John Deere AC-G6010HE, AC-G6010S, AC-G7510HE, AC-G8010S, AC-G7510H User Manual

AC-G6010H, AC-G6010HE,
AC-G6010S, AC-G6010SE,
AC-G7510H, AC-G7510HE,
AC-G8010S and AC-G8010SE
Generators

Operator’s Manual 1

Introduction

THANK YOU for purchasing a John Deere product.

READ THIS MANUAL carefully to learn how to operate
and service your machine correctly. Failure to do so could
result in personal injury or equipment damage. This manual
and safety signs on your machine may also be available in
other languages. (See your John Deere dealer to order.)

THIS MANUAL SHOULD BE CONSIDERED a permanent
part of your machine and should remain with the machine
when you sell it.

MEASUREMENTS in this manual are given in both
metric and customary U.S. unit equivalents. Use only
correct replacement parts and fasteners. Metric and inch

fasteners may require a specic metric or inch wrench.

RIGHT HAND AND LEFT HAND sides are determined by
facing the motor end of the machine.

The SERIAL NUMBER is located in the Specication or
Identication Numbers section. Accurately record all the

numbers to help in tracing the machine should it be stolen.
Your dealer also needs these numbers when you order

parts. File the identication numbers in a secure place

off the machine.

WARRANTY is provided from your John Deere dealer for
customers who operate and maintain their equipment as
described in this manual. The warranty is explained on

the warranty certicate shown in this manual.

This warranty provides you the assurance that your
dealer will back products where defects appear within
the warranty period. Should the equipment be abused,

or modied to change its performance beyond the original
factory specications, the warranty will become void.

PROTECT YOUR INVESTMENT......

Warning: This product contains lead, a
chemical known to the State of California
to cause birth defects or other reproductive
harm.

Wash your hands after handling this product.

2 Operator’s Manual

Use only John Deere Fuel Protect
Fuel Stabilizer with Ethanol Protection
TY27534 or TY27535. Developed to
ensure Optimum Performance and
Protection.

IMPORTANT...Use Year Round!

34-1904 012011

Contents

Page

Safety ........................................................................ 4

Safety Signs ............................................................. 5

Controls ................................................................. 12

Preparing the Generator ........................................ 13

Operation ................................................................ 17

Troubleshooting .....................................................22

Service .................................................................... 23

Storage .................................................................... 29

Specications ......................................................... 30

Accessoires .............................................................. 31

Warranty .............................................................32-34

All information, illustrations and specications in this manual are based

on the latest information available at the time of publication. The right is

reserved to make changes at any time without notice.

Operator’s Manual 3

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Safety

RECOGNIZE SAFETY INFORMATION

This is the safety alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury.

Follow recommended precautions and safe operating
practices.

UNDERSTAND SIGNAL WORDS

A signal word--DANGER, WARNING or CAUTION--is used

with the safety-alert symbol. DANGER identies the most

serious hazards.

DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.

FOLLOW SAFETY INSTRUCTIONS

Carefully read all safety messages in this manual and
safety signs on your machine. Keep safety signs in good
condition. Replace missing or damaged safety signs.
Be sure new equipment components and repair parts
include the current safety signs. Replacement safety signs
are available from your John Deere Customer Service
Representative.

Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.

Keep your machine in proper working condition.

Unauthorized modications to the machine may impair the

function and/or safety and affect machine life.

If you do not understand any part of this manual and need
assistance, contact your John Deere Customer Service
Representative.

4 Operator’s Manual

CARBON MONOXIDE - POISONOUS GAS

Use generator outdoors, away from open windows, vents, or
doors.

Generator exhaust contains carbon monoxide - a poisonous
gas that can kill you. You CAN NOT smell or see this gas.

Never use a generator in enclosed or partially-enclosed spaces.
Generators can produce high levels of carbon monoxide very
quickly. When you use a portable generator, remember that you
cannot smell or see carbon monoxide. Even if you can’t smell
exhaust fumes, you may still be exposed to carbon monoxide.

If you start to feel sick, dizzy, or weak while using a generator, get
to fresh air RIGHT AWAY. DO NOT DELAY. The carbon monoxide
from generators can rapidly lead to full incapacitation and death.

If you experience serious symptoms, get medical attention
immediately. Inform medical staff that carbon monoxide poisoning
is suspected. If you experienced symptoms while indoors, have

someone call the re department to determine when it is safe to

re-enter the building.

NEVER operate the generator in an explosive atmosphere, near

combustible materials or where ventilation is not sufcient to carry

away exhaust fumes. Exhaust fumes can cause serious injury
or death.

NEVER use a generator indoors, including in homes, garages,
basements, crawl spaces, and other enclosed or partially-enclosed
areas, even with ventilation. Opening doors and windows or using
fans will not prevent carbon monoxide build-up in the home.

Follow the instructions that come with your generator. Locate the
unit outdoors and away from doors, windows, and vents that could
allow the carbon monoxide gas to come indoors.

ONLY run generator outdoors and away from air intakes.

NEVER run generator inside homes, garages, sheds, or other
semi-enclosed spaces. These spaces can trap poisonous gases
EVEN IF you run a fan or open doors and windows.

If you start to feel sick, dizzy, or weak while using the generator,
shut if off and get fresh air RIGHT AWAY. See a doctor. You may
have carbon monoxide poisoning.

Install battery-operated carbon monoxide alarms or plug-in carbon
monoxide alarms with battery back-up in your home, according to
the manufacturer’s installation instructions. The carbon monoxide

alarms should be certied to the requirements of the latest safety

standards for carbon monoxide alarms. (UL 2034, IAS 6-96, or
CSA 6.19.01).

Test your carbon monoxide alarm frequently and replace dead
batteries.

Operator’s Manual 5

SAFETY WARNING WHEN REFUELING

Gasoline is extremely ammable and its vapors can explode if ignited.

Observe all safety regulations for the safe handling of fuel. Handle
fuel in safety containers. If the container does not have a spout, use a
funnel.

