Generac 15113410300 Portable Generator Owner's Manual

Owner's Manual

Generator

Wheel kit

Storage

Cover

Battery

charge cables

Spare Spark

Plug,Air Filter, and Oil

Filter

Spark PlugWrench

(2) Locking30 Amp plugs

Engineoil

Owner's manual

Engine manual

If any parts are missing or damaged, call

1-800-270-1408.

Safety Rules....................................

Assembly......................................

Know Your Generator .............................

Operation ....................................

Product Specifications.............................

Maintenance ....................................

Storage........................................

Troubleshooting .................................

Schematic ......................................

Wiring Diagram .................................

Replacement Parts.............................

Warranty .................................

Questions?

Help is just a moment away!

Call: Generac Generator

Helpline - 1-800-270-1408

M-F 8-5 CT

Web: www.generac-portables.com or www.briggsandstratton.com

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Last Page

EQUIPMENT

DESCRIPTION

This generator is an engine-driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliances,tools and motor loads.

This manual contains information for a generator that operates 120 and/or 240 Volt, single phase,60 Hz devices that require up to 6,500 watts (6.5 kW) of power that pull up to 54.2 Amps at 120Volts or 27.1 Amps at 240Volts.

CAUTION!

Do Not exceed the generator's wattage/amperage capacity.Add up the rated watts of all devices you are connecting to generator receptacles at one time.This total should not be greater than 6,500 watts. See

"Don't Overload the Generator" on page I I.

The generator's revolving field is driven at about 3,600 rpm by a single-cylinder engine.

Every effort has been made to ensure that informationin this manual is accurate and current However, Generac reserves the right to change,alter or otherwise improve the product and this document at any time without prior notice.

SAFETY RULES

This generator set was designed and manufactured for specific applications. Do Not attempt to modify the unit or use it for any application it was not designed for. If you have any questions about your generator's application, ask your dealer or consult the factory.

The manufacturer could not possibly anticipate every circumstance that might involvea hazard. For that reason warnings in the manual and warnings on tags or decals affixed to the unit are not all-inclusive. If you intend to handle, operate or service the unit by a procedure or method not specifically recommended by the manufacturer, first make sure that such a procedure or method will not render this equipment unsafe or pose a threat to you and others.

Read this manual

carefully and become familiar

with your generator

set. Know its applications, its limitations and any hazards involved.

or other re

_ Do Not tamper with engine dangerous and increaserisk of personal injuryor damageto equipment.The generator supplies correct rated frequency and voltage only when running at proper governed speed. Incorrect frequency and/or voltage can damagesome connected electrical loads. Operating at excessively

low speeds imposesa heavy load.When adequate engine power is not availableengine life may be shortened.

The Emission Control System for this generator is warranted for standards set by the Environmental

Protection Agency.For warranty informationrefer to the engine owner's manual.

_

_

ARNING!

You must isolatethe generator equipment if this unit is used for backup power.

Failure to isolate the generator from the

power utility may result in injury or death to electric utility workers and damage to the

generator

due to a backfeed of electrical energy.

Whenever the unit is providing backup power, the electric utility must be notified.

DANGER!

Generator

exhaust

gases contain in sumcient concentrations, carbon

monoxide

can cause unconsciousness or death.

Operate this equipment outdoors where adequate ventilation is available.

• The generator produces a very powerful voltage that can cause serious injury or death by electrocution. Never touch bare wires or receptacles. Never permit a child or any unqualified person to operate the generator.

• Never handle any kind of electrical cord or device while standing in water, while barefoot or while hands or feet are wet Death or serious injury from electrocution may result.

• Use a ground fault circuit interrupter (GFCI) in any damp or highly conductive area (such as metal decking or steel work).

• Never use worn, bare,frayed or otherwise damaged electrical cords with the generator. Death, serious injury and property damagefrom electrical shock may result

• Gasoline is highly FLAMMABLE

and its vapors are

EXPLOSIVE.

Never allow 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.

• Do Not overfitl the fuel tank.Always allow room for fuel expansion. If tank is overfllled, fuel can overflow

onto a hot engine and cause a FIRE or an

EXPLOSION.

• Never store a generator with fuel in the tank where gasoline vapors might reach an open flame, spark or pilot light (as on a furnace, water heater, clothes dryer). FIRE or an EXPLOSION may result.

• The unit requires an adequate flow of cooling air for its continued proper operation. Never operate the unit inside any room or enclosure where the free flow of cooling air into and out of the unit might be obstructed.

Allow at least2 feet of clearance on all sides of generator, even while operating unit outdoors, or you could damage the unit

• Never start, or stop the unit with electrical loads connected to receptacles with the connected devices turned ON. Start the engine and let it stabilize before connecting any electrical loads. Disconnect all electrical loads before shutting down the generator.

