Page 1
®
Owner’s Manual
This manual contains important safety instructions for gasoline generator models: G5000S, G8000S
that should be followed during installation and maintenance of the generator and batteries.
READ SAFETY WARNINGS AND OPERATING INSTRUCTIONS CAREFULLY, SAVE THESE INSTRUCTIONS.
Contents:
2-3 STANLEY Product Lines
3 Missing Parts Request Form
4 Warnings
5 Warnings and Specifications
6-7 Component Identification
8 Wheel Kit Installation & Battery Commissioning
9 Controls
10-11 Operating the Generator
12 Maintenance
13 Maintenance, Transporting and Storage
14-15 Troubleshooting
16 Warranty and Service
DO NOT RETURN THIS GENERATOR
TO THE STORE
HAVE QUESTIONS OR NEED HELP?
call our help-line: [1] 919-550-3259
or go to www.portablegenerator911.com or www.GXiOutdoorPower.com
Have the following information ready when you call us:
Date of Purchase: _______________________
Location of Purchase: _______________________
Serial #: _______________________
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
1 of 16 Rev. 5/2010
Page 2
STANLEY Product Lines
Models: G5000S & G8000S
For more information or where to purchase STANLEY outdoor power equipment, visit
us at: www.GXiOutdoorPower.com
Walk Behind Turf and Brush Mowers
• 36” Brush Mower
• HONDA GXV 530 V-twin engine
• Hydro Drive
• Convertible deck— easily converts to a finish mower.
Zero-Turn Commercial Mowers
• 54” and 62”
• HONDA GXV 530 V-twin engine
• Hydro Drive
Commercial Walk Behind Mowers
• 36” and 54” deck
• HONDA GXV 530 V-twin engine
• Belt drive or Hydro Drive
100” Tow Behind Mower
Model: 100TS
• Commercial duty STANLEY tow behind mower
• HONDA GXV 530 V-twin engine cuts up to 100 inches.
• 52 in. brush cut or a 52 in. finish cut mower with wings up.
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
2 of 16 Rev. 5/2010
Page 3
STANLEY Product Lines
Electric Pressure Washer
• 1450 psi to 1800 psi electric pressure washers
• 20 ft of high pressure hose and 35 ft. cord with GFCI protection
• Sleek and unique, high quality, stainless steel finish
• 13 Amps, 120V
• Auto-stop shut off system prolongs pump life
Generator Cord Accessories
240V, 10/4, heavy duty extension cords with L14-30 connectors at each end.
This cord reduces harmful voltage drops experienced when using most
120V extension cords
reach the desired length.
. Available in 15’ and 25’ lengths and can be combined to
Models: G5000S & G8000S
Missing Parts Request Form
Please indicate the part that you are missing:
Hardware bag
Wheel Kit
Other
Date of purchase
Model #:
5000
6500
6500EL
8000
Serial #:
Comments:
Name
Address
Phone
Email
IMPORTANT: Please include a copy your receipt. Without a receipt, your order will be
delayed.
E-mail : customerservice@gxioutdoorpower.com
Fax: 1-919-550-3277
Please scan and attach your proof of purchase to your e-mail.
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
3 of 16 Rev. 5/2010
Page 4
WARNINGS
Models: G5000S & G8000S
This owner’s manual is considered a permanent part of the generator
and should remain with the generator if resold. The information and
specifications included in this publication were in effect at the time of
approval for printing.
GXi Outdoor Power, LLC, reserves the right to discontinue or change
specifications or design at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission.
EMISSION CONTROL SYSTEM INFORMATION
The U.S. and California Clean Air Acts
EPA and California regulations require all manufacturers to furnish
written instructions describing the operation and maintenance of emission control systems. The following instructions and procedures must
be followed in order to keep the emissions from your STANLEY engine
within the emission standards. Maintenance, replacement, or repair of
the emission control devices and systems may be performed by any
engine repair establishment or individual, using parts that are
‘‘certified’’ to EPA standards.
SAFETY LABEL LOCATIONS
These labels warn you of potential hazards that can cause serious
injury. Read them carefully. If a label comes off or becomes hard to
read, contact your STANLEY generator dealer for a replacement.
SAFETY INFORMATION
STANLEY generators are designed to give safe and dependable
service if operated according to instructions. Read and understand this owner’s manual before operating your generator.
OPERATOR RESPONSIBILITY
Know how to stop the generator quickly in case of emergency. Understand the use of all generator controls, output receptacles, and connections. Be sure that anyone who operates the generator receives
proper instruction. Do not let children operate the generator.
WARNING
The engine exhaust from this product contains chemicals known to
the State of California to cause cancer, birth defects or other reproductive harm.
DANGER
CARBON MONOXIDE GAS
Exhaust contains poisonous carbon monoxide, a colorless and
odorless gas. Breathing exhaust can cause loss of consciousness
and may lead to death. To keep exhaust gas from accumulating,
use in an area with adequate ventilation. DO NOT use this generator in a garage, basement, crawlspace, enclosed shed, or any
other area that does not have adequate ventilation. DO NOT use
this generator near ventilation ducts or open windows that may
allow exhaust
gasses to enter your home or business. ONLY
operate this generator outdoors.
DANGER
Fire and Burn Hazards
The exhaust system gets hot enough to ignite some materials.