Do not overll the fuel tank, leave room for the fuel to expand.

Do not rell fuel tank while the engine is running. Before refueling

the generator, turn it off and let it cool down. Gasoline spilled on hot
engine parts could ignite.

Fill the tank only on an area of bare ground. While fueling the tank,

keep heat, sparks and open ame away. Carefully clean up any spilled

fuel before starting engine.

Always ll fuel tank in an area with plenty of ventilation to avoid

inhaling dangerous fumes.

NEVER store fuel for your generator in the home. Gasoline, propane,

kerosene, and other ammable liquids should be stored outside of living

areas in properly-labeled, non-glass safety containers. Do not store
them near a fuel-burning appliance, such as a natural gas water heater
in a garage. If the fuel is spilled or the container is not sealed properly,
invisible vapors from the fuel can travel along the ground and can be
ignited by the appliance’s pilot light or by arcs from electric switches in
the appliance.

GROUND FAULT CIRCUIT INTERRUPTER
PROTECTION

These generators are equipped with two GFCI (Ground Fault Circuit
Interrupters) 120V duplex receptacles for protection against the hazards
of electrical shock from defective attachments such as, tools, cords,
and cables.

WARNING: The GFCIs may not function unless the generator
is properly grounded. Follow the correct procedure
specified in the section labeled “GROUNDING
INSTRUCTIONS”

A GFCI is a device that interrupts electricity from either the utility or
generator by means of a special type of circuit breaker if a fault current

ow to the ground occurs.

WARNING: Only the 120V Duplex Receptacles are protected
by the GFCI.

A GFCI can be used only with generators that have the neutral wire
internally bonded to the frame, and the frame properly grounded to the
earth. A GFCI will not work on generators that do not have the neutral
wire bonded to the frame, or on generators which have not been properly
grounded. All John Deere generators have internally bonded ground
wires. A GFCI will not work if the unit is not properly grounded.

A GFCI may be required by OSHA regulations, the National Electric Code
and/or local and federal codes when operating a generator.

For additional protections against shock hazards due to defective
equipment attached to the twist-lock receptacles, consider the use of a
GFCI on each of these receptacles as well.

GFCIs and GFCI protected cord sets and cables may be purchased
from local electrical supply houses.

6 Operator’s Manual

ELECTRICAL HAZARDS

This product must be grounded. It has permanent conductor between
the generator (stator winding) and the frame. If it should malfunction or
breakdown, grounding provides a path of least resistance for electric
current to reduce the risk of electric shock.

DANGER - IMPROPER CONNECTION OF THE EQUIPMENT­ GROUNDING CONDUCTOR CAN RESULT IN A RISK OF
ELECTROCUTION. CHECK WITH A QUALIFIED
ELECTRICIAN OR SERVICE PERSON IF YOU ARE IN
DOUBT AS TO WHETHER THE UNIT IS PROPERLY
GROUNDED.

This generator is equipped with a grounding terminal for your
protection. Always complete the ground path from the generator to an
external ground source as instructed in the section labeled “Grounding
Instructions” in the Preparation section of this manual.

The generator is a potential source of electrical shock if not kept dry.
Keep the generator dry and do not use in rain or wet conditions. To
protect from moisture, operate it on a dry surface under an open,
canopy-like structure. Dry your hands if wet before touching the
generator.

Risk of electric shock if you operate this generator with a faulty GFCI
(Ground Fault Circuit Interrupter). Test GFCI before each use, see
Operations Instructions for further information. If GFCI fails test, DO

NOT use your generator. Contact your John Deere Customer Service
Representative.

Plug appliances directly into the generator. Or, use a heavy duty,
outdoor-rated extension cord that is rated (in watts or amps) at least
equal to the sum of the connected appliance loads. Check that the
entire cord is free of cuts or tears and that the plug has all three prongs,
especially a grounding pin.

NEVER try to power the house wiring by plugging the generator into
a wall outlet, a practice known as “back feeding”. This is an extremely
dangerous practice that presents an electrocution risk to utility workers
and neighbors served by the same utility transformer. It also bypasses
some of the built-in household circuit protection devices.

If you must connect the generator to the house wiring to power

appliances, have a qualied electrician install the appropriate equipment

in accordance with local electrical codes. Or, check with your utility
company to see if it can install an appropriate power transfer switch.

For power outages, permanently installed stationary generators are
better suited for providing backup power to the home. Even a properly
connected portable generator can become overloaded. This may result
in overheating or stressing the generator components, possibly leading
to a generator failure.

Operator’s Manual 7

IMPORTANT SAFETY INSTRUCTIONS

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WARNING: To reduce the risk of injury, read this operator’s
manual completely before using. When using this product,
the following basic precautions should always be followed:

1. Read all the instructions before using the product.

2. This product is equipped with a Ground Fault Circuit
Interrupter (GFCI) in the power cord to reduce the risk of
electrical shock. If replacement of the plug or cord is
needed, use only identical replacement parts.

3. Do not allow children or untrained persons to operate the
generator.

4. Do not operate the generator when fatigued or under the

inuence of drugs or chemicals. Stay alert. Watch what

you are doing.

5. Follow the maintenance instructions specied in this
manual.

6. When starting the generator, using recoil starter grip,
be sure that nothing is in a position to be hit by the
operator’s hand or arm.

7. Be sure the switch on electric power tools is in the “OFF”
position before plugging them into the generator.

8. Keep the immediate area free of all bystanders.

9. Be sure each person who operates this generator is
properly instructed in its safe operation.

8 Operator’s Manual

IMPORTANT SAFETY INSTRUCTIONS

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10. Do not operate the generator or any electrical tool in any
area where water or similar materials constitute
an electrical hazard to the operator. Do not operate on

wet surfaces, in rain or in snow.

11. Always be sure that the generator is on secure footing so
that it cannot slide or shift around, endangering workers.

12. Avoid contacting the hot exhaust manifold, mufer or

cylinder(s). Keep clear of all rotating parts.