• Do Not insert any object through cooling slots of the engine.Youcould damagethe unit or injure yourself.

• Never

operate the generator:

in rain; in any enclosed compartment;

when connected

electrical devices overheat; if electrical output

is lost; if

engine or generator sparks; if flame or smoke is observed while unit is running; if unit vibrates excessively.

GROUNDING THE

G EN ERATO R

The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground. Local electrical codes may also require proper grounding of the unit. For that purpose, a GROUNDING WING NUT is provided on the generator end (Figure I).

Generally, connecting a No. 12 AWG (American Wire

Gauge) stranded copper wire to the grounding wing nut and to an earth-driven copper or brass grounding rod

(electrode) provides adequate protection against electrical shock. Be careful to keep the grounding wire attached after connecting the stranded copper wire. However, locat codes may vary widely. Consult with a local electrician for grounding requirements in your area.

Properly grounding the generator helps prevent electrical shock if a ground fault condition exists in the generator or

in connected electrical devices. Proper grounding also helps dissipate static electricity, which often builds up in ungrounded devices.

useafterit hasbeenproperlyserviced oilandfuel.

If you have any problems

with

the assembly of your generator, please call the generator helpline at

1-800-270-1408.

IMPORTANT:

Any attempt to run the unit before it has been serviced with the recommended oil wilt result in an engine failure.

REMOVE G EN ERATOR

FROM CARTON

• Set the carton on a rigid flat surface with "This Side Up" arrows pointing upward.

• Carefully open the top flaps of the shipping carton.

Review"Cold Weather Operation" on page 9.

• Cut down corners at one end of carton from top to bottom and lay that side of carton down flat.

• Remove all packing material, carton fillers, etc.

• Remove the generator from the shipping carton.

INSTALL WHEEL KIT

The wheel kit is designed to greatly improve the portability of your generator.

NOTE:Wheel

kit is not intendedfor over-the-road use.

You will need a socket wrench with I/2" or 13mm sockets and a needle-nose plier to installthis kit.

Refer to Figure 2 and install the wheel kit as follows:

• Placethe generator on a hard flat surface.

• Stand at the engine end of the generator and gently tilt the generator forward, high enough to place wooden blocks beneath the cradle.This will allow you to add the wheels.

• Slide the axle through the holes in the brackets provided on the generator cradle.

• Slide one wheel and flat washer on each end of the axle.

Make sure the air inflation valve isoutward. Insert both retaining pins using the needle-nose plier. Remove the wooden blocks.

• Attach the vibration mounts to the support leg with

30mm capscrews, washers and lock nuts.

®

Lock

Axle

Capscrew

_20mm

Capscrew

Lock Nut

Retaining Pin

Wheel

Washer

_

andattach locknuts.

thesupportlegwith20mmcapscrews

• Use regular UNLEADED gasoline with the generator

engine. Do Not

use premium gasoline. Do Not mix oil with gasoline.

• Clean area around fuel fill cap, remove cap.

• Slowly add unleaded regular gasoline to fuel tank. Be careful not to overfill.Allow

about I/2" of tank space for fuel expansion (Figure 3).

BEFORE STARTING THE

ENGINE

Add

Oil

CAUTION!

Any attempt to crank or start the engine before it has been properly filled with the recommended oil may result in an engine failure.

To fill your engine with oil:

• Placegenerator on a level surface.

• Followthe oil grade recommendations and oil fill

instructionsgiven in the engine owner's manual.

NOTE: The generator's revolving field rides on a prelubricated and sealed ball bearing that requires no additional lubricationfor the life of the bearing.

Add

_

Gasoline

Never

fill fuel tank indoors. Never

unit to cool for two minutes before refueling. Do

Not

light a cigarette or smoke when filling the fuel

tank.

1/2" Air

Tank

• Install fuel cap and wipe up any spilled gasoline.

IMPORTANT: It is important to prevent gum deposits from forming in essential fuel system parts, such as the carburetor, fuel filter, 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 fuel can damage the fuel system of an engine while

in storage.

To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. See "Storage" on page 12. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur.

Do Not overfill the fuel tank.

KNOWYOUR GENERATOR

Read this owner's manual

and safety rules

before operating your generator.

Compare the illustrations with your generator, to familiarize yourself with the locations of various controls and adjustments.

Save this manual for future reference.