• Keep the generator at least 3 feet (1 meter) away from buildings
and other equipment during operation.
• Do not enclose the generator in any structure.
• Do not smoke when refueling.
• Keep flammable materials away from the generator.
• The muffler becomes very hot during operation and remains hot for
a while after stopping the engine. Be careful not to touch the muffler while it is hot.
• Let the engine cool before storing the generator indoors.
• Refuel in a well ventilated area with the engine stopped.
• Fuel vapors are extremely flammable and may ignite after the en-
gine has started. Make sure that any spilled fuel has been wiped
up before starting
the generator.
DANGER
Electocution hazard - Electricity can cause DEATH or SERIOUS
INJURY.
• Do not operate the generator in standing water.
• This product is not safe to operate when partially or totally sub-
merged in water.
• Ensure proper drainage in the region surrounding this generator.
• Properly ground the generator and verify ground is in place be-
fore each use. Grounding regulations vary by location, consult a
qualified local electrician for proper grounding instructions.
• Power cords and electrical equipment pose a risk of shock and
electrocution, especially if they are operated in wet conditions.
Inspect all equipment prior to every use and use only as directed
by the manufacturer.
• Use a cord with GFCI protection when using the power outdoors
or when moisture is present.
• Generators vibrate in normal use. During and after the use of the
generator, inspect the generator as well as extension cords and
power supply cords connected to it for damage resulting from
vibration. Have damaged items repaired or replaced as necessary. Do not use plugs or cords that show signs of damage such
as broken or cracked insulation or damaged blades.
NEVER START OR STOP THE ENGINE WITH DEVICES CONNECTED
TO THE GENERATOR.
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
WARNING
Generator must be installed by a qualified electrician and connected to transfer equipment as a separately derived system in accordance with the National Electrical Code, NFPA 70. The generator
shall be connected through transfer equipment that switches all
conductors other than the equipment grounding conductor. The
frame of the generator shall be connected to an approved grounding
electrode.
Improper connections to a building electrical system can allow
electrical current from the generator to backfeed into the utility
lines. Such backfeed may electrocute utility company workers or
others who contact the lines during a power outage, and the generator may explode, burn, or cause fires when utility power is restored.
Ground System
STANLEY portable generators have a system ground that connects generator frame components to the ground terminals in the AC output receptacles. The system ground is connected to the AC neutral wire.
Special Requirements
There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the
intended use of the generator. Please consult a qualified electrician,
electrical inspector, or the local agency having jurisdiction.
This generator does not meet US Coast Guard regulation 33 CFR-183
and should not be used on marine applications.
4 of 16 Rev. 5/2010
Page 5
WARNINGS
Models: G5000S & G8000S
DANGER
AC Applications
Before connecting an appliance or power cord to the generator:
1. Make sure that appliances are in good working order.
Faulty appliances or power cords can create a potential for
electrical shock. If an appliance begins to operate abnormally, becomes sluggish or stops suddenly, turn it off immediately.
2. Disconnect the appliance, and determine whether the problem is the appliance, or if the rated load capacity of the
generator has been exceeded.
3. Make sure that the electrical rating of the tool or appliance
does not exceed that of the generator. Never exceed the
maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30
minutes.
Substantial overloading will open the circuit breaker. Exceeding the time limit for maximum power operation or
slightly overloading the generator may not switch the circuit
breaker or circuit protector OFF, but will shorten the service
life of the generator.
Limit operation requiring maximum power to 30 minutes. For
continuous operation (longer than 30 minutes), do not exceed
80% of the rated power balanced equally on the A&B sides of
the Alternator.
WARNING
Failure to properly follow maintenance instructions and precautions can cause serious injuries or death. Always follow
the inspection and maintenance recommendations and
schedules in this owner’s manual.
Safety Precautions:
Make sure the engine is off before you begin any maintenance
or repairs. This will eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you
operate the engine.
• Burns from hot parts.
Let the engine and exhaust system cool before touching.
• Injury from moving parts.
Do not run the engine unless instructed to do so.
In the State of California a spark arrestor is required by law.
Other states may have similar laws. Federal laws apply on all
federal lands. If you equip the muffler with a spark arrestor, it
must be maintained in effective working order. See page 11.
Rapid retraction of the recoil starter cord can pull the
starter cord back faster than you can let go. When starting
the engine, pull the cord slowly until resistance is felt then
pull rapidly to avoid kickback
.
DANGER
Changing the speed of the generator by adjusting the governor can cause damage to the generator, devices attached to the generator, and may result in bodily injury. Do not adjust or tamper
with the engine speed setting.
