Page 1
Ultra Source Portable Generator
12,500 Watt
Owner’s
Manual
• SAFETY
• ASSEMBLY
• OPERATION
• TROUBLESHOOTING
• WARRANTY
AUTHORIZED DEALER SUPPORT:
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODEL: 004451-1
www.generac.com
or
1-888-436-3722
Page 2
Table of Contents
Portable Generator System
Introduction ............................................................. 1
Read this Manual Thouroughly ............................... 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 Wheel Kit ..................................4
1.2.2 Assembling the Handle ......................................4
1.2.3 Battery Connection ............................................4
1.3 Emissions Information ....................................................5
Section 2 – Operation ............................................. 6
2.1 Know the Generator .......................................................6
2.2 Cord Sets and Connection Plugs ....................................7
2.2.1 120 VAC, 20 Amp, Duplex Receptacle ...............7
2.2.2 120 VAC, 20 Amp, GFCI Receptacle ..................7
2.2.3 120 VAC, 30 Amp Receptacle ............................8
2.2.4 120/240 VAC, 30 Amp Receptacle .....................8
2.2.5 12 Volt DC, 10 Amp Receptacle .........................8
2.2.6 120/240 Volt AC, 50 Amp Receptacle ................8
2.3 How to Use the Generator ..............................................9
2.3.1 Grounding the Generator ....................................9
2.3.2 Connecting Electrical Loads ...............................9
2.3.3 Generator Location ............................................9
2.4 Don’t Overload the Generator ..........................................9
2.5 Wattage Reference Guide .............................................10
2.6 Before Starting the Generator .......................................10
2.6.1 Adding Engine Oil ............................................10
2.6.2 Adding Gasoline ...............................................10
2.7 To Start the Engine .......................................................11
2.8 Stopping the Engine .....................................................11
2.9 Automatic Idle Control ..................................................12
2.10 Cold Weather Operation/De-icer ....................................12
2.11 Low Oil Pressure Shutdown System .............................12
2.11.1 Initial Start-up ..................................................12
2.11.2 Sensing Low Oil Pressure ................................12
2.11.3 Restarting ........................................................12
2.12 Charging a Battery .......................................................12
Section 3 – Maintenance ...................................... 13
3.1 Maintenance Schedule .................................................13
3.2 Product Specifications ..................................................13
3.2.1 Generator Specifications ..................................13
3.2.2 Engine Specifications .......................................13
3.3 General Recommendations ...........................................13
3.3.1 Generator Maintenance ....................................13
3.3.2 To Clean the Generator .....................................14
3.3.3 Engine Maintenance .........................................14
3.3.4 Checking Oil Level ...........................................14
3.3.5 Changing the Oil and Oil Filter ..........................14
3.3.6 Replacing the Spark Plug .................................14
3.4 Service Air Cleaner .......................................................14
3.5 Clean Spark Arrestor Screen.........................................15
3.6 Adjusting Valve Clearance ............................................15
3.7 Storage .......................................................................16
3.8 Long Term Storage .......................................................16
3.9 Other Storage Tips .......................................................16
Section 4 – Troubleshooting ................................. 17
4.1 Troubleshooting Guide ..................................................17
Section 5 – Notes ................................................. 18
Section 6 – Warranty ............................................ 20
Page 3
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 NOTICE 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.
DANGER
Using a generator indoors CAN 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.
Exhaust heat/gases can ignite combustibles, structures
or damage fuel tank causing a fire. Keep at least five (5)
feet (1.5m) clearance on all sides of generator including
overhead.
Place generator outdoors in an area that will not accumulate •
deadly exhaust gas. DO NOT place generator where exhaust gas
could accumulate and enter inside or be drawn into a potentially
occupied building. Ensure exhaust has is kept away from any
windows, doors, ventilation intakes, or other openings that
can allow exhaust gas to collect in a confined area. Prevailing
winds and air currents should be taken into consideration when
positioning generator.
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, might result in minor or maderate injury.
NOTICE:
After this heading, read instructions that, if not complied with,
could result in equipment and/or property damage.
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.
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.
1
Page 4
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.
Never add fuel while unit is running or hot. 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.
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, near an open window, or in any area where
deadly exhaust gas can accumulate.
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.
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.
WARNING:
WARNING:
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 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.
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.
2
Page 5
IMPORTANT SAFETY INSTRUCTIONS
Portable Generator System
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.•
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.
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 or hot. DO NOT overfill the fuel tank. Always
allow room for fuel expansion. Never fill fuel tank indoors. Allow
unit/engine to cool entirely before adding fuel.
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 FLAMABLE 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.
3
Page 6
Section 1 – General Information
Portable Generator System
1.1 UNPACKING
Set the palleted carton on a rigid flat surface.•
Remove staples along bottom of carton that fasten car ton to •
pallet. Open carton from top.
Remove all packaging material.•
Remove separate accessory box.•
Lift carton off the generator.•
Remove generator from shipping pallet by removing bolts •
through the shipping brackets.
Figure 1 - Bracket Removal
Shipping
Bracket
1.2 ASSEMBLY
The generator requires some assembly prior to using it. If problems
arise when assembling the generator, please call the Generator
Helpline at 1-800-333-1322.