FuelTank

Oit Fill Cap

Circuit Breakers

(AC)__,,_

Choke Lever

120 Volt AC, 30 A

Receptacle

Run/Stop Switch

120/240Volt AC,

30 Amp Receptacle

12Volt DC, 10Amp

Receptacle

Air Cleaner

Spark Arrester Muffler

Idle Control Switch GroundingWing Nut

12 Volt DC, I 0 Amp Receptacle -- Recharge a discharged 12Volt automotive type battery through this receptacle.

120 Volt AC, 20 Amp, Duplex Receptacle -- May be

used to supply electrical power for the operation of

120Volt AC, 20 Amp, single phase,60 Hz electrical lighting, appliance,toot and motor loads.

120 Volt AC, 30 Amp Locking Receptacle -- May be

used to supply electrical power for the operation of

120Volt AC, 30 Amp, single phase,60 Hz electrical lighting, appliance,toot and motor loads.

120/240 Volt AC, 30 Amp Locking Receptacle -- May be used to supply 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.

Air Cleaner -- Uses a dry type filter element and foam pre-cleaner to limit the amount of dirt and dust sucked

into the engine.

Choke Lever -- Used when starting a cold engine.

120Volt AC, 20 Amp

Duplex Receptacle

Circuit Breakers (AC) -- Each receptacle is provided with a "push to reset" circuit breaker to protect the generator against electrical overload.

Fuel Tank -- Capacity of seven (7) U.S.gallons.

GroundingWing Nut--

Used for proper grounding of unit.

Idle Control Switch --With this switch set to ON, printed circuit board in control panel automatically reduces engine speed when no toad is connected and increases engine to proper speed when load is applied. However, be sure switch is OFF when starting engine.

Oil Fill Cap --Add oit to engine here.

Recoil starter -- Used to start the engine.

Run/Stop Switch -- Set this switch to "Run" before using recoil starter. Set switch to "Stop" to switch OFF engine.

Spark Arrester Muffler-

Exhaust muffler lowers engine noise and is equipped with a spark arrester screen.

OPERATING THE

GENERATOR

|

4.

Placethe choke lever in the "Full" choke position

(Figure7).

_ Never start or stop unit with devices turned ON.

Starting the Engine

Disconnect all electrical loads from the generator. Follow these start instructionsteps in numerical order:

I.

Turn the fuel valveto the "On" position (Figure 4).

2.

Make sure the Idle Control switch is in "Off' position

(Figure 5).

IDLE

3.

Set the Run/Stop switch to "Run" position (Figure 6).

5.

Grasp the recoil handle and pull slowly until slight resistance is felt.Then pull rapidly one time only to start engine.

• If engine starts,proceed to step 7.

•

If

engine fails to start, proceed to step 6.

6.

Move the choke lever to "Half" choke position, and pull recoil handle twice.

• If engine fails to start, repeat steps 4 thru 6.

7.

Move choke lever to "Run" position. If engine falters, move choke lever to "Half" choke position until the engine runs smoothly and then to "Run" position.

NOTE: If engine still fails to start after 3 pulls, check for proper oil level in crankcase.This unit is equipped with a

Low Oil Shutdown System.See engine manual.

Refer

to the engine

owner's manual for complete starting instructions.

Connecting Electrical Loads

• Let engine stabilize and warm up for a few minutes after starting.

• Plug in and turn on the desired 120 and/or 240 VottAC, single phase,60 Hz electrical loads.

• Do Not connect 240Volt loads to the 120Volt receptacles.

• Do Not connect 3-phase loads to the generator.

• Do Not connect 50 Hz loads to the generator.

• DO NOT OVERLOADTHE

GENERATOR.

See

"Don't Overload the Generator" on page I I.

Stopping the Engine

• Unplug all electrical loads from generator panel receptacles.Never start or stop engine with electrical devices plugged in and turned on.

• Put the idle control switch in the "Off' position.

• Let engine run at no-load for 30 seconds to stabilize the

internal temperatures of engine and alternator.

• Move run/stop switch to "Stop".

• Close the fuel shut-off valve.

Operating

Automatic Idle Control

This switch is designed to greatly improve fuel economy.

When this switch is turned ON, the engine will only run at its normal high governed engine speed when an electrical load is connected.When an electrical load is removed, the engine will run at a reduced speed. With

the

switch off, the engine will run at the normal high engine speed. Always have the switch off when starting and

stopping the engine.

Charging a Battery

Your generator has the capability of recharging a discharged

12Volt automotive or utility style storage battery. Do Not use the unit to charge any 6Volt batteries. Do Not use the unit to crank an engine having a discharged battery.

To recharge 12 Volt batteries, proceed as follows:

• Check fluid level in all battery cells.If necessary,add

ONLY distilled water to cover separators in battery cells.

Do Not use tap water.

• If the battery isequipped with vent caps,make sure they are installedand are tight.

• If necessary,clean battery terminals.

• Connect battery charge cable connector plug to panel receptacle identifiedby the words "12-VOLTS D.C".

