Owners Manual

SAFETY ASSEMBLY OPERATION TROUBLESHOOTING WARRANTY

Portable Generator

GP Series
COMMERCIAL INDUSTRIAL RESIDENTIAL
AUTHORIZED DEALER SUPPORT: www.generac.com or 1-888-436-3722
MODELS: 005622-1, 005623-1, 005732-0, 005736-0
Table of Contents Portable Generator System

Owner's Manual

Introduction... 1 Read this Manual Thoroughly.. 1 Safety Rules... 2

Standards Index... 3

Seccin 3 Mantenimiento.. 25
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 Programacin de mantenimiento.. 25 Especificaciones del producto.. 25 Recomendaciones generales... 26 Servicio del filtro de aire... 27 Abertura de la vlvula.. 27 General... 27 Almacenaje por perodos largos... 27 Otros consejos tiles para el almacenaje.. 27 Gua para la solucin de problemas.. 28
Section 1 General Information... 4
1.1 1.2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 Unpacking.... 4 Assembly.... 4 Know the Generator.. 4 Hourmeter.... 5 Cord Sets and Connection Plugs.. 6 How to Use the Generator.. 6 Dont Overload the Generator.. 7 Wattage Reference Guide... 7 Before Starting the Generator.. 7 To Start the Engine... 8 Stopping the Engine.. 9 Low Oil Level Shutdown System... 9 Maintenance Schedule... 9 Product Specifications... 9 General Recommendations... 10 Service Air Filter... 11 Valve Clearance... 11 General... 11 Long Term Storage.. 11 Other Storage Tips.. 11 Troubleshooting Guide... 12
Seccin 4 Solucin de problemas.. 28 Seccin 5 Notas.. 29 Seccin 6 Garanta... 30

Section 2 Operation... 4

Guide du propritaire.. 31
Introduction... 33 Lire soigneusement ce manuel... 33 Consignes de scurit... 34

Rpertoire-type.... 35

Section 3 Maintenance... 9
1.1 1.2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1

Section 1 Gnralits... 36

Dballage... 36 Montage... 36 Connatre la gnratrice... 36 Horamtre... 37 Cordons lectriques et fiches de branchement.. 38 Mode d'emploi de la gnratrice... 38 Ne pas surcharger la gnratrice.. 39 Guide de rfrence de puissance.. 39 Avant la mise en route de la gnratrice.. 39 Dmarrage du moteur.. 40 Arrt du moteur.... 41 Systme d'arrt en cas de faible niveau d'huile.. 41 Calendrier d'entretien... 41 Spcifications de l'appareil.. 41 Recommandations gnrales... 42 Entretien du filtre air.. 43 Jeu de soupape.... 43 Gnralits... 43 Rangement long terme.. 43 Autres conseils sur le rangement.. 43 Guide de dpistage des pannes... 44
Section 2 Fonctionnement.. 36
Section 4 Troubleshooting... 12 Section 5 Notes... 13 Section 6 Warranty... 14
Manual del propietario.. 15
Introduccin.... 17 Lea este manual atentamente... 17 Reglas de seguridad... 18

ndice de normas... 19

Section 3 Entretien... 41
Seccin 1 Informacin general.. 20
1.1 1.2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 Cmo desempacar.. 20 Ensamblaje... 20 Conozca el generador.. 20 Contador horario... 21 Juegos de cables y enchufes de conexin.. 22 Cmo utilizar el generador... 22 No sobrecargue el generador.. 23 Gua de referencia del vataje... 23 Antes de arrancar el generador.. 23 Cmo arrancar el motor... 24 Cmo parar el motor... 25 Sistema de apagado por bajo nivel de aceite. 25
Seccin 2 Funcionamiento.. 20
Section 4 Dpannage... 44 Section 5 Remarques... 45 Section 6 Garantie..Couvercle arrire

INTRODUCTION

Thank you for purchasing this model of the GP Series portable generator by Generac Power Systems, Inc. This model is a compact, high performance, air-cooled, engine driven generator designed to supply electrical power to operate electrical loads on job sites, or remote locations where no utility power is available or in place of utility power due to a power outage.