1.2.1 ASSEMBLING THE WHEEL KIT
The wheel kit is designed to greatly improve the portability of the
generator. A socket wrench with a 9/16” socket, a 1/2” socket, a
1/2” wrench and a pair of pliers are the tools that will be needed
for assembly of the wheel kit.
NOTICE:
The wheel kit is not intended for over-the-road use.
Refer to Figure 2 and install the wheel kit as follows:•
Place the generator on a hard flat surface.•
Stand at the engine end of the unit and gently tilt the generator •
forward, high enough to place wooden blocks beneath the
cradle. This will allow space to install the wheel assemblies.
Attach an axle bracket assembly with attached sleeve to either •
side of the frame. Ensure the sleeve faces outward.
Slide the axle through the sleeves on the axle brackets.•
Slide one wheel with flat washer to the outside and a spacer to •
the inside onto each end of the axle. Make sure the air inflation
valve on the wheel is facing outward.
Insert retaining pins and using pliers, bend out the ends to •
prevent the pins from falling out of the axle. Remove the
wooden blocks.
1.1.1 ACCESSORY BOX
Check all contents. If any parts are missing or damaged locate an
authorized dealer at 1-800-333-1322.
Contents include:
Owner’s Manual•
Bolt-on tubular handle•
Wheel Axle•
2 – Pneumatic Wheels•
2 – Axle Bracket Assemblies•
2 – Washers•
2 – Wheel Spacers•
2 – Cotter Pins•
Bolt-on Foot•
6 – Carriage Bolts, Washers, Nuts•
Battery Charge Cable•
Spark Plug Wrench•
2 Spark Plugs. •
Air Filter•
Pre-cleaner•
4
1.2.2 ASSEMBLING THE HANDLE
Attach the handle by aligning one side of the handle on the •
cradle, then spread the handle around the cradle and let it
spring into place. Secure the handle to the frame using the
5/16’ hex head bolts provided. Check each fastener to ensure
that it is secure.
Using the handle, lift the unit high enough to place wooden •
blocks under the unit. Attach the front support foot to the
underside of the cradle using the 3/8” carriage bolts provided.
Remove the shipping brackets from the cradle, if you have not •
already done so.
1.2.3 BATTERY CONNECTION
The battery shipped with the generator has been provided fully •
charged. Caution must be taken when connecting the battery.
Cut the tie wrap cable holding the RED and BLACK battery •
cables to the stator.
Connect the RED battery cable to the battery Positive terminal •
(+). After making sure that the connection is tight, slip the
rubber boot over the terminal connection.
Connect the BLACK battery cable to the battery Negative •
terminal (–). Make sure the connection is tight.
Double check all connections to ensure they are in the correct •
location and secure. See Figure 3.
Page 7
Section 1 – General Information
Figure 2 - Handle Assembly
Portable Generator System
Figure 3 - Battery Connections
Negative
Cable
Positive
Cable
1.3 EMISSIONS INFORMATIN
The Environmental Protection Agency (EPA) and the California Air
Resource Board (CARB) require that this generator comply with
exhaust emission standards. The generator is certified to meet
all applicable exhaust emission levels. This generator is certified
for use as a mobile engine. It is important that you follow the
maintenance specifications listed in this manual to ensure that the
engine complies with emission standards for the duration of its
life. This engine is certified to operate on gasoline. The emission
control system on the generator consists of the following:
Air Induction System•
~ Intake pipe/manifold
~ Air cleaner
Fuel System•
~ Carburetor
Ignition System•
~ Spark plug
~ Ignition module
Exhaust System•
~ Exhaust Manifold
~ Muffler
5
Page 8
Section 2 – Operation
Portable Generator System
The Emissions Compliance Period referred to on the Emissions
Compliance Label indicates the number of operating hours for
which the engine has been shown to meet Federal and California
emission requirements. See the table below to determine the
compliance period for this generator. The displacement of the
engine is listed on the Emissions Compliance Label.
Displacement Category Compliance Period
A 500 Hours
≥ 66 cc - < 225 CC
≥ 225 cc
B 250 Hours
C 125 Hours
A 1000 Hours
B 500 Hours
C 250 Hours
2.1 KNOW THE GENERATOR
Read the Owner’s Manual and Safety Rules before operating
this generator.
Compare the generator to this illustration to become familiarized
with the locations of various controls and adjustments. Save this
manual for future reference.
1. 12 Volt DC, 10 Amp Receptacle – This receptacle allows
the capability to recharge a 12 volt DC storage battery with
provided battery charge cables.
2. 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies electrical
power for the operation of 120 Volt AC, 20 Amp, single-phase,
60 Hz electrical lighting, appliance, tool and motor loads.
3. 120 Volt AC, 20A Duplex GFCI Receptacle – Supplies ground
fault protected electrical power for operation of 120 volt AC 20
amp, single-phase, 60 Hz electric lighting, appliances, tools
and motor loads.
4. 120 Volt AC, 30 Amp Locking Receptacle – Supplies electrical
power for the operation of 120 Volt AC, 30 Amp, single-phase,
60 Hz electrical lighting, appliance, tool and motor loads.
5. 120/240 Volt AC, 30 Amp Locking Receptacle – Supplies
electrical power for the operation of 120 and/or 240 Volt AC,
30 Amp, single-phase, 60 Hz, electrical lighting, appliance,
tool and motor loads.