• Connect battery charge cable clamp with red handle to the positive (+) battery terminal (Figure 8).

12 VOLT D.C.

RECEPTACLE

_

ARNING!

Storage batteries give off explosive will remain around the battery for a long time after it has been charged.The slightest spark can ignite the hydrogen and cause an explosion, resulting in blindness or other serious injury.

_hl Do Not permit smoking, open battery.Wear protective goggles,rubber apron and rubber gloves when working around a battery.

Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. If spill occurs flush area with clear water immediately.

÷

POS NEG

12 VOLT BA'rrERY

• Connect battery chargecable clamp with black handle to the negative (-) battery terminal (Figure 8).

• Start engine. Let the engine run while battery recharges.

• When battery has charged, shut down engine

NOTE: Use an automotive hydrometer to test battery state of charge and condition. Follow the hydrometer manufacturer's instructions carefully. Generally, a battery is considered to be at 100%state of charge when specific gravity of its fluid (as measured by hydrometer) is 1.260or

higher.

I:|

COLD WEATH ER

OPERATION

Under certain weather conditions (temperatures below

40°F [4°C] and a high dew point),your generator may experience icingof the carburetor and/or the crankcase breather system.

In an emergency, use the original shipping box as a temporary shelter:

• Cut off all flaps.

• Cut out one of the long sides of the box to expose exhaust side of unit. Ensure a minimum of two feet clearance between open side of box and nearest object.

• Cut appropriate slots to access receptacles of unit.

• Start unit, then place box over it.

IMPORTANT: Remove shelter when temperature is above 40°F [4°C].

For a more permanent shelter, build a structure that will enclose three sides and the top of the generator:

• Make sure entire muffler-side of generator is exposed.

Note that your generator may appear different from that shown in Figure 9.

• Ensure a minimum of two feet clearance between open side of box and nearest object.

• Face exposed end away from wind and elements.

• Enclosure should hold enough heat created by the generator to prevent problems.

A Never run unit indoors.Do Not

RECEPTACLES

120 Volt AC, 20 Amp, Duplex

Receptacle

Each receptacle (Figure 10) is protected against overload by a 20 Amp push-to-reset circuit breaker.

i I

Wind

J

i I

Use each receptacle to operate 120Volt AC, single-phase,

60 Hz electrical loads requiring up to 2,400 watts (2.4 kW) at 20Amps of current. Use cord sets that are rated for

125Volt AC loads at 20 Amps (or greater).

120/240 Volt AC, 30 Amp, Locking

Receptacle

Use a NEMA LI4-30 plug with this receptacle. Connect a

4-wire cord set rated for 250VoltAC loads at 30 Amps

(or greater) (Figure I I).You can use the same 4-wire cord you plan to run a 120Volt load.

_l_ Ill IlP,Tolp,11loltllHr:T_r_l

4-Wire Cord Set f

i

(Neutral)

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5-30 plug with this receptacle. Connect a

3-wire cord set rated for 125Volts AC at 30 Amps to the plug (Figure 12).

pa_ Ip,(o]kv_aF.'T o,

.

.

3-Wire Cord Set

-" ._

m

i

NEMA

L5-30

Neutral

120V

Hot

NEMA L 14-30

Y (Hot) |

/_7

X (Hot)

Ground

(Green)

This receptacle powers 120/240Volt AC, 60 Hz, single phase loadsrequiring up to 3,600 watts of power at

30 Amps for 120Volts; 6,500 watts of power (6.5 kW) at

30 Amps for 240Volts.The outlet is protected by a 30 Amp push-to-reset circuit breaker.

_

Ground (Green)

Use this receptacle to operate 120Volt AC, 60 Hz, single phase loads requiring up to 3,600 watts (3.6 kW) of power at 30 Amps.The outlet is protected by a 30 Amp push-to-reset circuit breaker.

12 Volt DC, I 0 Amp Receptacle

This connector (identified by the legend "I2-VOLT D.C") supplies 12Volts DC at I 0 Amps through battery charging cables for recharging 12Volt batteries (Figure 13).See

"Charging a Battery" on page 8.

this outlet is rated for generator is only rated for 6,500 watts. Powering loads that exceed the wattage/amperage capacity of the generator can damageit or cause serious injuries. 240 Volt loadspowered through this outlet should not exceed 27.1 Amps of current draw.

DON'T OVERLOAD

GENERATOR

YOU R

Capacity

You must make sure your generator can supply enough rated (running) and surge (starting) watts for the items you wilt power at the same time. Follow these simple steps:

I.

Select the items you will power at the same time.

2.

Total the rated (running) watts of these items.Thisis the amount of power your generator must produce to keep your items running. See Figure 14.

3.