13. Unless the tool or appliance is double insulated, it must
be grounded through a properly grounded receptacle.
(See Preparing the Generator, Grounding Instructions).
Tools and appliances which have 3 prong plugs must
be plugged into extension cords and electrical
receptacles with 3 holes. Before operating any electrical
item, be sure it is in good repair.

14. Follow instructions in this manual when testing Ground
Fault Circuit Interrupter to insure reliable operation.

15. Bewareofusingthisequipmentinconnedspaces.
Conned spaces, without sufcient fresh air ventilation,
can contain dangerous gases. Running gasoline engines
in such environments can lead to deadly explosions and/
or asphyxiation.

16. If your generator comes equipped with a transport
dolly, make sure this unit is secure during operation and
when transporting to prevent unexpected movement or
rolling.

17. Use extreme caution when lifting this generator. Do not
use dolly handles to lift this generator, use only
designated lifting hook to lift this generator. This
generator is heavy so proper lifting techniques should be
used.

SAVE THESE INSTRUCTIONS

Operator’s Manual 9

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.

Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.

Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating machine.

PREPARE FOR EMERGENCIES

Keep a rst aid kit and re extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital and re department near your telephone.
Be prepared if a re starts.

INSPECT GENERATOR

Be sure all covers, guards and shields are tight and in
place.

Locate all operating controls and safety labels.
Inspect power cord for damage before using. There is a

hazard of electrical shock from crushing, cutting or heat
damage.

SERVICE GENERATOR SAFELY

Before servicing the generator, disconnect all equipment and
battery (if equipped) and allow unit to cool down.

Service generator in a clean dry at area.

10 Operator’s Manual

SAFETY SIGNS FOR AC-G6010H/HE/S/SE, AC-G7510H/HE AND AC-G8010S/SE

DANGER DANGER PELIGRO

34-1676

GND

34-0889

062104-ENG.

34-0889

34-1679 or 34-1678

Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide. This is a

poison you cannot see or smell.

NEVER use inside a home
or garage, EVEN IF doors
and windows are open.

Only use OUTSIDE and far
away from windows, doors,
and vents.

L'utilisation d'un groupe électrogène à
l'intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.

Le gaz d'échappement du groupe
électrogène contient de l'oxyde de
carbone. C'est un gaz toxique que l'on
ne peut pas voir ou sentir.

Ne JAMAIS utiliser à l'intérieur d'une
maison ou d'un garage, MÊME SI les
portes et fenêtres s'ont ouvertes.

N'utiliser qu'à l'EXTÉRIEUR et bien éloigné
des fenêtres, portes, et conduits d'aération.

Utilizando un generador adentro
PUEDE MATARLE EN MINUTOS.

El escape de generador contiene
monóxido de carbono. Este es un
gas tóxico que usted no puede ver ni
puede oler.

Nunca utilice dentro de un hogar ni el
garaje, INCLUSO SI puertas y
ventanas estén abiertas.

Solo utilice AFUERAS y lejos de
ventanas abiertas, las puertas, y
descargas.

34-1916-031607-E-F-S.

34-1916

Operator’s Manual 11

Controls

CONTROLS FOR AC-G6010H/HE/S/SE, AC-G7510H/HE AND AC-G8010S/SE

E

B

C

F

A

H

D

Note: AC-G6010S is shown with

optional wheel and handle
kit and lifting hook kit

B

G

C

B

D

C

A

A

D

A -- Control Panel C -- Fuel Cap E -- Lifting Hook G -- Stand
B -- Fuel Tank D -- Oil Drain Plug F -- Handles H -- Wheels

12 Operator’s Manual

Preparing the Generator

GROUNDING INSTRUCTIONS

This product must be grounded. If it should malfunction or
breakdown, grounding provides a path of least resistance for
electric current to reduce the risk of electric shock.

DANGER - IMPROPER CONNECTION OF THE
EQUIPMENT-GROUNDING CONDUCTOR CAN
RESULT IN A RISK OF ELECTROCUTION.
CHECK WITH A QUALIFIED ELECTRICIAN OR
SERVICE PERSON IF YOU ARE IN DOUBT AS
TO WHETHER THE UNIT IS PROPERLY
GROUNDED.

The wing nut and ground terminal on the frame must always
be used to connect the generator to a suitable ground source.
The ground path should be made with #8 size wire. Connect the
terminal of the ground wire between the two star washers and
wing nut then tighten the wing nut fully. Connect the other end
of the wire securely to a suitable ground source.

The National Electric Code contains several practical ways in
which to establish a good ground source. Examples given below
illustrate a few of the ways in which a good ground source may
be established.

A metal underground water pipe in direct contact with the earth
for at least 10 feet can be used as a grounding source. If an pipe
is unavailable, an 8 foot length of pipe or rod may be used as the
ground source. The pipe should be 3/4 inch trade size or larger
and the outer surface must be noncorrosive. If a steel or iron rod
is used it should be at least 5/8 inch diameter and if a nonferrous
rod is used it should be at least 1/2 inch diameter and be listed
as material for grounding. Drive the rod or pipe to a depth of 8
feet. If a rock bottom is encountered less than 4 feet down, bury
the rod or pipe in a trench. All electrical tools and appliances
operated from this generator, must be properly grounded by use
of a third wire or be “Double Insulated”.

It is recommended to:

1. Use electrical devices with 3 prong power cords.

2. Use an extension cord with a 3 hole receptacle and a 3
prong plug at the opposite ends to ensure continuity of
the ground protection from the generator to appliance.

We strongly recommend that all applicable federal, state and

local regulations relating to grounding specications be checked

and followed.

LINE TRANSFER SWITCH

If this generator is used for standby service, it must have
a transfer switch between the utility power service and the
generator. The transfer switch not only prevents the utility
power form feeding into the generator, but is also prevents the
generator form feeding out into the utility company’s lines. This
is intended to protect the serviceman who may be working on
a damaged line.

