Owner’s
Manual
• SAFETY
• ASSEMBLY
• OPERATION
GP Series
7,000 & 8,000 Watt
Portable Generator
• TROUBLESHOOTING
• WARRANTY
AUTHORIZED DEALER SUPPORT:
www.generac.com
or
1-888-436-3722
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODELS: 005625-0, 005626-0
005680-0, 005681-0
Table of Contents
Portable Generator System
Introduction ................................................................... 1
Read this Manual Thoroughly ..................................... 1
Safety Rules .................................................................. 2
Standards Index.................................................................... 3
Section 1 – General Information ................................. 4
1.1 Unpacking ............................................................................. 4
1.1.1 Accessory Box ........................................................ 4
1.2 Assembly .............................................................................. 4
1.2.1 Assembling the Accessory Kit ................................ 4
1.2.2 Starter Connection (Electric Start Only) ................. 4
Section 2 – Operation .................................................. 5
2.1 Know the Generator ............................................................. 5
2.2 Hourmeter ............................................................................. 6
2.3 Cord Sets and Connection Plugs ......................................... 6
2.3.1 120 VAC, 20 Amp, Duplex Receptacle.................... 6
2.3.2 120/240 VAC, 30 Amp, Receptacle ......................... 6
2.4 How to Use the Generator .................................................... 6
2.4.1 Grounding the Generator ........................................ 6
2.4.2 Connecting Electrical Loads ................................... 7
2.5 Don’t Overload the Generator .............................................. 7
2.6 Wattage Reference Guide .................................................... 7
2.7 Before Starting the Generator .............................................. 8
2.7.1 Adding Engine Oil ................................................... 8
2.7.2 Adding Gasoline ...................................................... 8
2.8 Starting Pull Start Engines ................................................... 8
2.9 Starting Electric Start Engines ............................................. 9
2.10 Stopping the Engine ........................................................... 10
2.11 Low Oil Level Shutdown System ........................................ 10
2.10.1 Sensing Low Oil Level .......................................... 10
2.12 Charging a Battery (Electric Start Units Only) ................... 10
Section 3 – Maintenance ........................................... 10
3.1 Maintenance Schedule ....................................................... 10
3.2 Product Specifications ........................................................ 10
3.2.1 Generator Specifications ....................................... 10
3.2.2 Engine Specifications ............................................ 11
3.3 General Recommendations ................................................ 11
3.3.1 Generator Maintenance ........................................ 11
3.3.2 To Clean the Generator ........................................ 11
3.3.3 Engine Maintenance ............................................. 11
3.3.4 Checking Oil Level ................................................ 11
3.3.5 Changing the Oil ................................................... 11
3.3.6 Replacing the Spark Plug .................................... .12
3.3.7 Replacing the Battery ........................................... 12
3.4 Service Air Cleaner ............................................................ 12
3.5 Clean Spark Arrestor Screen ............................................. 13
3.6 Adjusting Valve Clearance .................................................. 13
3.7 Long Term Storage ............................................................. 14
3.8 Other Storage Tips ............................................................. 14
Section 4 – Troubleshooting ...................................... 15
4.1 Troubleshooting Guide ........................................................ 15
Section 5 – Notes ....................................................... 16
Section 6 – Warranty .................................. Back Cover
INTRODUCTION
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
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, vents, and in an
area that will not accumulate deadly exhaust
gas.
DANGER
Using a generator indoors WILL KILL YOU IN MINUTES. Exhaust contains
carbon monoxide, a poison gas you cannot see or smell.
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.
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.
Never add fuel while unit is running. Allow unit
to cool entirely before adding fuel.
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
NEVER operate the generator indoors, in a garage, near an
open window, or in an area that could accumulate exhaust
gas.
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 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:
DANGER
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. 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 - 12 volt Adapter Plug Charger* • 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
* Electric start units only.
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" 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 Foot stud through the Foot Support and Frame
Foot; Install 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.
1.2.2 STARTER CONNECTION (ELECTRIC START ONLY)
The unit has been deliberately shipped with the starter cable
disconnected.
To connect starter:
1. Locate starter cable (a hang tag is attached as shown in Figure
3).
2. Pull vinyl boot back onto starter cable.
3. Remove nut and washer from starter post.
4. Put starter cable onto post and re-install washer and nut.
4
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