DANGER

Using a generator indoors WILL KILL YOU IN a MINUTES. Exhaust contains carbon monoxide,
poison gas you cannot see or smell. in the home or in NEVER use as garages. ONLY partly enclosed areas such use outdoors and far from open windows, doors and vents.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Dealer for starting, operating and servicing procedures. Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

Using a generator indoors WILL KILL YOU IN MINUTES. Exhaust contains carbon monoxide, a poison gas you cannot see or smell.
After this heading, read instructions that, if not strictly complied with, will result in serious personal injury, including death and/or property damage.
NEVER use in the home or in partly enclosed areas such as garages. ONLY use outdoors and far from open windows, doors and vents.
wire and Always disconnect the spark plugcontact the place the wire where they cannot spark plug to prevent accidental starting when setting up, transporting, adjusting or making repairs to the generator. The generator produces dangerously high voltage that can cause extremely hazardous electrical shock. Avoid contact with bare wires, terminals, etc. Never permit any unqualified person to operate or service the generator. Never handle any kind of electrical cord or device while standing in water, while barefoot or while hands or feet are wet. Dangerous electrical shock will result. The National Electric Code requires the frame and external electrically conductive parts of the generator be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of the generator. Consult with a local electrician for grounding requirements in the area. Do not use worn, bare, frayed or otherwise damaged electrical cord sets with the generator. Operate generator only on level surfaces and where it will not be exposed to excessive moisture, dirt, dust or corrosive vapors. Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE. Do not permit smoking, open flames, sparks or heat in the vicinity while handling gasoline. Avoid spilling gasoline on a hot engine. Comply with all laws regulating storage and handling of gasoline. Allow generator and engine to cool entirely before adding fuel. Never add fuel while unit is running.
After this heading, read instructions that, if not strictly complied with, may result in serious personal injury and/or property damage.
After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property. NOTE: After this heading, read explanatory statements that require special emphasis. These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents. Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates is as follows:

or enclosure. NEVER operate the generator indoors, in an attached garage or near an open window.
Never start or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON. Start the engine and let it stabilize before connecting electrical loads. Disconnect all electrical loads before shutting down the generator. Do not insert objects through unit's cooling slots. Never operate generator: in rain; indoors or in any enclosed compartment; if connected electrical devices overheat; if electrical output is lost; if engine or generator sparks; if flames or smoke are observed while unit is running; if unit vibrates excessively. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

GENERAL HAZARDS

Never operate in an enclosed area or indoors. For safety reasons, the manufacturer recommends that the maintenance of this equipment is carried out by an Authorized Dealer. The engine exhaust fumes contain carbon monoxide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must be properly maintained. Do nothing that might render the exhaust system unsafe or in noncompliance with any local codes and/or standards. Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any fan guard while the unit is operating. Adequate, unobstructed flow of cooling and ventilating air is critical to correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator. The generator MUST be operated outdoors. When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued. Inspect the generator regularly, and contact the nearest Authorized Dealer for parts needing repair or replacement. Before performing any maintenance on the generator, disconnect its battery cables (if equipped) to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or () first. Reconnect that cable last. Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc. Do NOT operate generator in the rain.

WARNING:

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.
This product contains or emits chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all inclusive. If using a procedure, work method or operating technique that the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe.

ELECTRICAL HAZARDS

All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages as does the generator when it is in operation. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard. Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT. The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electrical system. In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a non-conducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help. Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

Remove all packaging material. Remove separate accessory box. Remove the generator from carton.

Figure 1 Wheel Assembly

1.1.1 ACCESSORY BOX
Check all contents. If any parts are missing or damaged locate an authorized dealer at 1-888-436-3722. Contents Include: 1 Owners Manual 1 - Left Handle Assembly 1 - Quart Oil SAE - Right Handle Assembly 2 - Never-Flat Wheels 1 - Frame Foot 1 - Foot Support 1 - Hardware Bag (containing the following): 2 - Rubber Feet 2 - 5/16 Bolts 2 - 5/16 Flat Washers 4 - 5/16 Locking Flange Nuts 4 - 5/16 Carriage Bolts 2 - 5/16 Locking Cap Nuts 2 - 1/2 Axle Bolts 2 - 1/2 Locking Flange Nuts 2 - 1/2" Flat Washers