6. 120/240 Volt AC, 50 Amp Receptacle – Supplies electrical
power for the operation of 120/240 Volt AC, 50 Amp, singlephase, 60 Hz, welder or motor loads.
7. Air Cleaner – Filters intake air as it is drawn into the engine.
8. Choke Knob – Used when starting a cold engine.
9. Winter/Summer Valve – See “Cold Weather Operation.”
(Section 2, page 12.)
10. Circuit Breakers (AC) – Each receptacle is provided with a
push-to-reset circuit breaker to protect the generator against
electrical overload. (50 amp uses toggle reset)
11. Fuel Tank – Tank holds 16 U.S. gallons of fuel.
12. Grounding Lug – Ground the generator to an approved earth
ground here. See the Grounding the Generator section for
details.
13. Idle Control Switch – The idle control runs the engine at
normal (high) speeds when there is an electrical load present
and runs the engine at idle (low) speeds when a load is not
present.
14. Start/Run/Stop Switch – Controls the operation of the
generator.
15. Oil Fill – Use this point to add oil to engine.
16. Fuse - 10 Amp – Protects the DC control circuit from overload.
If this fuse element has melted open the engine will not be able
to crank and start.
Figure 4 - Control Panel
10
1 17 13 2 3
4
56
10
Figure 5 - Generator Controls
11
7
15
12
6
Page 9
Section 2 – Operation
Portable Generator System
Figure 6 - Engine Control Panel
8
914
2.2 CORD SETS AND CONNECTION PLUGS
2.2.1 120 VAC, 20 AMP, DUPLEX RECEPTACLE
This is a 120 Volt outlet protected against overload by a 20 Amp
push-to-reset circuit breaker (Figure 7). 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.
2.2.2 120 VAC, 20 AMP, GFCI RECEPTACLE
This unit is equipped with a ground fault circuit interrupter (GFCI)
(Figure 8). This device meets applicable federal, state and local
codes.
A GFCI receptacle is different from conventional receptacles. In the
event of a ground fault, a GFCI will trip and quickly stop the flow of
electricity to prevent serious injury.
Definition: Instead of following its normal safe path, electricity
passes through a persons body to reach the ground. For example,
a defective appliance can cause a ground fault.
A GFCI receptacle does NOT protect against circuit overloads,
short circuits, or shocks. For example, electric shock can still
occur if a person touches charged electrical wires while standing
on a non-conducting surface, such as a wood floor.
Test the GFCI outlet every month as follows:
Plug a test lamp into the receptacle.•
Start the generator, the test lamp should be on.•
Press the “Test” button located on the front of the receptacle to •
trip the device.
This should stop the flow of electricity making the lamp shut off. •
The yellow trip indicator should now be on.
To restore the flow of electricity, press the “Reset” button on •
the front of the receptacle. If the GFCI does not perform in
this manner, do not use the receptacle. Contact a local service
dealer.
This outlet is protected against overload by a 20A push-to-reset •
circuit breaker. Use the outlet to power 120V AC, single-phase,
60 Hz, electrical loads requiring up to a combined 2400 watts
(2.4 kW) or 20 amps of current.
Figure 7 - 120 Volt AC, 20 Amp, Duplex Receptacle
Figure 8 - 120 VAC, 20 Amp GFCI Receptacle
7
Page 10
Section 2 – Operation
Portable Generator System
2.2.3 120 VAC, 30 AMP RECEPTACLE
Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire
cord set rated for 125 Volts AC at 30 Amps (or greater) to the plug
(Figure 9).
Use this receptacle to operate 120 Volt AC, 60 Hz, single phase
loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps.
The outlet is protected by a 30 Amp push-to-reset circuit breaker.
Figure 9 - 120 VAC, 30 Amp Receptacle
2.2.5 12 VOLT DC, 10 AMP RECEPTACLE
This receptacle allows you to recharge a 12 Volt automotive or
utility style storage battery with the battery charge cables provided.
This receptacle can not recharge 6 Volt batteries and can not
be used to crank an engine having a discharged battery. See
the section "Charging a Battery" before attempting to recharge a
battery.
Figure 11 - 12 Volt DC, 10 Amp Receptacle
2.2.4 120/240 VAC, 30 AMP RECEPTACLE
Use a NEMA L14-30 plug with this receptacle (Figure 10). 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 10 - 120/240 VAC, 30 Amp Receptacle
2.2.6 120/240 VOLT AC, 50 AMP RECEPTACLE
Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire
cord set rated for 250 Volts AC at 50 Amps to the plug.
Figure 12 - 120/240 VAC, 50 Amp Receptacle
50 A
Use this receptacle to operate 120/240 Volt AC, 60 Hz electrical
loads requiring up to 12,000 watts (12.0 kW) of power. This
receptacle is protected by a 50 Amp 2-pole circuit breaker.
Use this receptacle to operate 120 Volt AC, 60 Hz, single phase
loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps or
240 Volt AC, 60 Hz, single phase loads requiring up to 7200 watts
(7.2 kW) of power at 30 Amps. The outlet is protected by two 30
Amp push-to-reset circuit breakers.