GND

34-0889

062104-ENG.

THIS INSTALLATION MUST BE DONE BY A LICENSED
ELECTRICIAN AND ALL LOCAL CODES MUST BE
FOLLOWED.

Operator’s Manual 13

Preparing the Generator

UPPER LEVEL

ENGINE OIL

Use oil viscosity based on the expected air temperature
range during the period between oil changes.

Use a high quality detergent oil with API classications of

SJ or higher.

Check oil level before each operation and ensure that it
is maintained.

CAUTION: THIS ENGINE CRANKCASE IS NOT
FILLED WITH OIL AT THE FACTORY, SO BE
SURE TO FILL IT BEFORE OPERATING THE
ENGINE.

ENGINE OIL CAPACITY

MODEL # Liters Quart Ounces

AC-G6010H 0.6 0.63 20.3
AC-G6010HE 0.6 0.63 20.3
AC-G6010S 1.2 1.27 40.5
AC-G6010SE 1.2 1.27 40.5
AC-G7510H 1.1 1.16 37.2
AC-G7510HE 1.1 1.16 37.2
AC-G8010S 1.2 1.27 40.5
AC-G8010SE 1.2 1.27 40.5

TEMPERATURE CHART

OIL GAUGE

(Fig. 1)

NOTE: These engines are equipped with a “Low Oil”

shut-off system for engine protection. If the
engine fails to start, check engine crankcase
for oil.

To ll with oil:

1. Level the engine to ensure accurate inspection and

to prevent overlling.

2. Unscrew the oil gauge (Fig. 1), wipe the dipstick dry.

Reinsert the oil gauge back into the oil ll gauge opening.

Remove the oil gauge and check the oil level.

3. The oil level should be between the full and low marks
on the dipstick. (Fig. 2)

NOTE: When checking the oil be sure the engine is

level.

4. Fill with oil as required through the oil ll gauge

opening.

5. Replace the oil gauge and screw in rmly.

6. Wipe up any spilled oil.

(Fig. 2)

14 Operator’s Manual

Preparing the Generator

FUELING

WARNING: EXPLOSIVE FUEL!

GASOLINE IS EXTREMELY FLAMMABLE
AND ITS VAPORS CAN EXPLODE IF
IGNITED.

STORE GASOLINE ONLY IN APPROVED
CONTAINERS, IN WELL VENTILATED,
UNOCCUPIED BUILDINGS AND AWAY
FROM SPARKS OR FLAMES.

DO NOT FILL THE FUEL TANK WHILE THE
ENGINE IS HOT OR RUNNING, SINCE
SPILLED FUEL COULD IGNITE IF IT
COMES IN CONTACT WITH HOT PARTS OR
SPARKS FROM IGNITION. DO NOT START
THE ENGINE NEAR SPILLED FUEL.

NEVER USE GASOLINE AS A CLEANING
AGENT.

WARNING: DO NOT OVERFILL THE FUEL TANK,
LEAVE ROOM FOR THE FUEL TO EXPAND.

General Recommendations

• Purchase gasoline in small quantities and store in clean,

approved containers.

• To minimize gum deposits in your fuel system and to

insure easy starting, do not use gasoline left over from
the previous season.

• Do not add oil to the gasoline.

Fuel Type

• For best results use only clean, fresh, unleaded gasoline

with a pump sticker octane rating of 87 or higher.

• Unleaded gasoline is recommended as it leaves less

combustion chamber deposits.

GASOLINE/ALCOHOL BLENDS:
Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline
by volume) is approved, as a fuel. Other gasoline/alcohol
blends are not approved.

GASOLINE/ETHER BLENDS:
Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline
blends (up to a maximum of 15% MTBE by volume) are
approved as a fuel. Other gasoline/ether blends are not
approved.

Operator’s Manual 15

Preparing the Generator

BATTERY INSTALLATION

WARNING: SHOULD ONLY BE DONE BY AN

AUTHORIZED DEALER.

BATTERY REPLACEMENT #

JOHN DEERE TY23018 (DRY)
JOHN DEERE SWGT-H (WET)

HIGH ALTITUDE

At high altitude, the standard carburetor air/fuel mixture will
be too rich. Performance will decrease, and fuel consumption
will increase. A very rich mixture will also foul the spark plug
and cause hard starting. Operation at an altitude that differs

from that at which this engine was certied, for extended

periods of time, may increase emissions.

High altitude performance can be improved by specific

modications to the carburetor. If you always operate your

generator at altitudes above 5,000 feet (1,500 meters),

have your dealer perform this carburetor modication. This

engine, when operated at high altitude with the carburetor

modications for high altitude use, will meet each emission

standard throughout its useful life.

Even with carburetor modification, engine horsepower
will decrease about 3.5% for each 1,000-foot (300-meter)
increase in altitude. The effect of altitude on horsepower will

be greater than this if no carburetor modication is made.

NOTE:When the carburetor has been modied for high
altitude operation, the air/fuel mixture will be too lean
for low altitude use. Operation at altitudes below 5,000
feet (1,500 meters) with a modied carburetor may
cause the engine to overheat and result in serious
engine damage.

For use at low altitudes, have your servicing
dealer return the carburetor to original factory
specications.

16 Operator’s Manual

Operation

OPERATION

Recoil Start

NOTE: Read Operator’s Manual carefully before operating this

unit. Always make sure the unit is level and properly
grounded. Check engine oil before starting.

1. Open fuel valve fuel tank. (See Fig. 3)

2. Turn the idle control switch to the OFF position.
(See Fig. 4)

3. Move choke lever to full choke. If re-starting a warm engine,
the choke should be left in the off position. (See Fig. 5)

4. Turn the engine ignition switch to the ON position.

5. Pull recoil to start engine.

6. Once engine has started, slowly move choke lever to no
choke.

NOTE: When engine fails to start after several attempts, repeat

the starting procedures mentioned above with the choke
lever in the off position.