Product Specifications
Generator G5000S G8000S
Rated frequency 60 Hz 60 Hz
Rated voltage 120V / 240V 120V / 240V
Rated output power 5.0 kW (Max.) 8.0 kW (Max)
AC output (Max.) 20.8A 33.3A
Engine type OHV 4-Stroke OHV 4-Stroke
displacement 279 cc 401 cc
Compression ratio 8.2:1 8.0:1
Rated rotation speed 3600 RPM 3600 RPM
Rated power 10 Hp 15 Hp
Starting system Recoil Recoil and electric starter
Rotation direction Counter clockwise Counter clockwise
Fuel type Unleaded gasoline Unleaded gasoline
Low oil shutdown Yes Yes
Fuel tank size 12 gallons 12 gallons
Oil type / Capacity SAE 10W-30 0.9 quarts SAE 10W-30 1.1 quarts
Gross weight 207 lbs (94 kg) 235lbs (107kg)
Battery N/A 12 AH 12 VDC
Integrated voltmeter Yes Yes
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
5 of 16 Rev. 5/2010
Page 6
Component Identification
Models: G5000S & G8000S
Fuel Tank
Choke Lever
Air Filter
Fuel Valve
Recoil Starter (Assembly)
Digital Meter
On/ Off & Start Switch
(electric start option)
Fuel Cap
Generator models may have
different features and/or options than
shown in these diagrams. STANLEY reserves the right to alter product features
and specifications without notice.
Main Breaker
ON/OFF Switch
Remote Generator Panel
Main Breaker
Pull Out Handle Bars
Ground Lug
L14-30 240V/120V
Twist Lock Connector
Carburetor
Valve Cover
Battery (electric start option only)
Alternator
Muffler Guard
Exhaust Pipe
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
6 of 16 Rev. 5/2010
Page 7
Access panel latches
Component Identification
Models: G5000S & G8000S
Alternator
Weather Shield
Engine Serial Number stamped
on the engine block
Access Panel
Additional equipment required to safely operate this generator:
1. Gas can.
2. Unleaded gasoline.
3. SAE 10W-30 - 1.1 quarts for STANLEY 11hp, 13hp, 14hp, and 15hp engines, 0.9 quarts required for STANLEY 10 HP.
4. An oil fill funnel.
5. Gasoline fuel stabilizer (for storing your generator).
6. 120V and/or 240V extension cords.
7. An adjustable wrench or a 12mm socket for oil changes.
Note: A spark arrestor was supplied with your generator and must be installed for use within the State of California. See supplemental instructions.
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
7 of 16 Rev. 5/2010
Page 8
Wheel Kit Assembly
Models: G5000S & G8000S
Approximate assembly time is 5
minutes.
Supplied with your generator:
1. Two(2) foot assemblies with two (2)
13 mm nuts.
2. Two (2) wheel axle assemblies.
Two pre-assembled, retractable, handle bars, one on
each side of the generator frame. Twist to lock /
unlock. Pull or push to extend / retract.
Step
Insert each foot assembly through
1
holes in the frame. Tighten nut with
13mm wrench or socket.
Commissioning the Battery
The battery is an optional feature. The battery is used to start a
generator equipped with an electric starter. Not all generators are
sold with batteries. Please verify with your retailer if you believe
the battery is missing.
Insert each axle and tighten the
Step
2
bolt to secure in place using a 13
mm wrench or socket.
Battery Terminals
Pre-assembled wheel / axle
assembly.
WARNING
Lead acid storage batteries contain sulfuric acid which can cause
serious injuries. The battery also gives off explosive gases. Keep
sparks, flames and cigarettes away. Provide adequate ventilation
when charging or using batteries. Battery posts, terminals and
related accessories contain lead and lead compounds. Avoid spills
of electrolyte and wash hands thoroughly after handling.
Use gloves and safety glasses when handling and installing lead
acid batteries.
If you get electrolyte in your eyes, flush your eyes with clean water for 15 minutes and seek medical attention. Keep out of reach of
children.
FOR YOUR SAFETY AND CONVENIENCE, THE
BATTERY WAS SHIPPED SEALED AND
PRE-CHARGED.
The battery is ready to be connected to the generator.
To connect the battery, use an adjustable wrench or 8 mm socket to
secure the BLACK wire to the negative (-) terminal and the RED
wire to the positive (+) terminal. Do not allow the wrench to con-
tact any other part of the generator when tightening the battery
terminals.
Battery
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
8 of 16 Rev. 5/2010
Page 9
Controls
Models: G5000S & G8000S
WARNING
The engine was shipped without engine oil. DO NOT START THE
ENGINE WITHOUT FILLING THE ENGINE WITH OIL. Use SAE 10W30 for normal conditions and SAE 5W-30 when the ambient temperature is below 32° F.
Choke Rod
The choke is used to
provide an enriched
fuel mixture when
starting a cold engine.
It can be opened and
closed by operating
the choke rod manually. Pull the rod out
toward CLOSED to
enrich the mixture for
cold starting. Open
once the engine is
running.
Turn clockwise
to turn fuel valve
on.
Fuel Valve Lever
The fuel valve is located between the fuel
tank and carburetor.
When the valve lever is
in the ON position, fuel
is allowed to flow from
ON
F
F
O
the fuel tank to the
carburetor. Be sure to
return the fuel valve
lever to the OFF position after stopping the
engine.
Engine Switch
To start and stop the engine.
Recoil Starter
To start the engine, pull the starter grip lightly until resistance is felt,
then pull briskly.
NOTICE:
Do not allow the starter grip to snap back against the engine. Return it
gently to prevent damage to the starter.
The recoil starter is used to start the engine if the generator is not
equipped with a 12 volt battery to operate the starter motor, or if the
battery does not contain adequate charge to operate the starter motor.