8
Page 11
Section 2 – Operation
Portable Generator System
2.3 HOW TO USE THE GENERATOR
If you have any problems operating your generator, please call the
generator helpline at 1-800-333-1322.
2.3.1 GROUNDING THE GENERATOR
The National Electrical Code requires that the frame and
external electrically conductive parts of this generator be
properly connected to an approved earth ground. Local electrical
codes may also require proper grounding of the unit. For that
purpose, generally, connecting a No. 10 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut and to an
earth-driven copper or brass grounding rod (electrode) provides
adequate protection against electrical shock. However, local codes
may vary widely. Consult with a local electrician for grounding
requirements in your area.
Figure 13 - Grounding the Generator
Ground Lug
2.3.3 GENERATOR LOCATION
Exhaust heat/gases can ignite combustibles, structures
or damage fuel tank causing a fire. Keep at least five (5)
feet (1.5m) clearance on all sides of generator including
overhead.
Place generator outdoors in an area that will not accumulate •
deadly exhaust gas. DO NOT place generator where exhaust gas
could accumulate and enter inside or be drawn into a potentially
occupied building. Ensure exhaust has is kept away from andy
windows, doors, ventilation intakes, or other openings that
can allow exhaust gas to collect in a confined area. Prevailing
winds and air currents should be taken into consideration when
positioning generator.
Proper grounding of the generator will help prevent electrical
shock in the event of a ground fault condition in the generator
or in connected electrical devices. Proper grounding also helps
dissipate static electricity, which often builds up in ungrounded
devices.
2.3.2 CONNECTING ELECTRICAL LOADS
DO NOT connect 240 Volt loads to 120 Volt receptacles. DO NOT
connect 3-phase loads to the generator. DO NOT connect 50 Hz
loads to the generator.
Let engine stabilize and warm up for a few minutes after •
starting.
Plug in and turn on the desired 120 or 240 Volt AC, single •
phase, 60 Hz electrical loads.
Add up the rated watts (or amps) of all loads to be connected •
at one time. This total should not be greater than (a) the rated
wattage/amperage capacity of the generator or (b) circuit
breaker rating of the receptacle supplying the power. See the
"Don't Overload the Generator" section.
2.4 DON’T OVERLOAD THE GENERATOR
Overloading a generator in excess of its rated wattage capacity
can result in damage to the generator and to connected electrical
devices. Observe the following to prevent overloading the unit:
Add up the total wattage of all electrical devices to be connected •
at one time. This total should NOT be greater than the
generator's wattage capacity.
The rated wattage of lights can be taken from light bulbs. The •
rated wattage of tools, appliances and motors can usually be
found on a data plate or decal affixed to the device.
If the appliance, tool or motor does not give wattage, multiply •
volts times ampere rating to determine watts (volts x amps =
watts).
Some electric motors, such as induction types, require about •
three times more watts of power for starting than for running.
This surge of power lasts only a few seconds when starting
such motors. Make sure you allow for this high starting wattage
when selecting electrical devices to connect to your generator:
1. Figure the watts needed to start the largest motor.
2. Add to that figure the running watts of all other connected
loads.
The Wattage Reference Guide on page 10 is provided to assist
you in determining how many items your generator can operate
at one time. (Note: All figures are approximate. See data plate on
appliance for wattage requirements.)
9
Page 12
5W -3 0
Sy nt he ti c 5 W- 30
SA E 30 , 1 0W -3 0
Section 2 – Operation
Portable Generator System
2.5 WATTAGE REFERENCE GUIDE
Device ...........................................................................Running Watts
*Air Conditioner (12,000 Btu) .......................................................1700
*Air Conditioner (24,000 Btu) .......................................................3800
*Air Conditioner (40,000 Btu) .......................................................6000
Battery Charger (20 Amp) ............................................................... 500
Belt Sander (3") ............................................................................1000
Chain Saw ....................................................................................1200
Circular Saw (6-1/2") .........................................................800 to 1000
*Clothes Dryer (Electric) .............................................................. 5750
*Clothes Dryer (Gas) ......................................................................700
*Clothes Washer ...........................................................................1150
Coffee Maker ................................................................................1750
*Compressor (1 HP) ..................................................................... 2000
*Compressor (3/4 HP) .................................................................. 1800
*Compressor (1/2 HP) .................................................................. 1400
Curling Iron .....................................................................................700
*Dehumidifier .................................................................................650
Disc Sander (9") ...........................................................................1200
Edge Trimmer ................................................................................. 500
Electric Blanket ...............................................................................400
Electric Nail Gun ...........................................................................1200
Electric Range (per element) .........................................................1500
Electric Skillet ...............................................................................1250
*Freezer ..........................................................................................700
*Furnace Fan (3/5 HP) .................................................................... 875
*Garage Door Opener ..........................................................500 to 750
Hair Dryer .....................................................................................1200
Hand Drill ........................................................................... 250 to 1100
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.
10
2.6 BEFORE STARTING THE GENERATOR
Prior to operating the generator, engine oil and gasoline will need
to be added, as follows:
2.6.1 ADDING ENGINE OIL
NOTICE:
When adding oil to the engine crankcase in the future, use only
high quality detergent oil rated with API service classification
SF or SG SAE 30 weight. Use no special additives.