7. Allow the unit to run for two (2) minute warm-up.

8. Make sure the generator is grounded. See Preparing the
Generator; Grounding Instructions.

9. Turn main breaker to ON position (AC-G6010 units only).

10. Test the GFCI receptacle(s) on the unit. Push the test
button. The reset button should pop out and there should
be no power at the receptacle. Apply a test load or lamp
to each receptacle to verify. IF THE RESET BUTTON DOES
NOT POP OUT, DO NOT USE THE RECEPTACLES(S).
SEE DEALER FOR SERVICE IMMEDIATELY.

11. If GFCI receptacle(s) test correctly, rmly push the reset
button to restore power. A distinctive click should be
heard or felt when this is complete. IF THE
RECEPTACLE(S) DO NOT RESET PROPERLY, DO
NOT USE THE RECEPTACLE(S). SEE DEALER FOR
SERVICE IMMEDIATELY.

(Fig. 3)

(Fig. 4)

12. Turn idle control switch to ON position. Loads can now be
applied to unit.

NOTE: This engine is equipped with a “Low Oil” shutdown

system for engine protection. The engine stops when
the oil level gets too low. The engine will not restart
without adding oil. Refer to Preparing the Generator;
Engine Fuel Capacity for instructions on adding oil.

(Fig. 5)

(Subaru Shown)

Operator’s Manual 17

Operating the Generator

OPERATION

Electric Start

NOTE: Read Operator’s Manual carefully before operating this

unit. Always make sure the unit is level and properly
grounded. Check engine oil before starting.

1. Open fuel valve on unit or engine. (See Fig. 3)

2. Turn the idle control switch to the OFF position.
(See Fig. 4)

3. Move choke lever to full choke. If re-starting a warm engine,
the choke should be left in the off position. (See Fig. 5)

4. Turn the engine ignition switch to the ON position.

5. Start the engine by turning the key switch fully clockwise
until the engine starts, then release the switch.

NOTE: Do not crank the engine continuously for more than

30 seconds at a time. If the engine does not start, allow
for a 3 minute cool down period between starting
attempts. Failure to follow these guidelines can damage
the starter motor.

If the starter does not turn the engine over, shut off

the starter immediately. Do not make further attempts to
start the engine until the condition is corrected. Do not
jump start using another battery.

6. Once engine has started, slowly move choke lever to no
choke.

7. Allow the unit to run for two (2) minute warm-up.

8. Turn main breaker to ON position (AC-G6010 units only).

9. Test the GFCI receptacle(s) on the unit. Push the test button.
The reset button should pop out and there should be no
power at the receptacle. Apply a test load or lamp to each
receptacle to verify. IF THE RESET BUTTON DOES NOT
POP OUT, DO NOT USE THE RECEPTACLES(S). SEE
DEALER FOR SERVICE IMMEDIATELY.

10. If GFCI receptacle(s) test correctly, rmly push the reset
button to restore power. A distinctive click should be heard or
felt when this is complete. IF THE RECEPTACLE(S)
DO NOT RESET PROPERLY, DO NOT USE THE
RECEPTACLE(S). SEE DEALER FOR SERVICE
IMMEDIATELY.

11. Turn idle control switch to ON position. Loads can now be
applied to unit.

NOTE: This engine is equipped with a “Low Oil” shutdown

system for engine protection. The engine stops when
the oil level gets too low. The engine will not restart
without adding oil. Refer to Preparing the Generator;
Engine Fuel Capacity for instructions on adding oil.

18 Operator’s Manual

Operating the Generator

SHUTDOWN

1. Remove all load by turning off electrical appliances and
unplugging electric cords.

2. Allow engine to run at idle speed to cool for two (2)
minutes.

NOTE: Failure to allow the engine to cool at idle for two (2)

minutes may result in damage to the generator.

3. Turn engine key or ignition switch off.

4. Close fuel valve on unit or engine.

CONTROLS

OIL WARNING DEVICE:

NOTE: This engine is equipped with a “Low Oil” shutdown

system for engine protection. The engine stops when
the oil level gets too low. The engine will not restart without
adding oil. If the unit is tilted too much during operation, it
may suddenly stop even though the oil level is not low.

Check the engine oil before restarting the engine. If the unit is
tilted, level the engine, then check the oil before restarting the
engine.

CONTROL PANEL :
The generators are equipped with the following items:

- Idle Control Switch

- Hour Meter

- Volt Meter

- Circuit Breakers

- Two 125 Volt, 20 Amp, Duplex (2 outlets), GFCI protected

receptacles.

- One 125 Volt, 30 Amp, Locking Type Receptacle.

- One 125/250 Volt, 20 Amp, Locking Type Receptacle

(AC-G6010).

- One 125/250 Volt, 30 Amp, Locking Type Receptacle

(AC-G7510, AC-G8010).

NOTE: The 125 Volt, 30 Amp, 125/250 Volt, 20 Amp and 125/250

Volt, 30 Amp locking receptacles ARE NOT GROUND
FAULT PROTECTED. If ground fault protection on these
receptacles is necessary or desired, external protection
devices must be used. Refer to the section on “Ground
Fault Interrupter” for more information.

WARNING: NEVER EXCEED THE RATING OF A
RECEPTACLE. These receptacles are
protected against overloads by resetting
magnetic type circuit breakers. If a circuit
breaker trips, the cause should be determined
and corrected prior to continuing use.

Operator’s Manual 19

Operating the Generator

CONTROLS

HOUR METER:
These generators are equipped with an hour meter that records run time
for the unit. This is very useful in scheduling maintenance. See periodic
maintenance chart for suggested maintenance schedule.

VOLT METER:
These generators are equipped with a volt meter. The volt meter is used
to monitor the unit for proper voltage.

IDLE CONTROL OPERATION:
The idle control is factory installed. This electrical device is designed to
let the engine run at fuel saving low idle speed when the generator is not
loaded, and at full normal governed speed when a load is applied. The
idle system overrides the engine governor to provide idle speed. When
a load is applied, the electronic circuit reacts to de-energize the idle
system so that the engine can resume full governed operating speed.