RECOIL STARTER
STARTER GRIP
Oil Alert System
The Oil Alert system is designed to prevent engine damage caused by
an insufficient amount of oil in the crankcase. Before the oil level in the
crankcase can fall below a safe limit, the Oil Alert system will automatically stop the engine (the engine switch will remain in the ON position).
The Oil Alert system should not take the place of checking the oil level
before each use. If the engine stops and will not restart, check the
engine oil level (see page 14) before troubleshooting in other areas.
Ground Terminal
The generator ground terminal is connected to the
frame of the generator, the metal non-currentcarrying parts of the generator, and the ground
terminals of each receptacle.
WARNING
Before using the ground terminal, consult a qualified electrician,
electrical inspector or local agency having jurisdiction for local
codes or ordinances that apply to the intended use of the generator.
Engine ON / OFF / Start Switch
(electric start shown)
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
NOTE: SYSTEM GROUND IS CONNECTED TO THE AC NEUTRAL ON
THIS GENERATOR. CONSULT AN ELECTRICIAN WHEN CONNECTING THIS GENERATOR TO YOUR HOME OR BUSINESS ELECTRICAL
PANEL TO ENSURE GROUNDING MEETS THE LOCAL ELECTRICAL
CODE
No part of this publication can be printed or copied without written permission.
9 of 16 Rev. 5/2010
Page 10
Operating the Generator
Models: G5000S & G8000S
DANGER
CARBON MONOXIDE GAS
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a
poison you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot
smell the exhaust, you could be breathing CO.
NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of
carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOT supply enough fresh
air.
ONLY use a generator outside and far away from windows,
doors, and vents. These openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into
the home. ALWAYS use a battery-powered or batterybackup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator
has been running, move to fresh air RIGHT AWAY. See a
doctor. You could have carbon monoxide poison.
DANGER
Electocution hazard - Electricity can cause DEATH or SERIOUS INJURY.
• Do not operate the generator in standing water.
• This product is not safe to operate when partially or totally submerged
in water.
• Ensure proper drainage in the region surrounding this generator.
• Properly ground the generator and verify ground is in place before
each use. Grounding regulations vary by location, consult a qualified
local electrician for proper grounding instructions.
• Power cords and electrical equipment pose a risk of shock and electrocution, especially if they are operated in wet conditions. Inspect all
equipment prior to every use and use only as directed by the manufacturer.
• Use a cord with GFCI protection when using the power outdoors or
when moisture is present.
• Generators vibrate in normal use. During and after the use of the generator, inspect the generator as well as extension cords and power
supply cords connected to it for damage resulting from vibration. Have
damaged items repaired or replaced as necessary. Do not use plugs
or cords that show signs of damage such as broken or cracked insulation or damaged blades.
NEVER START OR STOP THE ENGINE WITH DEVICES CONNECTED TO
THE GENERATOR.
WARNING
Step 1.
Ensure all electrical loads are removed from the generator. Disconnect
all the extension cords and ensure the main breaker is in the OFF position. Remove all flammable materials and debris from the area. Make
sure the generator is level.
Step 2.
Check the oil level.
• Put the generator on a level surface with the engine stopped.
• Remove the oil filler cap.
• Check the oil level. If the oil level is low, fill it until the oil is over-
flowing. It will take approximately 0.9 - 1.5 quarts of oil depending
on the model of generator.
If additional oil is need, SAE 10W-30 engine oil is recommended for
most general purpose applications. In cold weather climate, use SAE
5W-30.
Step 3.
Make sure there is fuel in the gasoline tank. Look at the fuel level indi-
cated by removing the fuel cap to inspect the contents of the fuel tank.
The fuel filter can also be inspected once the fuel cap is removed.
Ensure the fuel filter is clean of dirt and debris. Tightly secure the fuel
cap after your inspection is complete.
Fuel can damage paint and plastic. Be careful not to spill fuel when
filling your fuel tank. Damage caused by spilling fuel is not covered
under warranty. Use unleaded gasoline with a pump octane rating of
86 or higher. This engine is certified to operate on unleaded gasoline.
Unleaded gasoline produces fewer engine and spark plug deposits and
extends exhaust system life. Never use stale or contaminated gasoline
or an oil/gasoline mixture. Avoid getting dirt or water in the fuel tank.
WARNING
DO NOT overfill the tank. Leave a 1 inch air gap in the tank. Gasoline is highly flammable and explosive. You can be burned or seriously injured when refueling.
• Stop engine and keep heat, sparks, and flame away.
• Refuel only outdoors.
• Wipe up spills immediately.
This portable generator is not for use with gasoline/ethanol blends
with over 15% ethanol.
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
10 of 16 Rev. 5/2010
Page 11
Operating the Generator
Models: G5000S & G8000S
Step 4.
Set the fuel valve lever to the ON position by rotating it clockwise.
Step 5.
Pull the choke lever to the CLOSED position. See page 7 for a diagram
of the choke lever.
Step 6.
Turn the generator ON/OFF switch to the “ON” position.
Step 7.
Start the engine
1. If you have an electric starter, turn the switch to the START position, hold it there for 5 seconds and let it come to rest in the ON
position once the engine has started.
2. If you are using the recoil starter, pull slightly on the cord until you
feel some pressure. Once you feel the back-pressure building,
rapidly pull the cord.
Step 8.
Once the generator is running, push the choke lever into the OPEN position.