Estimate how many surge (starting) watts you will need. Surge wattage isthe short burst of power needed to start electric motor*driven tools or appliances such as a circular saw or refrigerator.

Becausenot all motors start at the same time, total surge watts can be estimated by adding only the item(s) with the highest additional surge watts to the total rated watts from step 2.

Example:

Tool or Appliance

Rated (Running)

Watts

1200 Window Air

Conditioner

Refrigerator

Deep Freezer

Television

Light (75 Watts)

800

50O

50O

75

3075 Total

Running Watts

Total Rated (Running)Watts

Highest Additional SurgeWatts

= 3075

= 1800

Total Generator Output Required = 4875

Additional Surge

(Starting)Watts

1800

1600

500

1800 Highest

Surge Watts

Power Management

To prolong the life of your generator and attached devices, it is important to take care when adding electrical loads to your generator.There should be nothing connected to the generator outlets before starting it's engine.The correct and safe way to managegenerator power is to sequentially add loads as follows:

I.

With nothingconnected to the generator, start the engine as described in this manual.

2.

Plug in and turn on the first load, preferably the largest load you have.

3.

Permit the generator output to stabilize (engine runs smoothly and attached device operates properly.

4.

Plug in and turn on the next load.

5.

Again, permit the generator to stabilize.

6.

Repeat steps 4 and 5 for each additional load.

Never add more loads than the generator capacity.Take

special care to consider surge loads in generator capacity, as described above.

Tool or Appliance

Rated*

(Running)

Watts

Additional

Surge

(Starting)

Watts

Essentials

LightBulb - 75 watt

Deep Freezer

Sump Pump

Refrigerator/Freezer - 18 Cu. Ft.

Water Well Pump- I/3 HP

Heating/Cooling

Window AC - 10,000 BTU

Window Fan

FurnaceFan Blower - I/2 HP

Kitchen

Microwave Oven - 1000Watt

Coffee Maker

Electric Stove - Single Element

Hot Plate

Family

Room

DVD/CD Player

VCR

Stereo Receiver

Color Television - 27"

Personal Computer w/I 7" monitor

Other

Security System

AM/FM Clock Radio

Garage Door Opener - I/2 HP

Electric Water Heater - 40 Gallon

DIY/Job Site

Quartz Halogen Work Light

Airless Sprayer - I/3 HP

Reciprocating Saw

Electric Drill - I/2 HP

Circular Saw - 7 I/4"

Miter Saw - I0"

Planer/Jointer - 6"

Table Saw/RadialArm Saw - I0"

Air Compressor - I-I/2 HP

75

500

8O0

8O0

1000

12O0

3OO

8O0

1000

1500

1500

25O0

I00

I00

450

50o

80o

18o

30o

480

40O0

1000

600

960

1000

1500

1800

1800

2000

2500

5O0

1200

1600

20O0

1800

6O0

1300

520

1200

960

1000

1500

1800

1800

2000

2500

*Wattages listed are approximate only. Check toot or appliance for actual wattage.

II •

SPECIFICATIONS

Maximum SurgeWatts ................

10,500 watts

Continuous Wattage Capacity ...........

Power Factor ..............................

6,500 watts

Rated Maximum Continuous AC Load Current:

1.0

At 120Volts .......................

At 240 Volts .......................

Phase.................................

Rated Frequency .......................

FuelTank Capacity ...................

ShippingWeight .........................

54.2 Amps

27. I Amps

I-phase

60 Hertz

7 U.S.gallons

200 Ibs.

GENERAL MAINTENANCE

RECOMMENDATIONS

The Owner/Operator is responsible for making sure that all periodic maintenance tasks are completed on a timely basis;that all discrepancies are corrected; and that the unit is kept clean and properly stored. Never operate a

damaged or defective

generator.

Engine Maintenance

See engine owner's manual for instructions.

and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings.

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 or oil.

• 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 opening on generator.These openings must be kept clean and unobstructed.

STO RAG E

The generator should be started at least once every seven claysand allowed to run at least 30 minutes. If this cannot be done and you must store the unit for more than

30 days,use the following guidelines to prepare it for storage.

Generator Storage

• Clean the generator as outlined in "To Clean the

Generator"

• Check that cooling air slots and openings on generator are open and unobstructed.

_

AUTION!

Avoid prolonged or repeated skin been shown to cause skin cancer in certain laboratory animals.Thoroughly wash exposed areas with soap and water.

KEEPOUT OF REACH OF CHILDREN. DON'T

POLLUTE. CONSERVE RESOURCES.RETURN

USED OILTO COLLECTION CENTERS.

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, leavesor any other foreign material.

NOTE: Do Not use a garden hose to clean generator.