The idle control system controls the engine speed in the following
manner:

1. With the idle control switch in the “OFF” position, start the engine.

2. After one or two minute warm up period, apply load and move the
switch to the “ON” position. The engine will throttle back to idle speed
following a 5-8 second delay.

3. When a load is applied to the generator, the idle control system
becomes de-energized. The engine then accelerates to normal
operating speed, controlled by the governor.

4. When the load is removed, the idle system becomes re-energized and
throttles the engine back to idle speed after a 5-8 second delay.

NOTE: While the engine is idling, the generator voltage is automatically

reduced to reduce generator temperatures. The voltage will return
to normal levels immediately upon the application of load.

MAIN BREAKER (AC-G6010 units only):
These generators are equipped with a main circuit breaker which
protects the unit in an overload condition. This main breaker must be
“ON” for any power to be drawn from the unit.

20 Operator’s Manual

Operating the Generator

CONTROLS

CABLE SIZE:
Equipment damage can result from low voltage. Therefore, to prevent
excessive voltage drop between the generator and the equipment,
the cable should be of adequate gauge for the length used. The cable
selection chart gives the maximum cable lengths for various gauges of
wire which can adequately carry the loads shown.

CURRENT LOAD IN WATTS MAXIMUM CABLE LENGTH (FEET)
IN AMPS 120 VOLTS 240 VOLTS #8 WIRE #10 WIRE #12 WIRE #14 WIRE #16 WIRE

2.5 300 600 1000 600 375 250
5 600 1200 500 300 200 125

7.5 900 1800 350 200 125 100
10 1200 2400 250 150 100 50
15 1800 3600 150 100 65
20 2400 4800 175 125 75 50
25 3000 6000 150 100 60
30 3600 7200 125 65
40 4800 9600 90

ELECTRIC MOTOR LOADS:
It is characteristic of common electric motors in normal operation to draw
up to six times their running current while starting. This table may be
used to estimate the watts required to start “CODE G” electric motors.

CAUTION: IF AN ELECTRIC MOTOR FAILS TO START OR
REACH RUNNING SPEED, TURN OFF THE
APPLIANCE OR TOOL IMMEDIATELY TO AVOID
EQUIPMENT DAMAGE. ALWAYS CHECK THE
REQUIREMENTS OF THE TOOL OR APPLIANCE
BEING USED COMPARED TO THE RATED OUTPUT
OF THE GENERATOR.

WATTS REQUIRED TO START MOTOR
MOTOR (H.P.) RUNNING WATTS REPULSION INDUCTION CAPACITOR SPLIT PHASE

1/8 275 600 850 1200
1/6 275 600 850 2050
1/4 400 850 1050 2400
1/3 450 975 1350 2700
1/2 600 1300 1800 3600
3/4 850 1900 2600
1 1100 2500 3300

Operator’s Manual 21

Troubleshooting

Symptom Problem Solution

Engine will not start. Engine switch is off. Turn engine switch to the ON position.

Fuel Tank empty. Fill tank per instructions in this manual.

Fuel Valve is off. Turn Fuel Valve on.

Inadequate engine oil. Check oil level. This engine is
equipped with a low oil sensor. The
engine cannot be started unless the oil
level is above the prescribed lower
limit.

No spark at spark plug. Remove the spark plug cap. Clean any
dirt from around the plug base, then
remove the spark plug. Install the
spark plug in the plug cap. Turn the
engine switch on.

Grounding the electrode to any engine
ground, pull the recoil starter to see if
sparks jump across the gap. If there is
no spark, replace the plug.

Reinstall the plug and start engine
according to instructions in this
manual.

Consult John Deere Customer
Service.

Generator has no output. Circuit breakers tripped. Reset circuit breakers.

Inadequate cord sets or Check cord sets or extension cords
extension cords. capabilities in section Controls;
Cable Size in this manual.
Consult John Deere Customer
Service.

22 Operator’s Manual

Service

MAINTENANCE

Keep all air vents clear.
Keep the generator clean. DO NOT spray with water.
Periodically check all fasteners and tighten, see the periodic maintenance chart.

GFCI TEST RECORDS:
As with any other safety devices, the GFCIs supplied with these generators must be checked every month to insure that
they are functioning properly. To test the GFCIs, follow the instructions and then enter the date of the test below.

1. With the generator running and the idle control switch in the “START” position, push the “TEST” button. The
“RESET” button should pop out. This should result in the power being off at both outlets of the duplex receptacle.
Verify this by plugging a test lamp into each outlet.

WARNING: IF THE RESET BUTTON DOES NOT POP OUT, DO NOT USE THE RECEPTACLE(S). SEE

AUTHORIZED John Deere CUSTOMER SERVICE REPRESENTATIVE FOR SERVICE IMMEDIATELY.

2. If the GFCI test correctly, restore power by FIRMLY pushing the “RESET” button back in until you hear or feel a
distinctive “click”. IF THE GFCI FAILS TO RESET PROPERLY, DO NOT USE EITHER OUTLET OF THE DUPLEX
RECEPTACLE. Have the unit serviced by an authorized John Deere Customer Service Representative immediately.

3. High vibration or severe mechanical shock loads may cause the GFCIs to trip. IF EITHER GFCI TRIPS BY
ITSELF AT ANY TIME, reset it and perform test procedures 1 and 2.

4. Repeat steps 1-3 for the second GFCI.

WARNING: ALTHOUGH THE ABOVE TEST PROCEDURES WILL INDICATE PROPER GFCI OPERATION ON
AN UNGROUNDED OR IMPROPERLY GROUNDED GENERATOR, THE GENERATOR MUST STILL
BE GROUNDED PER THE GROUNDING INSTRUCTIONS LISTED ON PAGE 16 FOR THE GFCI TO

FUNCTION PROPERLY AND PROTECT THE USER FROM ELECTRICAL FAULTS.