Step 9.
Let the generator warm up for approximately 3 minutes before applying
any electrical loads.
Step 10.
Apply loads to the generator one at a time, allowing the generator to
stabilize after you add each incremental load. Add the loads with the
largest surge power requirement first. This would include refrigerators,
air-conditioners, large motors, and pumps. Add smaller loads once the
generator has stabilized with the larger loads.
ALWAYS UNPLUG APPLIANCES AND REMOVE ALL ELECTRICAL
LOADS BEFORE REFUELING. THEN FOLLOW STEPS 2 - 10.
WARNING
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.
To determine maximum load that you may safely connect to this
generator:
1. Calculate the maximum continuous power required by adding up
the running power of each appliance. The total running power of
your appliances cannot exceed the maximum output power of this
generator.
2. Calculate the surge power by:
i) Adding up the running power of each appliance with an * and
in bold below.
ii) Multiplying the total by 1.5.
iii) Adding this to the total running power calculated in step 1
above.
The surge power requirements of your appliances cannot exceed
the surge power rating of this generator.
Typical Residential Loads
Appliance Running Power
Light bulbs (each) 75 Watts
Stove element (each) 1000 Watts
Microwave 1500 Watts
Coffee maker 700 Watts
Television 750 Watts
VCR 250 Watts
Computer & monitor 800 Watts
Space heater 1500 Watts
Washing machine 1000 Watts
NG clothes dryer 750 Watts
Electric clothes dryer 5500 Watts
Dishwasher 1850 Watts
Water heater 5000 Watts
Electric furnace 5000 Watts
Toaster 1200 Watts
Box fan* 750 Watts
Window A/C - 8000 BTU* 2400 Watts
Central A/C (per ton)* 2800 Watts
Furnace blower* 850 Watts
2 hp well pump* 2000 Watts
Refrigerator* 1000 Watts
Freezer* 1000 Watts
WARNING
Connecting a load larger than this generator’s power rating may damage the circuit breakers, alternator and sensitive appliances.
Continuously loading this generator above 80% of its maximum output
power will shorten the life of the generator.
Balance the load evenly between the A and B outlets to maximize the
output power.
Appliances with electric motors require an
additional
150%
power when they are starting up (indicated by an * and in bold in
the following chart ).
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
STOPPING THE GENERATOR
In an emergency:
To stop the engine in an emergency, move the engine switch to the
OFF position and turn the fuel valve OFF.
In normal use:
1. Turn the AC circuit breaker to the OFF position (if applicable).
2. Disconnect all loads and extension cords.
3. Allow the engine to run with no load for 3 minutes.
4. Turn the engine switch to the OFF position.
5. Turn the fuel valve lever to the OFF position.
6. Allow the generator to cool off before touching any engine or alternator components. It may take as long as 30 minutes before the
generator is cool enough to touch safely.
11 of 16 Rev. 5/2010
Page 12
Maintenance
Models: G5000S & G8000S
MAINTENANCE
The Importance of Maintenance
Good maintenance is essential for safe, economical, and trouble-free
operation. It will also help reduce air pollution.
To help you properly care for your generator, the following pages
include a maintenance schedule, routine inspection procedures, and
simple maintenance procedures using basic hand tools. Other service tasks that are more difficult, or require special tools, are best
handled by professionals and are normally performed by a STANLEY
technician or other qualified mechanic.
The maintenance schedule applies to normal operating conditions. If
you operate your generator under severe conditions, such as sustained high-load or high-temperature operation, or use it in unusually
wet or dusty conditions, consult your servicing dealer for recommendations applicable to your individual needs and use.
Maintenance, replacement, or repair of the emission control
devices and systems may be performed by any engine repair
establishment or individual, using parts that are ‘‘certified’’ to
EPA standards.
Maintenance Schedule
Item Before each
Engine oil (Check) X
Engine Oil (Change) X
Air Cleaner (Check) X
Air Cleaner Wash X
Fuel filter Cup (Clean) X
Spark Plug (Clean) X
Spark Plug (Change) X
Optional Spark Arrestor (Clean) X
Valve Clearance (Adjust) X*
Fuel Tank and Filter (Clean) X*
Fuel Tube (Check)
Combustion Chamber (Clean)
* Should be performed by an authorized STANLEY service center.
20hrs or
use
every 3
Every 2 yrs (replace if necessary)*
After every 250 hrs*
month
50 hrs or
every 3
months
100 hrs or
every 6
months
300 hrs or
every 1
year
Replacement Parts
The emission control systems on your STANLEY engine were designed,
built, and certified to conform with EPA and California emission regulations. We recommend the use of genuine STANLEY parts whenever
you have maintenance done. These original-design replacement parts
are manufactured to the same standards as the original parts, so you
can be confident of their performance. The use of replacement parts
that are not of the original design and quality may impair the effectiveness of your emission control system.
A manufacturer of an aftermarket part assumes the responsibility that
the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not
result in a failure of the engine to comply with emission regulations.
Engine Oil Change
Drain the oil while the engine is warm to assure rapid and complete
draining.
1. Remove the drain plug and sealing washer, remove the oil filler
cap, and drain the oil.
2. Reinstall the drain plug and sealing washer. Tighten the plug securely.
3. Refill with the recommended oil (SAE 10W-30 ) and check the oil
level.