Water can enter engine fuel system and cause problems. In addition, if water enters generator through cooling air slots, some of the water will be retained in voids and cracks of the rotor and stator winding insulation.Water

_ Storage covers can be flammable.

generator. Let the unit coot for a sufficient time before placing the cover on the unit.

Engine Storage

See engine owner's manual for instructions.

Other

Storage Tips

• Do Not store gasoline from one season to another.

• Replace fuel container if it starts to rust. Rust andlor dirt in fuel can cause problems if it's used with this unit.

• Store in clean and dry area.

TROUBLESHOOTING

Problem

Engine is running,

but

no AC output is

available.

Cause

I.

Circuit breaker is open.

2.

Poor connection or defective cord set.

3.

Connected device is bad.

4.

Faultin generator.

I.

Short circuit in a connected load.

2.

Generator is overloaded.

Engine

runs good

but bogs down when loads are connected.

3.

Engine speed is too slow.

Engine will not start; or

starts and runs rough.

4.

Shorted generator circuit.

I.

Run/Stop switch set to "Stop".

2.

Dirty air cleaner.

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. Excessivelyrich fuel mixture.

Engine shuts down during operation.

Engine lacks power.

Engine "hunts" or falters.

I I.

Intake valve stuck open or closed.

12. Engine has lost compression.

I.

Out of gasoline.

2.

Low oil level.

3.

Fault in engine.

I.

Load is too high.

2.

Dirty air filter.

3.

Engine needs to be serviced.

I.

Choke is opened too soon.

2.

Carburetor is running too rich or too lean.

Solution

I.

Reset circuit breaker.

2.

Check and repair.

3.

Connect another device that is in good condition.

4.

Contact Generac service facility.

I.

Disconnect shorted electrical load.

2.

See "Don't Overload the Generator" on page I I.

3.

Contact Generac Power Systems service facility.

4.

Contact Generac service facility.

I.

Set switch to "Run".

2.

Clean or replace air cleaner.

3.

Fill fuel tank.

4.

Drain gastank and fill with fresh fuel.

5.

Connect wire to spark plug.

6.

Replace spark plug.

7.

8.

Drain gastank; fill with fresh fuel.

Put choke lever to "Run" position.

9.

10.

Fill crankcase to proper level.

Contact Generac Power Systems

II.

12.

service facility.

Contact Generac Power Systems service facility.

Contact Generac Power Systems service facility.

Fill fuel tank.

I.

2.

3.

I.

Fill crankcase to proper level.

Contact Generac Power Systems service facility.

See "Don't Overload the Generator"

2.

3.

on page I I.

Replace air filter.

Contact Generac Power Systems

I.

2.

service facility.

Move choke to halfway position till engine runs smoothly.

Contact Generac Power Systems service facility.

SCHEMATIC

1 2

POWER

REGULATOR

BOARD

18

LDP

SWITCH

YEL i

/

\

/

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LED

RED

POWER POWER i i

155 156

22 44

22 44

I

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I BLU/WHT £2 I 30A

ENG

IGNITION

BATTERY

CHARGE

66

13

AUTO

/_

RESET B

L_

_tS_

55

55

_55_

([_ _+ )_

77

IIA

30A

0

WIRING DIAGRAM

20A

F

1_0/240V 2_ 30A

GRN I

_ //

/ / _

GROUND

Lm

........

_4 _

_ _

÷

SHROUB

_i_ _o ,_

_.....

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,

ANODE

_

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LO_ OIL

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N

NUT

ENGINE

ON

BLOCK

EXPLODEDVIEW-

45 /

MAIN UNIT

62 _/40

27

29

58

50 55

31 i

25

6

\

11

\

8

77

38

5

10

\

16_

49

19

17

24

26

75

24 \\

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24

25

59

67

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72

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PARTS LISTMAIN UNIT

Item Part #

I NSP

2 A92531GS

3 A92731GS

4 92247GS

5 92679GGS

6 92681AGS

7 65791GS

8 96796GS

9 22129GS

10 86307GS

II 25254GS

12 92609GS

13 82857GS

14 40976GS

15 66476GS

16 92532GS

17 22142GS

18 A7433GS

19 90239GS

20 81917GS

21 B4986GS

22 83083GS

23 22531GS

24 189160GS

25 66825CGS

26 74908GS

27 86308BGS

28 65795GS

29 66849AGS

30 67022GS

31 84132GS

32 66386GS

33 66849GS

34 B4871GS

35 22769GS

36 86494GS

37 86292GS

38 77395GS

39 83465GS

40 78831BGS

41 80270GS

42 78299GS

I

I

I

I

I

2

I

I

I

I

4

4

4

I

I

2

4

2

2

I

2

4

I

2

I

I

I

2

12

I

4

4

I

I

Qty

Description

ENGINE

SUPPORT,Support

SUPPORT,Engine & Muffler

HOUSING, EngineAdapter

ASSEMBLY,Rotor (Inclds Item 7)