Select the oil’s viscosity grade according to the expected operating
temperature. Do not use SAE 10W-40.
SAE 30, 10W-30
Synthetic 5W-30
5W-30
Above 40°F• , use SAE 10W-30 or SAE 30.
Below 40°F• , use synthetic 5W-20 or 5W-30.
Although multi-viscosity oils (5W-30, 10W-30, etc.) improve
starting in cold weather, these multi-viscosity oils will result in
increased oil consumption when used above 32°F. Check your
engine oil level more frequently to avoid possible damage from
running low on oil.
Place generator on a level surface.•
lean area around oil fill and remove oil fill cap and dipstick.•
Wipe dipstick clean.•
Slowly fill engine with oil through the oil fill opening until it •
reaches the full mark on the dipstick. Stop filling occasionally
to check oil level. DO NOT OVERFILL.
Install dipstick. Install oil fill cap and finger tighten securely.•
Check engine oil level before starting each time thereafter.•
2.6.2 ADDING GASOLINE
Never fill fuel tank indoors. Never fill fuel tank when
engine is running or hot. Allow unit and engine to cool
entirely before adding fuel. DO NOT light a cigarette or
smoke when filling the fuel tank.
Do not overfill the fuel tank. Always leave room for fuel
expansion. Fuel can overflow onto hot engine and cause
a FIRE or EXPLOSION. Wip up any spilled gasoline
immediately.
Page 13
Section 2 – Operation
Portable Generator System
Use regular UNLEADED gasoline with the generator engine. Do •
not use premium gasoline. Do not mix oil with gasoline.
Clean area around fuel fill cap, remove cap.•
Slowly add unleaded regular gasoline to fuel tank. • Be careful not
to overfill. Allow about 1/2" of tank space for fuel expansion,
as shown here.
Install fuel cap and wipe up any spilled gasoline.•
Figure 14 - Fuel Tank
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 "Storage" on page 18. Never use engine or carburetor
cleaner products in the fuel tank as permanent damage may
occur.
Locate the Idle Control ON/OFF switch on the control panel and •
set it to the “OFF” position.
Figure 16 - Idle Control Switch
Move engine CHOKE knob to “Full Choke” position.•
Figure 17 - Full Choke Position
2.7 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.
ake sure the unit is in a level position.•
Open the fuel shut-off valve.•
Figure 15 - Fuel Shut-off Valve
To start engine, press and hold the Star t/Run/Stop switch in •
the “Start” position. The engine will crank and attempt to start.
When the engine starts, release the switch to the run position.
When the engine starts, move choke knob to “1/2 Choke” •
position until the engine runs smoothly and then to “Run”
position. If engine falters, move choke knob to “1/2 Choke”
position until the engine runs smoothly and then to “Run”
position.
NOTICE:
If engine fires, but does not continue to run, move choke lever
to “Full Choke” and repeat starting instructions.
2.8 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.
Turn “Off” the Idle Control switch (if on).•
Let engine run at no-load for several minutes to stabilize the •
internal temperatures of engine and generator.
Move Start/Run/Stop switch to “Off” position.•
Close fuel valve.•
11
Page 14
Section 3 — Maintenance
Portable Generator System
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” on page 9 carefully.
2.9 AUTOMATIC IDLE CONTROL
This feature is designed to greatly improve fuel economy. When
this switch is turned “On”, the engine will only run at its normal
fast governed engine speed when electrical load is connected.
When the load is removed, the engine will run at a reduced speed
of 2100 RPM. With the switch “Off”, the engine runs at the normal
fast engine speed all the time. Always have the switch OFF when
starting and stopping the engine.
2.10 COLD WEATHER OPERATION/DE-ICER
Under certain weather conditions (temperatures below 40° F (4°
C) and a high dew point), the engine may experience icing of the
carburetor and/or the crankcase breather system. To eliminate
this problem, this generator engine is fitted with a winter/summer
valve. this directs hot air into the carburetor during cold weather
operation. Always make sure the winter/summer valve is in the
correct location relative to the weather conditions.
2.11 LOW OIL PRESSURE SHUTDOWN SYSTEM
The engine is equipped with a low oil pressure sensor that shuts
down the engine automatically when the oil pressure drops below
10 psi. If the engine shuts down by itself and the fuel tank has
enough gasoline, check engine oil level.
2.11.1 INITIAL START-UP
A delay built into the low oil shutdown system allows oil pressure
to build during starting. The delay allows the engine to run for
about 10 seconds before sensing oil pressure.
2.11.2 SENSING LOW OIL PRESSURE
If the system senses low oil pressure during operation, the engine
shuts down.
2.11.3 RESTARTING
If you try to restart the engine within 10 seconds after it shuts
down, the engine may NOT start. The system needs 5 to 10
seconds to reset.
If you do restart the engine after such a shutdown and have
not corrected the low oil pressure, the engine runs for about 10
seconds as described above and then stops.
2.12 CHARGING A BATTERY
DANGER
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.
DANGER
Do not permit smoking, open 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 caustic
sulfuric acid solution that can cause severe burns. If spill
occurs flush area with clear water immediately.