Dispose of used motor oil in a manner that is compatible with the environment. Do not throw it in the trash, pour it on the ground, or down a
drain.
Air Cleaner Service
A dirty air cleaner will restrict air flow to the carburetor. To prevent
carburetor malfunction, service the air cleaner regularly. Service more
frequently when operating the generator in extremely dusty areas.
NOTICE:
Never run the generator without the air filter. Rapid engine wear will
result.
1. Unsnap the air cleaner cover clips, remove the air cleaner
cover, and remove the element.
2. Wash the air cleaner element in a solution of household detergent and warm water, then rinse thoroughly, or wash in
nonflammable or high flashpoint solvent. Allow the air cleaner
element to dry thoroughly.
3. Soak the air cleaner element in clean engine oil and squeeze
out the excess oil. The engine will smoke during initial startup
if too much oil is left in the air cleaner element.
4. Reinstall the air cleaner element and the cover.
Fuel Filter Cleaning
The fuel filter cup / screen prevents dirt which may be in the fuel
from entering the carburetor. The fuel filter should be inspected
and cleaned on a regular basis. For best results, clean the filter
with gasoline and a toothbrush or blow the debris out of the filter
with air pressure.
Spark Plug Service
In order to service the spark plug, you will need a spark plug
wrench. Recommended spark plugs: BPR5ES (NGK) and W16EPRU (DENSO). To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.
If the engine has been running, the muffler will be very hot. Be
careful not to touch the muffler.
1. Remove the spark plug cap.
2. Clean any dirt from around the spark plug base.
3. Use a spark plug wrench to remove the spark plug.
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
12 of 16 Rev. 5/2010
Page 13
4. Visually inspect the spark plug. Discard
it if the insulator is cracked, chipped or
fouled.
5. Measure the plug gap with a feeler
gauge. Correct as necessary by carefully bending the side electrode. The
gap should be: 0.028 to 0.031 in (0.70 to
0.80 mm)
Maintenance
TRANSPORTING
When transporting the generator, turn the engine switch and the fuel
valve OFF. Keep the generator level to prevent fuel spillage. Fuel vapor
or spilled fuel may ignite.
Take care not to drop or strike the generator when transporting. Do not
place heavy objects on the generator. When transporting the generator
by loading it on to a vehicle, secure to the generator frame as shown.
Models: G5000S & G8000S
6. Check that the spark plug washer is in good condition, and thread
the spark plug in by hand to prevent cross-threading.
7. After the spark plug is seated, tighten with a spark plug wrench to
compress the washer.
If installing a new spark plug, tighten 1/2 turn after the spark plug seats
to compress the washer. If reinstalling a used spark plug, tighten 1/8 to
1/4 turn after the spark plug seats to compress the washer.
NOTICE:
The spark plug must be securely tightened. An improperly tightened
spark plug can become very hot and could damage the engine. Use
only the recommended spark plugs or equivalent.
Optional Spark Arrestor Maintenance
If the generator has been running, the muffler will be very hot. Allow it
to cool before proceeding.
The spark arrester must be serviced
every 50 hours to keep it functioning as designed.
Clean the spark arrester as follows:
1. Loosen the screw by the exhaust port of the muffler 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.
SCREW
DANGER
Contact with a hot engine or
exhaust system can cause
serious burns or fires. Let the
engine cool before transporting or storing the generator.
STORING
Before storing the unit for an extended period:
1. Be sure the storage area is free of excessive humidity and dust.
2. Service according to the table below:
STORAGE TIME Recommended Service Procedure to prevent hard s tarting:
1 to 2 months Fill with fresh gasoline and add gasoline stabilizer*.
2 months to 1 year Fill with fresh gasoline and add gasoline stabilizer*.
Drain the carburetor float bowl.
1 year or longer
* Use gasoline stabilizers that are formulated to extend storage life. Contact your authorized STANLEY generator dealer
for conditioner recommendations.
Fill with fresh gasoline and add gasoline stabilizer*.
Drain the carburetor float bowl.
Remove the spark plug. Put a tablespoon of engine oil into the cylinder. Turn the engine
slowly with the recoil starter to distribute the oil. Reinstall the spark plug.
Change the engine oil.
After removal from storage, drain the stored gasoline into a suitable container, and fill with
fresh gasoline before starting.
SPARK ARRESTOR
Optional Starter Motor Fuse Replacement
If the fuse is blown, the starter motor won’t operate. Turn the engine
switch to the OFF position. Remove the fuse holder cover and replace
the fuse. The specified fuse is 10A.
NOTICE:
Never use a fuse with a
different rating from that
specified. Serious damage
to the electrical system or
fire may result.
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
Storage Preparation
1. Drain the carburetor by loosening the drain screw. Drain the gasoline into a suitable container. Place 4 ounces of fuel stabilizer in
the fuel tank.
2. Change the engine oil (page 10 ).
3. Remove the spark plug, and pour about a tablespoon of clean
engine oil into the cylinder. Turn the engine several revolutions
slowly with the recoil starter to distribute the oil, then reinstall the
spark plug.
4. Slowly pull the starter grip until resistance is felt. At this point, the
piston is coming up on its compression stroke and both the intake
and exhaust valves are closed. Storing the engine in this position
will help to protect it from internal corrosion.