ASSEMBLY,Stator

BEARING

WASHER, 22.2 O.D. x 3 Thk

WASHER, M8 Lock

HHMS, 5/16 - 24 x 3/4 SEMS

HHCS, 5/16 - 24 x 9-7/8"

MOUNT, Vibration

MOUNT, Vibration

SCREW, M8 - 1.25 x 20

CAPSCREW, M6 - 1.0 x 12mm

BRACKET,Muffler

SCREW,5/16 - 18 x 3/4"

MUFFLER

GASKET, Muffler

PIN, 4 mm x 10 Rott

DECAL, Ground

SCREEN,Spark Arrester

HHCS, 5/16-18 x I-3/4"

NUT, 5/16-18 Serrated Flange

CARRIER, Rear Bearing

TAPTITE, M5-0.8 x 10

BOLT,M6 -I x 165 mm Stator

RECTIFIER,Battery Charge

TAPTITE, M5-0.8 x 20

GROMMET, Rubber

ASSEMBLY,Power Regulator

ASSEMBLY,Brush Holder

TAPTITE, M5 - 0.8 x 16

COVER, Bearing Carrier

WASHER,#10 Int. Shakeproof

SCREW, M6 -I.0 x 16Wing

HHCS, # I0 Self Driller

NUT, M6 Flange Lock

GROMMET,Tank

HHCS, M6-1.0 x 60, SEMS

VALVE,Tank

BUSHING, PlasticTank

Item Part #

43 B4363GS

44 BI998GS

45 J92039GS

46 92665GS

47 85000GS

48 14353621GS

49 26850GS

50 39287GS

51 92982GS

52 189407GS

53 49820GS

54 22145GS

55 187104GS

56 BB5586GS

57 B4605GS

58 B4135GS

59 AI87024GS

60 92630GS

61 189406GS

62 93826GS

Qty Description

CAP, Fuel Gauge

TANK,ASM, 7- Gal (Includes

Items 41 & 42)

SHIELD, Heat

INSULATION #2- I/4" Thick

CLIP,Insulation

WIRE, Ground

2 WASHER, M6 Shakeproof

2 HHCS, M81.25x45

I DECAL, Danger

2 DECAL, Heat Shield

2 NUT, M8 Nylok

4 WASHER, FIat, 5/16- M8

4 WASHER, Nylon

2 HANDLE

2 GRIP

2 PIN, with Lanyard

CRADLE

ASSEMBLY,Control Panel

DECAL, Control Panel

DECAL, Start Instructions

SHIELD, Heat

CRIMPTITE, 10-24 x I/2"

63 J96068GS

64 56893GS

65 A8927GS

66 189417GS

67 43438GS

68 37806GS

69 70185GS

70 731 I IGS

71 65787GS

72 84882GS

73 72347GS

74 B4767GS

75 B2153GS

76 73054GS

77 77816GS

78 20566GS

79 AB3061GS

2

MANUAL, Engine

MANUAL, Owners

PLUG, 240V,30A 4-Prong

PLUG, 125V,30A 3-Prong

OIL FILTER

ELEMENT,Air Cleaner

CABLE, Battery Charge

WRENCH, Spark Plug

SPARK PLUG

COVER, Storage

6 SCREW,Self Driller, 12-14 x 7/8"

I DECAL, Fuel Shut Off

2 DECAL, Caution Hot Muffler

I DECAL, 1-800

OIL BOTTLES,28 oz.

Optional

Accessories Not Included:

84883GS Cord Wrap

EXPLODED VIEW AND PARTS LIST - CONTROL PANEL

19

\\\\_

2O 21

19

8

6

10

6

10

11

15

\

16 17

\

26

18

7

8

22

25

9

2

Item Part #

I A92070GS

2

23897GS

3

49226GS

4 91526GS

5 82538GS

6 82881GS

7 43181GS

8 43182GS

9 90418GS

I0 75207AGS

I I 75207GS

12 23365GS

13 68868GS

Qty Description

I

PANEL,Control

4 FLATWASHER,#10 M5

4 LOCKWASHER, M5

4 SCREW, M5-0.8 x 12mm

I SWITCH, Idle Control

4 LOCK WASHER, 7/16"

4 SCREW,M3-0.5xl0mm

4 LOCKWASHER, M3

I OUTLET, 12V

2 CIRCUIT BREAKER,30A

2 CIRCUIT BREAKER,20A

6 WASHER,#8 Shakeproof

I OUTLET, 120Vott, 30Amp

Locking

I|:!