Your generator has the capability of recharging a discharged 12
Volt automotive or utility style storage battery. Do not use the unit
to charge any 6 Volt batteries. Do not use the unit to crank an
engine having a discharged battery.
To recharge 12 Volt batteries, proceed as follows:
Check fluid level in all battery cells. If necessary, add ONLY •
distilled water to cover separators in battery cells. Do not use
tap water.
If the battery is equipped with vent caps, make sure they are •
installed and are tight.
If necessary, clean battery terminals.•
Connect battery charge cable connector plug to panel receptacle •
identified by the words "12-VOLT D.C."
Connect battery charge cable clamp with red handle to the •
positive (+) battery terminal.
Connect battery charge cable clamp with black handle to the •
negative (-) battery terminal.
Start engine. Let the engine run while battery recharges. Engine •
idle control switch must be in off position for battery charging.
When battery has charged, shut down engine.•
NOTICE:
Use an automotive hydrometer to test battery state of charge and
condition. Follow the hydrometer manufacturer's instructions
carefully. Generally, a battery is considered to be at 100% state
of charge when specific gravity of its fluid (as measured by
hydrometer) is 1.260 or higher.
12
Page 15
Section 3 — Maintenance
Portable Generator System
3.1 MAINTENANCE SCHEDULE
Operation Maintenance Daily Every Season Every Season Every Season
Check Oil Level
Service Air Pre-Cleaner
9
9**
Change Oil and Oil Filter‡
Clean Spark Arrestor Screen
Adjust Valve Clearance
9
9
Service Air Cleaner
Replace Spark Plugs
‡ Change oil after first 8 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 cleaner parts if very dirty..
3.2 PRODUCT SPECIFICATIONS
3.2.1 GENERATOR SPECIFICATIONS
Model .................................................................................. GPS 12500
Model # .................................................................................004451-1
Rated Max. Power .....................................................................12.5 kW
Surge Power ...........................................................................18.75 kW
Rated AC Voltage ......................................................................120/240
Rated Max AC Load
Current @ 240V .................................................................52.0 Amps
Current @ 120V ...............................................................104.0 Amps
Rated Frequency ..................................................... 60 Hz @3600 RPM
Phase ................................................................................ Single Phase
Rated DC Voltage ...................................................................... 12 Volts
Rated Max DC Load Current @ 12 Volts ............................. 10 Amperes
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 (3) of this manual
should be made at least once each season. Follow the requirements
in the "Maintenance Schedule" chart on page 14.
NOTICE:
Once a year you should replace the spark plug and replace the
air filter. A new spark plug and clean air filter assure proper fuelair mixture and help your engine run better and last longer.
9*
9**
9
3.2.2 ENGINE SPECIFICATIONS
Rated Horsepower @ 3600 RPM .......................................................30
Displacement ............................................................................... 990cc
Spark Plug Type ...................................Champion RC14YC or Equivalent
Spark Plug Gap ............................................... 0.040 inch or (1.01 mm)
Gasoline Capacity .......................................................... 16 U.S. gallons
Oil Type....................................................Summer – SAE 30 or 10W-30
Winter – Synthetic 5W-20 or 5W-30
Oil Capacity
w/ Filter Change .......................................................................1.5 Qts.
w/o Filter Change .....................................................................1.2 Qts.
Run Time/Fuel Consumption-1/2 Load .....10 Hours/1.6 gallons per hour
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.
13
Page 16
Section 3 — Maintenance
Portable Generator System
Never insert any object or tool through the air cooling
slots, even if the engine is not running.
NOTICE:
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.
3.3.3 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.
Use the following instructions to change the oil while the engine
is still warm:
Clean area around oil drain hose and plug.•
Remove oil drain plug from end of hose and oil fill plug to drain •
oil completely into a suitable container.
When oil has completely drained, install oil drain plug and •
tighten securely.
Place a suitable container beneath the oil filter and turn •
filter counterclockwise to remove. Discard according to local
regulations.
Coat gasket of new filter with clean engine oil. Turn filter •
clockwise until gasket contacts lightly with filter adapter. Then
tighten an additional 3/4 turn.
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 RC14YC spark plug or equivalent. The correct air
gap is 1.01 mm (0.040 in.). Replace the plug once each year. This
will help your 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 1.01 mm (0.040 in.). Install the
correctly gapped spark plug into the cylinder head.
Figure 18 - Spark Plug Gap
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 AND OIL FILTER
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.
Change the oil and filter after the first eight hours of operation.
Change the oil every 100 hours thereafter. If you are running this
unit under dirty or dusty conditions, or in extremely hot weather,
change the oil more often.
14
3.4 SERVICE AIR CLEANER
Your engine will not run properly and may be damaged if you run it
using a dirty air cleaner. Clean or replace the air cleaner paper filter
once a year. Clean or replace more often if operating under dusty
conditions. Clean foam pre-cleaner every month or more often
under dusty conditions.
To clean or replace foam pre-cleaner:
Remove air cleaner cover, then foam pre-filter.•
Wash pre-cleaner in soapy water. Squeeze pre-filter dry in clean •
cloth (DO NOT TWIST).