FOOT FOOT SUPPORT

Figure 2 Install Handle Kit

1.2 ASSEMBLY

The generator requires some assembly prior to using it. If problems arise when assembling the generator, please call the Generator Helpline at 1-888-436-3722.
1.2.1 ASSEMBLING THE ACCESSORY KIT
The wheels are designed into the unit to greatly improve the portability of the generator. NOTE: The wheels are not intended for over-the-road use. 1. Refer to Figure 1 and install Wheels as follows: Slide the 1/2 Axle Bolt through the 1/2" Flat Washer, the Wheel and Wheel bracket on frame. Install 1/2 Locking Flange Nuts onto 1/2 Flange Bolt. 2. Refer to Figure 1 and install Frame Foot, Foot Support, and Rubber Feet as shown. Slide Rubber Bumper stud through the Foot Support and Frame Foot. Install the 5/16" Locking Flange Nuts. Slide 5/16 Bolt through 5/16 Flat Washer and then through holes in Frame Rail. Slide Frame Foot onto 5/16 Bolts; Install 5/16 Locking Flange Nuts. 3. Refer to Figure 2 and install Handles as shown. Remove top Curved Head Bolts and Cap Nuts (Cap Nuts will be re-used). Slide Handle Assembly over Frame Tube, aligning 2 holes. Slide 5/16 Carriage Bolts through; Install 5/16 Cap Nuts.

2.1 KNOW THE GENERATOR

Read the Owners Manual and Safety Rules before operating this generator. Compare the generator to Figures 3 through 5 to become familiarized with the locations of various controls and adjustments. Save this manual for future reference. 1. 120 Volt AC, 20 Amp, Duplex Receptacle Supplies electrical power for the operation of 120 Volt AC, 20 Amp, single-phase, 60 Hz electrical lighting, appliance, tool and motor loads. 2. 120/240 Volt AC, 30 Amp Locking Receptacle Supplies electrical power for the operation of 120 and/or 240 Volt AC, 30 Amp, single-phase, 60 Hz, electrical lighting, appliance, tool and motor loads. 3. Circuit Breakers (AC) Each receptacle is provided with a push-to-reset circuit breaker to protect the generator against electrical overload.

Section 2 Operation Portable Generator System

Figure 3 - Control Panel

Figure 5 - Generator Controls
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Hourmeter Tracks hours of operation. Air Filter Filters intake air as it is drawn into the engine. Choke Knob Used when starting a cold engine. Fuel Tank Tank holds 6.6 U.S. gallons of fuel. Grounding Lug Ground the generator to an approved earth ground here. See "Grounding the Generator" for details. Run/Stop Switch Controls the operation of the generator. Muffler Quiets the engine. Handles Pivot and retract for storage. Press the spring-loaded button to move handles. Gas Cap Fuel fill location. Fuel Gauge Shows fuel level in tank. Oil Fill Add oil here. Recoil Starter Use to start engine manually. Fuel Shut Off Valve between fuel tank and carburetor. Oil Drain Use to drain engine oil.

2.2 HOURMETER

The Hourmeter tracks hours of operation for scheduled maintenance: There will be a "CHG OIL" message every 100 hours. The message will flash one hour before and one hour after each 100 hour interval, providing a two hour window to perform service. This message will actually begin flashing at 99 hours and disable itself at 101 hours again, providing a two hour window to perform the service. Every 200 hours the "SVC" icon on the lower left hand corner of the display will flash. The message will flash one hour before and one hour after each 200 hour interval providing a two hour window to perform service. When the hour meter is in the Flash Alert mode, the maintenance message will always alternate with elapsed time in hours and tenths. The hours will flash four times, then alternate with the maintenance message four times until the meter resets itself. 100 hours - CHG OIL Oil Change Interval (Every 100 hrs) 200 hours - SVC Air Filter Interval (Every 200 hrs)
Figure 4 - Generator Controls
2.3 CORD SETS AND CONNECTION PLUGS
2.3.VAC, 20 AMP, DUPLEX RECEPTACLE
This is a 120 Volt outlet protected against overload by a 20 Amp push-to-reset circuit breaker (Figure 6). Use each socket to power 120 Volt AC, single phase, 60 Hz electrical loads requiring up to a combined 2400 watts (2.4 kW) or 20 Amps of current. Use only high quality, well-insulated, 3-wire grounded cord sets rated for 125 Volts at 20 Amps (or greater). Keep extension cords as short as possible, preferably less than 15 feet long, to prevent voltage drop and possible overheating of wires.