WARNING
Gasoline is extremely flammable and is explosive under certain
conditions. Perform this task in a well-ventilated area with the
engine stopped. Do not smoke or allow flames or sparks in the
area during this procedure.
13 of 16 Rev. 5/2010
Page 14
Troubleshooting
Models: G5000S & G8000S
Symptom: Potential Causes Solution
Engine won't start Fuel valve off/out of fuel Fill tank with fuel and turn fuel valve on
Engine Switch in off position Turn engine switch to on position
Spark arrestor clogged Remove spark arrestor, clean and replace.
Choke is open
Close choke by pulling choke handle out.
Open choke after starting.
Oil level too low
Fill oil to top of opening with recommended
grade of oil.
Oil float stuck in shipment
Fill oil to top of opening, disconnect the yellow wire from the low oil level switch. The
switch is located on the engine above the
oil drain plug. It is a small gold colored box
with a yellow and a black wire.
Start the unit and run it for one hour minimum - this will get enough movement of hot
oil to free the float if this is the cause.
Re-attach the yellow wire and run the unit.
Fuel filter is dirty
Check for fuel flow to carburetor by removing drain screw. Clean or replace fuel filter.
Fuel is contaminated
Drain fuel tank and carburetor. Replace or
clean filter and carburetor float bowl. Fill
tank with clean fuel.
Spark plug boot off/loose Press spark plug boot firmly on spark plug.
Spark plug fouled or failed Remove spark plug, clean or replace
Carburetor clogged
Remove float bowl and clean components
and jets. Replace carburetor if varnish or
gum has accumulated from improper stor-
age.
Recoil is hard to pull Spark arrestor clogged Remove, clean and replace.
Engine flooded with fuel after storage with fuel
valve in on position
Remove spark plug and slowly pull recoil to
discharge excess fuel. Clean and re-install
spark plug.
Valve clearance too large
Rest exhaust valve clearance to .008", call
customer help line.
Engine starts, but then shuts off
Remove/Clean spark arrestor Remove, clean and replace.
after running for short time
Oil level too low
Fill oil to top of opening with recommended
grade of oil.
Engine runs: rough/vibrating/
Fuel valve off/out of fuel Fill tank with fuel and turn fuel valve on
Spark plug fouled or failed Remove spark plug, clean or replace
Remove/Clean spark arrestor Remove, clean and replace.
oscillating
The choke is not open Push choke lever in.
Over loading generator Disconnect some appliances
Air filter is dirty Clean air filter
Fuel filter is dirty
Check for fuel flow to carburetor by remov-
ing drain screw. Clean or replace fuel filter.
Fuel is contaminated
Drain fuel tank and carburetor. Replace or
clean filter and carburetor float bowl. Fill
tank with clean fuel.
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
14 of 16 Rev. 5/2010
Page 15
Troubleshooting
Models: G5000S & G8000S
Symptom: Potential Causes Solution
Engine runs, low speed, bogs
Remove/Clean spark arrestor Remove, clean and replace.
down under load or does not
maintain 60Hz
Choke is not open Push choke lever in
Over loading generator Disconnect some appliances / devices
Air filter is dirty Clean air filter
Fuel filter is clogged
Fuel filter is dirty
Fuel is contaminated
Engine oil leak Oil fill cap loose or cross threaded
Oil drain plug loose tighten both drain plugs
Debris under oil drain plug gasket
Loose crankcase bolt(s) Tighten crankcase bolts
Valve cover bolt loose Tighten bolt
Contaminates will clog filter, not allowing
fuel to get to engine
Check for fuel flow to carburetor by removing drain screw. Clean or replace fuel filter.
Drain fuel tank and carburetor. Replace or
clean filter and carburetor float bowl. Fill
tank with clean fuel.
Wipe all oil off unit, remove both oil fill caps,
inspect and replace. Tighten securely.
Remove drain plug and debris. Inspect gasket for damage and replace if damaged.
Fuel leak at tank shut-off Shut-off valve loose
Oil leaking from shaft Oil seals failed, call customer help line
Tighten nut on shut-off valve/replace shutoff valve
Fuel leaking out of carburetor Fuel drain screw loose Tighten fuel drain screw
Engine runs, Volt meter shows 0
Volts, no power to outlets
Engine runs and volt meter
Carburetor float seat not seating Flush with clean fuel
Breaker tripped
Disconnect all loads and turn breaker to off
and back to on to reset.
Disconnected or damaged wiring inside unit Call customer helpline
Faulty extension cord/power strip Use different power strip or extension cord
shows 240VAC but no power
goes to connected devices
Voltage too high/low Engine speed low or high
Breaker or GFCI trippedon extension cord or
power strip
Rest breaker and remove loads from power
strip
Verify frequency reading is 58Hz to 62Hz on
meter. Call customer helpline if frequency is
above 58Hz. See engine speed troubleshooting if engine speed is below 58Hz.
Alternator damaged Call customer helpline
Speed screw damaged or bent Call customer helpline
Voltage is 120 VAC on 1 phase
but too high/low on other phase
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
Alternator phase is damaged Call customer helpline
No part of this publication can be printed or copied without written permission.