Clean air cleaner cover before re-installing it.•
Page 17
Section 3 — Maintenance
Portable Generator System
To clean or replace paper air filter:
Remove air cleaner cover; then remove foam pre-filter (service •
if necessary) and remove paper filter.
Clean paper filter by tapping it gently on a solid surface. If the •
filter is too dirty, replace it with a new one. Dispose of the old
filter properly.
Clean air cleaner cover then slip pre-cleaner over filter. Next •
insert new paper filter into the base of the air cleaner. Re-install
air cleaner cover.
Figure 20 - Air Cleaner
Cover
Pre-Cleaner
Base
Filter
NOTICE:
To order a new air filter, please contact the nearest authorized
service center at 1-800-333-1322.
3.5 CLEAN SPARK ARRESTOR SCREEN
The engine exhaust muffler has a spark arrestor screen. Inspect
and clean the screen at least once each year. If unit is used
regularly, inspect and clean more often.
NOTICE:
If you use your 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.
Clean and inspect the spark arrestor as follows:
Remove the screen retaining bracket by removing the screw.•
Slide the spark arrestor screen out from the tail pipe.•
Inspect screen and replace if torn, perforated or otherwise •
damaged. DO NOT USE a defective screen. If screen is not
damaged, clean it with commercial solvent.
Replace the screen and the retaining bracket.•
Figure 21 - Spark Arrestor
3.6 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, you should adjust the valve
clearance in the engine.
Important: If you feel uncomfortable about doing this procedure or
you don't have the proper tools, please take your generator in to the
nearest service center to have the valve clearance adjusted. This is
a very important step to insure longest life for your engine.
To adjust valve clearance:
Make sure the engine is at room temperature.•
Make sure that the spark plug wire is removed from the spark •
plug and out of the way.
Remove the four screws attaching the valve cover with a #2 or •
#3 phillips screwdriver.
Make sure the piston is at Top Dead Center (TDC) of its •
compression stroke (both valves closed). To get the piston
at TDC, remove the intake screen at the front of the engine to
gain access to the flywheel nut. Use a large socket and socket
wrench to rotate the nut and hence the engine. While watching
the piston through the spark plug hole. The piston should move
up and down. The piston is at TDC when it is up as high as it
can go.
Loosen the rocker jam nut. Use an 10mm allen wrench to turn •
the pivot ball stud while checking clearance between the rocker
arm and the valve stem with a feeler gauge. Correct clearance
is 0.002-0.004 inch (0.05-0.1 mm).
NOTICE:
You must hold the rocker arm jam nut in place as you turn the
pivot ball stud.
When valve clearance is correct, hold the pivot ball stud in place
with the allen wrench and tighten the rocker arm jam nut. Tighten
the jam nut to 174 in/lbs. torque. After tightening the jam nut,
recheck valve clearance to make sure it did not change.
Install new valve cover gasket.•
Re-attach the valve cover.•
15
Page 18
Section 3 — Maintenance
Portable Generator System
Figure 22 - Valve Clearance Adjustment
NOTICE:
Start all four screws before tightening or you will not be able to
get all the screws in place. Make sure the valve cover gasket
is in place.
Re-attach the spark plug wire to the spark plug.•
Repeat the process for the other cylinder.•
3.7 STORAGE
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
you must store the unit 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.
3.8 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 around gasoline.
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. Press the
“Start” button and allow engine to crank for 2 seconds. Then
press the “Stop” button.
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.•
3.9 OTHER STORAGE TIPS
Do not store gasoline from one season to another.•
Replace your gasoline can if your can starts to rust. Rust and/•
or dirt in your gasoline will cause problems with the carburetor
and fuel system.
If possible, store your 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 your unit with a suitable protective cover that does not •
retain moisture.
DANGER
NEVER cover your generator while engine and exhaust
area are warm.
16
Page 19
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 crank. 1. 10 amp fuse at rear of generator control panel has
Engine will not start; or starts and
runs rough.
Engine shuts down during
operation.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
melted open.
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. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator” .
3. Contact Authorized Service Facility.
4. Contact Authorized Service Facility.
1. Replace fuse with only an identical 10 amp
replacement fuse.
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.
Engine lacks power. 1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
Engine “hunts” or falters. 1. Choke is opened too soon.
2. Carburetor is running too rich or too lean.
No Battery Charge DC output. 1. Battery posts are corroded.
2. Battery cable is bad.
3. Battery is defective.
4. Receptacle is bad.
1. Reduce load (see “Don’t Overload the Generator”).
2. Clean or replace air filter.
3. Contact Authorized Service Facility.
1. Move choke to halfway position until engine runs
smoothly.
2. Contact Authorized Service Facility.
1. Clean battery posts.
2. Replace cable.
3. Check battery condition; replace if defective.
4. Contact Authorized Service Facility.
17
Page 20
Section 5 — Notes
18
Page 21
Section 5 — Notes
19
Page 22
Section 6 — Warranty
Portable Generator System
CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power
Systems, Inc. (Generac), are pleased to explain the Emission Control System warranty on your new 2008 and later generator. New equipment
that use small spark-ignited engines must be designed, built, and equipped to meet stringent anti-smog standards for the state of California
and the federal government. Generac will warrant the emission control system on your generator for the period of time listed below provided
there has been no abuse, neglect, unapproved modification or improper maintenance of your equipment.
