitedenginesmust be designed,built, and equippedto meet stringentanti-smogstandardsfor the state of Californiaandthe federalgovernment.Generac will warrant the emission control system on your equipment for the periodof time listed below providedthere has been no abuse, neglect, unapproved modificationor impropermaintenanceof your equipment.

The emission control system on this equipment includes all components whose failure would increasethe emissions of any regulated pollutant. These componentsare listedin the EmissionsInformation sectionof this manual.

MANUFACTURER'S WARRANTY COVERAGE:

This ECSWarrantyis validfor two years, orfor the same period as specifiedinthe GeneracLimitedWarranty,whicheveris longer.Forequipmentwith hour meters,the warranty periodis anumberof hoursequalto halfthe Useful Lifeto which the equipmentis certified,or the warrantyperiod specified abovein years,whicheveris less.The Useful Life canbe found on the EmissionControl Labelon the engine. If, during such warranty period,any emission-related

part on your equipmentis found to be defectivein materialsor workmanship,repairsor replacementwill be performed by a GeneracAuthorizedWarranty ServiceDealer.

OWNER'S WARRANTY RESPONSiBiLiTiES:

Asthe equipmentowner,you areresponsiblefor the completionofall requiredmaintenanceaslisted in your factory suppliedOwner'sManual.Forwarranty purposes,Generacrecommendsthat you retain all receipts covering maintenanceon your generator,butGeneraccannot deny warranty solely due to the lack of receipts.

You shouldbe awarethat Generacmay denyany and/or all warranty coverageor responsibilityif your equipment,or a part!component thereof, hasfailed

dueto abuse,neglect,improper maintenance,or unapprovedmodifications.

Youare responsiblefor contacting a Genera¢AuthorizedWarranty Dealer as soon as a problemoccurs.Thewarranty repairs should be completed in a reasonable amount oftime, not to exceed30 days.

Warrantyservicecan be arrangedbycontacting eitheryour sellingdealeror a GeneracAuthorizedWarrantyServiceDealer.TolocatetheGeneracAuthorized WarrantyService Dealernearestyou, call our toll free numberbelow, or email emissions@generac.com.

1-800-333-1322

IMPORTANTNOTE: This warranty statement explainsyour rights and obligations underthe Emission ControlSystem Warranty,which is providedto you by Generacpursuantto federallaw.Seealsothe "GeneracLimitedWarrantiesfor GeneracPowerSystems, Inc.,"which is enclosedherewithon a separate sheet,also providedto you by Generac. Notethat this warranty shall not apply to any incidental,consequentialor indirect damagescausedby defects in materialsor workmanshipor anydelayin repairor replacementofthe defectivepart(s). This warranty isin placeof allotherwarranties,expressedor implied. Specifically,Generacmakesno other warrantiesas to the merchantabilityor fitness for a particular purpose.Any implied warranties allowed by law shall

be limited in durationto theterms ofthe expresswarranty provided herein.Some statesdo not allow limitationson how long an impliedwarranty lasts, so

the abovelimitation may not apply to you.

TheECSWarrantyappliesonlytothe emissioncontrol system ofyour newequipment.Boththe ECSWarrantyand the GeneracWarrantydescribeimportant rightsand obligations with respectto your new engine.

Warrantyservice canbe performed onlyby a GeneracAuthorizedWarranty ServiceFacility.Whenrequestingwarrantyservice, evidencemust bepresented showingthe dateof the sale to the originalpurchaser/owner.

Ifyou haveany questionsregardingyourwarranty rights andresponsibilities,you shouldcontact Generacat the following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 * WHITEWATER, WI 53190

Part 1 of 2

PartNo. 0J8147C Rev.A 01/12

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