15 of 16 Rev. 5/2010
Page 16
Limited Warranty & Service
Models: G5000S & G8000S
PRODUCTS COVERED BY THIS WARRANTY:
Engine 24 months / 200 hours 6 months / 200 hours 3 months / 200 hours
Battery 3 months 3 months 3 months
Alternator 24 months / 200 hours 6 months / 200 hours 3 months / 200 hours
Electrical and Frame Components 24 months / 200 hours 6 months /200 hours 3 months / 200 hours
Emission Controls 24 months 24 months 24 months
NONCOMMERCIAL/
NONRENTAL
(FROM THE DATE OF ORIGINAL RETAIL PURCHASE)
LENGTH OF WARRANTY:*
COMMERCIAL RENTAL
*LENGTH OF WARRANTY: All warranty coverage except emission controls expires when the operating hours exceed 200 hours.
TO QUALIFY FOR THIS WARRANTY:
The product must be purchased in the United States from a dealer authorized by GXi Outdoor Power, LLC to sell those products. This warranty applies to first retail
purchaser / owner during the applicable warranty time period. SAVE YOUR PROOF OF PURCHASE RECEIPT.
WHAT STANLEY POWER EQUIPMENT WILL REPAIR OR REPLACE UNDER WARRANTY:
STANLEY will repair or replace, at its option, any part that is proven to be defective in material or workmanship
under normal use during the applicable warranty
time period subject to the exclusions stated herein. This warranty is void if the owner fails to follow the prescribed maintenance and operating procedures described in this manual. This specifically refers to ensuring routine oil changes are made, that fuel stabilizer is used for long-term storage, that the generator is not
overloaded, and that the generator loads are distributed evenly between the A and B outlets. Dirty carburetors, spark plugs, air filters, fuel filters, and freight or
handling damage are not covered under warranty.
STANLEY has the right to recover warranty administration costs from the owner if the root cause of the malfunction was found to be other than defective material or
workmanship. In particular, this warranty does not cover: contaminants in the fuel or oil; damage caused by not following the prescribed warnings and operating
practices; failure to follow proper maintenance and storage procedures; and physical damage due to shipping or handling or storage. Damage to the generator that
occurs as a result of connecting a STANLEY generator to household wiring without the use of a UL approved transfer switch device that is connected to the home or
business and grounded as per applicable local electrical codes, is not covered by this warranty.
Warranty repairs will be made without charge for parts and labor for the first year. After the first year, this limited warranty covers the costs of replacement parts
only.
TO OBTAIN WARRANTY SERVICE:
You must take the STANLEY Power Equipment product, accessory, replacement part, apparel or the power equipment on which the accessory or replacement part is
installed, and proof of purchase, at your expense, to any STANLEY Power Equipment service location in the United States, who is authorized to service that product,
during the service location’s normal business hours. If you are unable to obtain warranty service, or are dissatisfied with the warranty service you receive, take the
following steps: First, contact the manager of the service center involved; normally this will resolve the problem. However, if you should require further assistance,
EXCLUSIONS:
THIS WARRANTY DOES NOT EXTEND TO PARTS AFFECTED OR DAMAGED BY ACCIDENT AND/OR COLLISION, NORMAL WEAR, FUEL CONTAMINATION, USE IN AN
APPLICATION FOR WHICH THE PRODUCT WAS NOT DESIGNED OR ANY OTHER MISUSE, NEGLECT, INCORPORATION OR USE OF UNSUITABLE ATTACHMENTS OR
PARTS, UNAUTHORIZED ALTERATION, OR ANY CAUSES OTHER THAN DEFECTS IN MATERIAL OR WORKMANSHIP OF THE PRODUCT. Consumable parts such as oil,
spark plugs, filters, carburetors, are not covered by this warranty.
DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIED WARRANTIES:
STANLEY DISCLAIMS ANY RESPONSIBILITY FOR LOSS OF TIME OR USE OF THE PRODUCT, TRANSPORTATION, COMMERCIAL LOSS, OR ANY OTHER INCIDENTAL
OR CONSEQUENTIAL DAMAGE. ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN LIMITED WARRANTY.
This warranty is void if the manufacturing date and the serial number on the equipment has been removed or the equipment has been modified.
EMISSION CONTROL SYSTEM INFORMATION
The U.S. and California Clean Air Acts
EPA and California regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. The
following instructions and procedures must be followed in order to keep the emissions from your STANLEY engine within the emission standards. Maintenance,
replacement, or repair of the emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are
‘‘certified’’ to EPA standards.
The emission control systems on your STANLEY engine were designed, built, and certified to conform with EPA regulations. We recommend the use of genuine
STANLEY parts whenever you have maintenance done. These original-design replacement parts are manufactured to the same standards as the original parts, so
you can be confident of their performance. The use of replacement parts that are not of the original design and quality may impair the effectiveness of your emission
control system. A manufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or
re-builder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.
Emission controls are covered by this warranty for all uses for a period of 2 years from original retail purchase date, this coverage extends to subsequent owners of
the product with proof of original purchase. For emissions warranty service call 1-800-393-0668 or e-mail customerservice@gxioutdoorpower.com .
STANLEY is a registered trademark of The Stanley Works or its affiliates and are used under license by GXi Outdoor Power LLC.
No part of this publication can be printed or copied without written permission.
16 of 16 Rev. 5/2010
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