Your emission control system may include parts such as the: carburetor, ignition system, fuel system catalytic conver ter, and other associated emission-related components (if equipped).
MANUFACTURER’S WARRANTY COVERAGE:
This emission control system is warranted for two years. If, during such warranty period, any emission-related part on your equipment is
found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service
Dealer.
OWNER'S WARRANTY RESPONSIBILITIES:
As the generator owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner's Manual.
For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your generator, but Generac cannot deny
warranty solely due to the lack of receipts.
As the generator owner, you should be aware that Generac may deny any and/or all warranty coverage or responsibility if your generator,
or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or the use of counterfeit
and/or "grey market" parts not made, supplied or approved by Generac.
You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs. The warranty repairs should be
completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer. To locate the
Generac Authorized Warranty Service Dealer nearest you, call our toll free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS
Warranty), which is provided to you by Generac pursuant to California and federal law. See also the "Generac Limited Warranties for Generac
Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by Generac. Note that this warranty shall not
apply to any incidental, consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part(s). This warranty is in place of all other warranties, expressed or implied. Specifically, Generac makes no other
warranties as to the merchantability or fitness for a particular purpose. Some states do not allow limitations on how long an implied warranty
lasts, so the above limitation may not apply to you.
The ECS Warranty applies only to the emission control system of your new equipment. If there is any conflict in terms between the ECS
Warranty and the Generac Warranty, the Generac Warranty shall apply. Both the ECS Warranty and the Generac Warranty describe important
rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence
must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Par t 1
20
Part No. 0H1912 Rev. A 05/09
Page 23
Section 6 — Warranty
Portable Generator System
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines:
(a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin on the date the new equip-
ment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment and to each sub-
sequent purchaser/owner that the ECS when installed was:
(1) Designed, built and equipped so as to conform with all applicable regulations; and
(2) Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS Warranty Period.
(c) The warranty on emissions-related parts will be interpreted as follows:
(1) Any warranted part that is not scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the ECS Warranty
Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any
such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for the ECS Warranty
Period. A statement in the Owner’s Manual to the effect of "repair or replace as necessary" shall not reduce the ECS Warranty Period. Any such
part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the period of time prior
to first scheduled replacement point for that part. If the par t fails prior to the first scheduled replacement, the part shall be repaired or replaced by
Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS warranty shall be warranted for
the remainder of the period prior to the first scheduled replacement point for that part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a Generac
Authorized Warranty Service Facility.
(5) Notwithstanding the provisions of subsection (4) above, warranty services or repairs must be provided at Generac Authorized Service Facilities.
(6) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for diagnostic
costs if the repair is deemed warrantable.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand
for such parts.
(8) Any Generac authorized and approved emission-related replacement parts may be used in the performance of any ECS warranty maintenance or
repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts may not be used to modify or repair a Generac engine. Such use voids this
ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any
warranted parts of Generac equipment caused by the use of such an unapproved, add-on, modified, counterfeit and/or "grey market" part.
EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING (IF EQUIPPED):
1) FUEL METERING SYSTEM
A. CARBURETOR AND INTERNAL PARTS
B. PRESSURE REGULATOR
2) AIR INDUCTION SYSTEM
A. INTAKE MANIFOLD
B. AIR FILTER
3) IGNITION SYSTEM
A. SPARK PLUGS
B. IGNITION COILS / MODULE
4) AIR INJECTION SYSTEM
A. PULSE AIR VALVE
5) EXHAUST SYSTEM
A. CATALYST
B. THERMAL REACTOR
C. EXHAUST MANIFOLD
Par t 2
Part No. 0H1912 Rev. A 05/09
21
Page 24
Section 6 — Warranty
Portable Generator System
GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR GUARDIAN
®
“12,500 WATT AND 15,000 WATT PORTABLE GENERATORS”
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its Guardian generator will be free
from defects in materials and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part
which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective. Any
equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty
Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/
owner. This warranty applies only to Generac Guardian portable generators and is not transferable.
WARRANTY SCHEDULE
Consumer applications are warranted for 2 (two) years. Commercial applications are warranted for 1 (one) year. Rental applications are
warranted for 90 (ninety) days.
CONSUMER APPLICATION
YEARS ONE and TWO - 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):
• Engine - All Components
• Alternator - All Components
NOTE: For the purpose of this warranty "consumer use" means personal residential household use by original purchaser. This does not apply
to units used for Prime Power in place of utility where utility power service normally exists. Once a generator has experienced commercial or
rental use, it shall thereafter be considered a non-consumer use generator for the purpose of this warranty.
All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Generac Guardian portable generators that utilize non-Generac replacement parts.
• Costs of normal maintenance and adjustments.
• Failures caused by any contaminated fuels, oils or lack of proper oil levels.
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper use. As with all mechanical
devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when
normal use has exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing,
lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent and/or insect infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement
of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty
period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Overnight freight costs for replacement par t(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER
WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how
long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC
BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S
NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not
apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
Generac® Power Systems, Inc.
P.O. Box 297 • Whitewater, WI 53190
Manual Part No. 0H3406 Rev A (05/26/09) Printed in U.S.A.
Loading...