IMPORTANT: It is important to prevent gum deposits from forming in fuel system parts such as the carburetor, fuel hose or tank during storage. Alcohol-blended fuels (called gasohol, ethanol or methanol) can attract moisture, which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. See the "Storage" section. Never use engine or carburetor cleaner products in the fuel tank as permanent damage may occur.

2.8 TO START THE ENGINE

Never start or stop engine with electrical devices plugged into the receptacles AND
devices turned on. Unplug all electrical loads from the unit's receptacles before starting the engine. Make sure the unit is in a level position. OPEN the Fuel Shut-off Valve (Figures 10 and 11).

2.7.2 ADDING GASOLINE

Never fill fuel tank indoors. Avoid spilling gasoline on hot engine. Allow engine/unit to cool entirely before adding fuel. Never fill fuel tank when engine is running or hot. DO NOT light a cigarette or smoke when filling the fuel tank. Gasoline is highly flammable and its vapors are explosive.
Figure 10 - Fuel Shut-off Valve
Do not overfill the fuel tank. Always leave room for fuel expansion. If the fuel tank is over-filled, fuel can over flow onto hot engine and cause an explosion. Use regular UNLEADED gasoline with the generator engine. Do not use any gasoline with more than 10% added ethanol. Do not use E85 gasoline. Do not mix oil with gasoline. Clean area around fuel fill cap, remove cap. Slowly add unleaded regular gasoline to fuel tank. Fill to bottom of screen filter. Be careful not to overfill (Figure 9). Install fuel cap and wipe up any spilled gasoline.
Figure 11 - Fuel Shut-off Decal

Figure 9 - Fuel Tank

Fuel Tank

DO NOT Fill Above Lip

Section 3 Maintenance Portable Generator System
Turn engine RUN/STOP switch to ON position (Figure 12). Pull engine CHOKE knob outward to FULL CHOKE position (Figure 12). To start engine, firmly grasp the recoil handle and pull slowly until increased resistance is felt. Pull rapidly up and away. When engine starts, move choke knob to 1/2-CHOKE position until engine runs smoothly and then fully into RUN position. If engine falters, move choke back out to 1/2-CHOKE position until engine runs smoothly and then to RUN position. NOTE: If engine fires, but does not continue to run, move choke lever to FULL CHOKE and repeat starting instructions.
2.10.1 SENSING LOW OIL LEVEL
If the system senses a low oil level during operation, the engine shuts down. The engine will not run until the oil has been refilled to the proper level.

3.1 MAINTENANCE SCHEDULE

Follow the calendar intervals. More frequent service is required when operating in adverse conditions noted below. Check Oil Level Change Oil Check Valve Clearance Service Air Filter Replace Spark Plug At Each Use *Every 100 hours or Every Season ***Every Season ** Every 200 hours or Every Season Every Season

Figure 12 - Choke Position
Change oil after first 30 hours of operation then every season. * Change oil and oil filter every month when operating under heavy load or in high temperatures. ** Clean more often under dirty or dusty operating conditions. Replace air filter parts if they cannot be adequately cleaned. *** Check valve clearance and adjust if necessary after first 50 hours of operation and every 100 hours thereafter.
3.2 PRODUCT SPECIFICATIONS
3.2.1 GENERATOR SPECIFICATIONS
Rated. Power.. 5.0/5.5/6.5 kW** Surge Power.. 6.25/6.88/8.0 kW Rated AC Voltage... 120/240 Rated AC Load Current @ 240V (5.0/5.5/6.5 kW).. 20.8/22.9/27.1 Amps** Current @ 120V (5.0/5.5/6.5 kW).. 41.6/45.8/54.2 Amps** Rated Frequency.. 60 Hz @ 3600 RPM Phase... Single Phase
** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambient temperature, altitude, engine condition, etc. Maximum power decreases about 3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 6 C (10 F) above 16 C (60 F) ambient temperature.
IMPORTANT: Do not overload the generator. Also, do not overload individual panel receptacles. These outlets are protected against overload with push-to-reset-type circuit breakers. If amperage rating of any circuit breaker is exceeded, that breaker opens and electrical output to that receptacle is lost. Read Dont Overload the Generator carefully.