Year Jan. Feb. March April May June July Aug. Sept. Oct. Nov. Dec.

NOTE: Situations exist where a GFCI will not afford any protection against the hazards of electrical shock.

EXAMPLE: if a person touches two or more conductors from a damaged cord set and is not in direct contact
with the ground, he or she may receive a shock. Since there is no path to ground for a ground fault current to
ow through, the GFCI will not operate and serious injury may result.

The GFCI are merely an added safety feature. There are no substitutes for good safety precautions, correct
electrical practices and proper maintenance of cords, equipment and connections.

Operator’s Manual 23

GENERATOR MAINTENANCE

EVAPORATIVE EMISSION COMPONENTS:
The unit you have purchased includes the following
components that are in compliance with California Air
Resources Board Evaporative Emission Standards;

1. Fuel Hose

2. Fuel Hose Fittings

3. Fuel Tank and Cap

4. Carbon Canister and Mounting Brackets

These components should be inspected on a daily basis
for cracks, leaks, and abnormal wear. If cracking, leaks
or abnormal wear has occurred, the components should
be replaced immediately.

IDLE CONTROL ADJUSTMENT:

NOTE: The automatic idle speed is set between 2640

and 2940 RPM.

The idle speed has been pre-set at the factory and
should rarely require readjustment. We recommend that
all adjustments of this nature be made by a John Deere
Customer Service Representative.

Service

Erratic idle operation of the engine usually indicates a
need for carburetor adjustment to provide a smooth idle.
The idle control will not function properly when the idle
speed is below the recommended limits or the carburetor
is improperly adjusted.

HAVE THE UNIT SERVICED BY AN AUTHORIZED
JOHN DEERE CUSTOMER SERVICE REPRESENTA­TIVE.

24 Operator’s Manual

MAINTENANCE

ENGINE:
The engine for this generator is governed to operate
at speeds close to 3600 RPM (60Hz) throughout the
operating load range. The no load speed (before a load
is applied) will be just a bit higher than the load speed
and is normally set to 3750 RPM.

WARNING: DO NOT TAMPER WITH THE
GOVERNOR MECHANISM, CHANGE
THE SETTING EXPERIMENTALLY, OR
PUSH THE THROTTLE OPEN IN AN
ATTEMPT TO GENERATE MORE
ELECTRICAL CURRENT; EQUIPMENT
DAMAGE OR PERSONAL INJURY MAY
RESULT.

GOVERNOR SPEED ADJUSTMENT SHOULD
BE MADE ONLY BY A JOHN DEERE CUSTOMER
SERVICE REPRESENTATIVE.

CHECKING ENGINE OIL:
Check oil level before each operation and ensure that it
is maintained per Preparing the Generator; Engine Oil
Capacity section.

Service

CHANGING ENGINE OIL:

Change oil after the rst 20 hours of operation. Thereafter

it should be changed every 100 hours.

1. Make sure the unit is on level ground. Run the engine
to warm the oil.

2. Stop the engine.

3. Remove the oil drain plug. (See Fig. 6)

CAUTION: OIL BEING DRAINED MAY BE HOT.
TO REDUCE THE RISK OF BURN INJURY,
HANDLE WITH CARE. DISPOSE OF USED
OIL PROPERLY.

4. Drain oil while engine is warm, into a suitable
container.

5. Reinstall the oil drain plug.

6. Remove oil gauge and rell with new oil. (Fig. 7)

7. Check the oil level as instructed in Preparing the
Generator; Engine Oil Capacity section.

OIL DRAIN PLUG

(Fig. 6)

UPPER LEVEL

(Fig. 7)

8. Wipe up any spilled oil.

Operator’s Manual 25

Service

MAINTENANCE

AIR CLEANER:

WARNING: RISK OF FIRE OR EXPLOSION. DO
NOT USE GASOLINE OR LOW FLASH-
POINT SOLVENTS TO CLEAN THE
ELEMENT. CLEAN THE ELEMENT IN A
WELL VENTILATED AREA. ENSURE
THAT NO SPARKS OR FLAMES ARE
NEAR THE WORKING AREA, THIS
INCLUDES ANY APPLIANCE WITH A
PILOT LIGHT.

CAUTION: NEVER RUN THE ENGINE WITHOUT
THE AIR FILTER, SERIOUS DANGER
CAN RESULT.

Check the air cleaner daily or before starting the engine.
Check for and correct heavy buildup of dirt and debris along
with loose or damaged components. (See Fig. 8)

1. Unsnap the air cleaner cover and remove the elements.

(Fig. 8)

2. Clean the elements:

FOAM PRE-CLEANER ELEMENT: Wash the foam pre­cleaner element in warm water with detergent. Rinse the
foam pre-cleaner element thoroughly until all traces of
detergent are eliminated. Squeeze out excess water, but do
not wring. Allow the foam pre-cleaner element to air dry.

Saturate the foam pre-cleaner element with new engine oil.
Squeeze out all excess oil. DO NOT put engine oil on the
foam damper.

NOTE: Clean the foam pre-cleaner element every 25 hours

of operation (more often under extremely dusty or
dirty condition)

PAPER AIR CLEANER ELEMENT: Do not wash the paper
element or use pressurized air, as this will damage the
element. Clean by gently tapping the element to remove
dust. Replace the element if damaged, bent or extremely
dirty. Handle new element carefully; do not use if the sealing
surfaces are bent or damaged.

NOTE: Replace the paper element every 100 hours (more

often under extremely dusty conditions.)

5. Reinstall the foam pre-cleaner element and the paper
air cleaner element. Close air cleaner cover and clasp
shut.

26 Operator’s Manual

MAINTENANCE

Service

CLEANING AND GAPPING SPARK PLUG:
If the plug is contaminated with carbon, remove it using a
plug cleaner or wire brush.

Check the spark plug gap and reset it if necessary. The spark
plug gaps are listed below. To change the gap, bend the side­electrode only, using a spark plug tool. (Fig. 9)

Install and tighten the spark plug. Connect the spark plug
lead.