Item Part #

14 43437GS

15 68759GS

16 43180GS

17 22264GS

18 51715GS

19 64526GS

20

83970GS

21 64525GS

22 87962GS

23 84335GS

24 84134GS

25 B92069GS

26 84028GS

Qty Description

I OUTLET, 120V/240V,30A

Locking

I OUTLET, 120V,20A Duplex

6 FLATWASHER, M4

6 LOCKWASHER,#8 M4

6 NUT, M4-0.7 Hex

8 SCREW,#6-32 x 3/8"

I BOARD, System Control

4 STAND-OFF, 3/4" Hex

I CIRCUIT BREAKER.12V,10A

I ASSEMBLY,

I GROMMET, Rubber Conn.

I BOX, Control Panel

I TRANSFORMER, Idle Control

EXPLODED VIEWAND PARTS LIST-WHEEL KIT

5 14

®

11

4

8

Item Part #

I BB5586GS

2 B4966GS

3 93693GGS

4 87005AGS

5 39287GS

6 BI86927GS

7 27007GS

8 42909GS

Qty Description

2 HANDLE

2 WHEEL

I AXLE

2 PIN, Retaining

2 HHCS, M8- 1.25 x45

I LEG,Support

2 MOUNT, Vibratlon

2 CAPSCREW, Hex Hd. M8- 1.25

x 30

Item Part #

9 52858GS

I0 22247GS

II 39253GS

12 22145GS

13 49820GS

14 187104GS

15 B4605GS

16 B4135GS

Qty Description

4 NUT, Lock M8

2 WASHER,Wheel

2 CAPSCREW,Hex Hd. - M8 -

1.25 x 20

6 WASHER, Flat, 5/16-M8

2 NUT, M8 Nylok

4 WASHER, Nylon

2 GRIP

2 PIN, with Lanyard

Warranty Schedule:

Engine

All other parts

Consumer*

Warranted solely by the engine manufacturer

2 years (2rid year parts only)

Commercial*

I Year

With the exception of European Community Countries, all units bound for export shall be warranted for One (I) Year in

Consumer applications, and 90 days in Commercial applications as defined below.

*NOTE: For the purpose of this warranty

"consumer use" means personal residential

household use by original

purchaser.This warranty does not apply to units used for prime power in place of utility. "Commercial

Use" means

all other uses, including rental, construction, commercial and income producing purposes. Once a generator

has

experienced commercial use, it shall thereafter be considered a commercial use generator for the purposes of this

waJ'ranty.

During the warranty period, the COMPANY will, at is option, repair or replace any part which, upon examination by the

COMPANY, is found to be defective under normal use and service**.AII transportation costs under warranty, including return to the factory if necessary,are to be borne by the purchaser and prepaid by the purchaser.This warranty does not cover normal maintenance and service and does not apply to a generator set, alternator, or parts which have been subjected to improper or unauthorized installation or alteration, misuse, negligence,accident, overloading, overspeeding,improper maintenance, repair or storage so as,in the COMPANY's judgement, to adversely affect its performance and reliability.

**NORMAL

WEAR: As with all mechanical devices, the generator needs periodic parts service and replacement

to

perform well.This warranty will not cover repair when normal

wear has exhausted the life of a part or generator.

WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESSFOR A

PARTICULAR PURPOSETOTHE EXTENT PERMITTED BY LAW.THE DURATION OFANY IMPLIEDWARRANTIES

WHICH CANNOT BE DISCLAIMED IS LIMITED TO THETIME PERIODAS SPECIFIEDIN THE EXPRESS

WARRANTY. LIABILITY FOR CONSEQUENTIAL, INCIDENTAL OR SPECIAL DAMAGES UNDER ANY AND ALL

WARRANTIES IS EXCLUDED. THE COMPANY ALSO DISCLAIMS ANY RESPONSIBILITY FOR INCIDENTAL OR

CONSEQUENTIAL DAMAGES,SUCH AS THE LOSSOF TIME OR THE USEOF THE POWER EQUIPMENT, OR ANY

COMMERCIAL LOSS DUETOTHE FAILUREOFTHE EQUIPMENT:AND ANY IMPLIEDWARRANTIES ARE

LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY.

Some states do not allow limitations on how long an impliedwarranty lasts, or the exclusion or limitation of incidentalor consequential damages,so the above limitations or exclusions may not apply to you.Thls warranty gives you specific legal rights and you may also have other rights, which vary from state to state.

For service, see your nearest COMPANY authorized warranty service facility or call 1-877-544-0982.Or look on the internet at www.generac-portables.com.Warranty service can be performed only by a COMPANY authorized service facility.This warranty will not apply to service at any other facility.At the time of requesting warranty service, evidence of original purchase date must be presented.