2.9 STOPPING THE ENGINE

Shut off all loads, then unplug the electrical loads from generator panel receptacles. Never start or stop the engine with electrical devices plugged in and turned on. Let engine run at no-load for several minutes to stabilize the internal temperatures of engine and generator. Move Run/Stop switch to OFF position. Close fuel valve.
3.2.2 ENGINE SPECIFICATIONS
Displacement...389 cc Spark Plug Type.NHSP F7RTC or Champion RN9YC Spark Plug Gap.. 0.028-0.031 inch or (0.70-0.80 mm) Gasoline Capacity... 6.6 U.S. gallons Oil Type..See Chart in "Before Starting the Generator" Section Oil Capacity... 1.1 L (1.16 Qts.) Run Time at 50% Load (5.0/5.5/6.5 kW)..10/10/9 Hours Class II Emission Certified* * The engine manufacturer must warrant the emission control system for a period of two years. This warranty coverage is in addition to the warranty provided by Generac, and may cover the engine even if Generacs warranty does not.

2.10 LOW OIL LEVEL SHUTDOWN SYSTEM
The engine is equipped with a low oil level sensor that shuts down the engine automatically when the oil level drops below a specified level. If the engine shuts down by itself and the fuel tank has enough gasoline, check engine oil level.
3.3 GENERAL RECOMMENDATIONS
The warranty of the generator does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain the generator as instructed in this manual. Some adjustments will need to be made periodically to properly maintain the generator. All adjustments in the Maintenance section of this manual should be made at least once each season. Follow the requirements in the "Maintenance Schedule". NOTE: Once a year replace the spark plug and replace the air filter. A new spark plug and clean air filter assure proper fuel-air mixture and help the engine run better and last longer.

3.3.4 CHECKING OIL LEVEL

See the Before Starting the Generator section for information on checking the oil level. The oil level should be checked before each use, or at least every eight hours of operation. Keep the oil level maintained.

3.3.5 CHANGING THE OIL

Change the oil after every 100 hours. If running this unit under dirty or dusty conditions, or in extremely hot weather, change the oil more often.
may cause Hot oil draining oil.burns. Allow engine to cool before Avoid prolonged or repeated skin exposure with used oil. Thoroughly wash exposed areas with soap. NOTE: Whenever possible, run engine for approximately five (5) minutes to get the engine oil hot. This will aid in draining the oil. Use the following instructions to change the oil while the engine is still warm: Clean area around oil drain plug. Remove oil drain plug from engine and oil fill plug to drain oil completely into a suitable container. When oil has completely drained, install oil drain plug and tighten securely. Fill oil sump with recommended oil. (See Before Starting the Generator for oil recommendations). Wipe up any spilled oil. Dispose of used oil at a proper collection center.

3.3.1 GENERATOR MAINTENANCE
Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture or any corrosive vapors. Cooling air slots in the generator must not become clogged with snow, leaves, or any other foreign material. Check the cleanliness of the generator frequently and clean when dust, dirt, oil, moisture or other foreign substances are visible on its exterior surface.
the air Never insert any object or tool throughrunning. cooling slots, even if the engine is not NOTE: DO NOT use a garden hose to clean generator. Water can enter the engine fuel system and cause problems. In addition, if water enters the generator through cooling air slots, some water will be retained in voids and crevices of the rotor and stator winding insulation. Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.
3.3.6 REPLACING THE SPARK PLUG
Use Champion RN9YC spark plug or equivalent. Replace the plug once each year. This will help the engine start easier and run better. 1. Stop the engine and pull the spark plug wire off of the spark plug. 2. Clean the area around the spark plug and remove it from the cylinder head. 3. Set the spark plug's gap to 0.70-0.80 mm (0.028-0.031 in.). Install the correctly gapped spark plug into the cylinder head (Figure 13).
3.3.2 TO CLEAN THE GENERATOR
Use a damp cloth to wipe exterior surfaces clean. A soft, bristle brush may be used to loosen caked on dirt, oil, etc. A vacuum cleaner may be used to pick up loose dirt and debris. Low pressure air (not to exceed 25 psi) may be used to blow away dirt. Inspect cooling air slots and openings on the generator. These openings must be kept clean and unobstructed.
Figure 13 - Spark Plug Gap

3.3.3 ENGINE MAINTENANCE

generator, always When working on thecable from battery. Also disconnect negative disconnect spark plug wires from spark plug and keep wire away from spark plug.