Recommended Spark Plug:

Engine Subaru Honda

Spark Plug NGK BR-6HS NGK BPR6ES
Spark Plug Gap 0.6 - 0.7 mm

(0.02-0.03 in.)
Torque - New 8.7-10.9 ft-lb
Torque - Retighten 16.6-19.5 ft-lb

0.7 - 0.8 mm
(0.03 in.)

SPARK ARRESTOR:

If the generator has been running, the mufer will be very

hot. Allow it to cool before proceeding.

NOTE: Remove and clean spark arrester every 100 hours
or as necessary.

Spark Plug Gap

(See recommendations)

(Fig. 9)

SCREW

NOTE: Product users on United States forest service land, and

in some states, must comply with re
prevention regulations.

Clean the spark arrester as follows: (Fig. 10 and 11)

1. Loosen the screw by the exhaust port of the mufer and

remove the spark arrester.

2. Use a brush to remove carbon deposits from the spark
arrester screen. Inspect the screen for breaks or tears and
replace it if necessary.

3. Install the spark arrester in the reverse order of removal.

Spark arrestors are available from your local John Deere
Customer Service. Other user requirements may apply, check
with your Federal, State or local authorities.

SPARK ASSESTER

(Fig. 10)

SPARK ARRESTER SCREEN

(Fig. 11)

Operator’s Manual 27

Service

MAINTENANCE

PERIODIC MAINTENANCE CHART:
To ensure satisfactory operation over an extended
period of time, an engine requires normal maintenance
at regular intervals. The Periodic Maintenance Chart
below shows periodic inspection and maintenance items
and suitable intervals. The bullet mark designates that
the corresponding item should be performed at that
interval.

NOTE: Some adjustments require the use of special tools

or other equipment. An electronic tachometer will
facilitate setting idle and running speeds.

Daily Every Every Every Before
25hrs. 100 hrs. 200 hrs. Storage

Check fuel •
Check engine oil •
Check for loose or lost nuts and bolts •
Check for leaks •
Check cylinder and head ns for
dust and dirt •
Check battery electrolyte level •
Check fuel lines (replace if necessary) •
Clean air cleaner foam element (**) •
Tighten nuts and bolts (*) •
Change engine oil (*) •
Clean fuel lter •
Replace air cleaner paper element (**) •

Clean dust and dirt from

cylinder and cylinder head ns (**) •
Clean and regap spark plug •
Add fuel stabilizer •
Run unit dry •

* Perform these operations after the rst 5 hours of use, then at the recommended intervals.

** Service more frequently under dusty conditions.

NOTE: These items must be performed with the proper tools. See your John Deere Customer Service Representative

for service, unless you have the proper equipment and mechanical prociency.

28 Operator’s Manual

Storage

Service

STORING GENERATOR

SHORT TERM (1-6 months):

1. Add gasoline conditioner and stabilizer at the specied

concentration.

2. Run the unit for two (2) minutes to ensure the mixed
fuel is in the entire fuel system. Close the fuel valve
and run the unit until it stops.

3. Remove the spark plug, pour 1-2 teaspoons (5-10cc) of
engine oil into the cylinder, slowly pull the starter handle
2 or 3 times, reinstall the spark plug and tighten
securely.

4. Clean the exterior surface of the generator and apply
a rust inhibitor.

5. Store the generator in a dry, well ventilated place.

LONG TERM (More than 6 months):

1. Add gasoline conditioner and stabilizer at the specied

concentration.

2. Run the generator until the fuel tank and carburetor
are dry. As the engine is beginning to die, move the
choke lever to the choke position.

NOTE: Turn off the idle control to decrease the run time.

3. Remove the spark plug, pour 1-2 teaspoons (5-10cc) of
engine oil into the cylinder, slowly pull the starter handle
2 or 3 times, reinstall the spark plug and tighten
securely.

4. Clean the exterior surface of the generator and apply
a rust inhibitor.

5. Store the generator in a dry, well ventilated place.

WARNING: FUEL SHOULD BE DRAINED IN A
WELL VENTILATED AREA AND STORED
IN A CONTAINER APPROVED FOR
GASOLINE.

Operator’s Manual 29

Specications

SPECIFICATIONS

ITEM SPECIFICATION

AC-G6010H/HE AC-G6010S/SE AC-G7510H/HE AC-G8010S/SE

Engine Honda Subaru Honda Subaru

Watts (AC) Rated 5000 watts 5000 watts 6500 watts 6900 watts

Watts (AC) Max. 6000 watts 6000 watts 7500 watts 8000 watts

Rated Voltage (AC) 120/240V 120/240V 120/240V 120/240V

Max. Amperage 50.0/25.0 50.0/25.0 62.5/31.3 66.7/33.3

Cont. Amperage 41.7/20.8 41.7/20.8 54.2/27.1 57.5/28.8

Frequency 60 60 60 60

Fuel Tank Capacity 7.3 gal. 7.3 gal. 7.3 gal. 7.3 gal.

Run Time Hours /
Tank of Fuel* 8.0 hrs. 7.9 hrs. 6.9 hrs. 6.7 hrs.

Battery for Electric Start #32-0058

* Rated at Full Load

NOTE: Unit ratings are established based on operation at standard conditions of 60° F and at sea level. The

performance of the generator must be de-rated for temperature and altitude by 1% for every 10° F above 60° F
and 3.5% for every 1000 feet above sea level. Due to the operational characteristics of the thermal type circuit
breaker, the power available from the generator will decrease slightly with a corresponding increase in ambient
temperature.

Due to continuing product improvements, specications are subject to change without notice.

RECORD SERIAL NUMBER

Write you model number, machine serial number and date
of purchase in the spaces provided below. Your dealer
needs this information when ordering parts.

Model No. ______________________________________________

Machine Serial No. _______________________________________

Date of Purchase ________________________________________

(To be lled in by purchaser)

30 Operator’s Manual