3.4 SERVICE AIR FILTER

The engine will not run properly and may be damaged if using a dirty air filter. Clean the air filter every 200 hours or once a year (Figure 14). Clean or replace more often if operating under dusty conditions. Remove air filter cover. Wash in soapy water. Squeeze filter dry in clean cloth (DO NOT TWIST). Clean air filter cover before re-installing it. NOTE: To order a new air filter, please contact the nearest authorized service center at 1-888-436-3722.

3.7 LONG TERM STORAGE

It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor, fuel hose or tank during storage. Also, experience indicates that alcohol-blended fuels (called gasohol, ethanol or methanol) can attract moisture, which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer, as follows: Remove all gasoline from the fuel tank.

the generator NEVER coverare warm. while engine and exhaust area
Section 4 Troubleshooting Portable Generator System
4.1 TROUBLESHOOTING GUIDE

PROBLEM

Engine is running, but no AC output is available.
1. 2. 3. 4. 1. 2. 3. 4. Circuit breaker is open. Poor connection or defective cord set. Connected device is bad. Fault in generator. Short circuit in a connected load. Generator is overloaded. Engine speed is too slow. Shorted generator circuit.

CORRECTION

1. 2. 3. 4. 1. 2. 3. 4. Reset circuit breaker. Check and repair. Connect another device that is in good condition. Contact Authorized Service Facility. Disconnect shorted electrical load. See Dont Overload the Generator. Contact Authorized Service Facility. Contact Authorized Service Facility.
Engine runs good but bogs down when loads are connected.
Engine will not start; or starts and runs rough.
1. Fuel Shut-off is OFF. 2. Dirty air filter. 3. Out of gasoline. 4. Stale gasoline. 5. Spark plug wire not connected to spark plug. 6. Bad spark plug. 7. Water in gasoline. 8. Overchoking. 9. Low oil level. 10. Excessive rich fuel mixture. 11. Intake valve stuck open or closed. 12. Engine has lost compression. 1. Out of gasoline. 2. Low oil level. 3. Fault in engine. 1. Load is too high. 2. Dirty air filter. 3. Engine needs to be serviced. 1. Choke is opened too soon. 2. Carburetor is running too rich or too lean.
1. Turn Fuel Shut-off ON. 2. Clean or replace air filter. 3. Fill fuel tank. 4. Drain fuel tank and fill with fresh fuel. 5. Connect wire to spark plug. 6. Replace spark plug. 7. Drain fuel tank; fill with fresh fuel. 8. Put choke knob to No Choke position. 9. Fill crankcase to proper level. 10. Contact Authorized Service Facility. 11. Contact Authorized Service Facility. 12. Contact Authorized Service Facility. 1. Fill fuel tank. 2. Fill crankcase to proper level. 3. Contact Authorized Service Facility. 1. Reduce load (see Dont Overload the Generator). 2. Clean or replace air filter. 3. Contact Authorized Service Facility. 1. Move choke to halfway position until engine runs smoothly. 2. Contact Authorized Service Facility.
Engine shuts down during operation.

Engine lacks power.

Engine hunts or falters.

Section 5 Notes

Section 6 Warranty Portable Generator System
GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR GP SERIES PORTABLE GENERATORS
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its GP Series generators will be free from defects in materials and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac GP Series portable generators and is not transferable from original purchaser. Save your proof-of-purchase receipt. If you do not provide proof of the initial purchase date, the manufacturers shipping date of the product will be used to determine the warranty period.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. GENERACS ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERACS NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. This warranty gives you specific legal rights. You also have other rights from state to state.
GENERAC POWER SYSTEMS, INC. P.O. BOX 8 Waukesha, WI 53187 Ph: (888) GENERAC (436-3722) Fax: (262) 544-4851 To locate the nearest Authorized Dealer visit our website www.generac.com
Part No. 0G9451 Revision D (10/27/08) Printed in U.S.A.

Manual Part No. 0H1023

Rev. B (12/23/08)

Printed in U.S.A.