Generac 1338-1 Generator Owner's Manual

GENE 'AC

The Reliable Ones

9000WATT

Portable Generator Owner's Manual

DANGER[

This generator is designed for outdoor use only Never use this generator inside any building or enclosure including the generator compartment of a recreational vehicle (RV). Carbon

monoxide

poisoning, fire and/or an explosion may result.

No user performed modifications, including venting of exhaust and/or cooling ventilation, will eliminate the danger, Always have at least two feet of clearance on all sides of the generator even while operating the unit outdoors.

DANGER[

You must isolate the generator from the electric utility by opening the electrical system's 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.

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

Environmental Protection Agency. For warranty information refer to the Engine Owner's manual.

Model No. 1338-1 (9,000 Watt AC Generator) Manual No. B5178 Revision 0 (8/25/1999)

Visit our Generac website: www.generac-portables.com

This is the safety alert symbol. It is used to alert you to potential personal injury hazards Obey all safety

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, appliance, tool 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 9,000 watts (9.0kW) of power that pull up to 75 Amps at 120 Volts or

37.5 Amps at 240 Volts.

CAUTION] Do not exceed the generator's watts of all devices you are connecting to generator receptacles at one time. This total should not be greater than 9,000 watts for this generator. In most cases rated watts of the electrical device can be found on the device nameplate. If the device nameplate gives only volts and amps, multiply volts times amps to obtain watts (volts x amps = watts).

The generator's revolving field is driven at about

3600 rpm by a twin-cylinder engine.

Every effort has been expended to make sure that the information in this manual is both accurate and current. However, Generac reserves the right to change, alter or otherwise improve the product at any time without prior notice.

DANGER]

Do not tamper with engine governed speed. High operating speeds are dangerous and increase the risk of personal

injury or damage to equipment. The generator supplies correctly rated frequency and voltage

only when running at proper governed speed.

Incorrect frequency and/or voltage can

damage some connected electrical loads.

Operating at excessively low speeds imposes

a heavy load and, when adequate engine

power is not available, may shorten engine life

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 involve a 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.

DANGER!

You must isolate the generator from the electric utility by opening the electrical system's main circuit breaker or main switch 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.

DANGER!

Generator exhaust gases contain DEADLY carbon monoxide gas.

Carbon monoxide, if breathed in sufficient concentrations, can cause unconsciousness

or death. Operate this

equipment outdoors where adequate

ventilation is available.

GeneracPortableProducts9,000WattGenerator

• Thegeneratorproducesa verypowerfulvoltagethat cancauseseriousinjuryor deathbyelectrocution.

generator.

• Neverhandleanykindofelectricalcordor device whilestandinginwater,whilebarefootor while handsorfeetarewet.Deathor seriousinjuryfrom

• Never operate the generator:

in rain; in any enclosed compartment; if 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

GENERATOR

The National Electric Code requires the frame and external electrically conductive parts of the generator be properly connected to approved earth ground.

Local electrical codes may also require proper grounding of the unit. A grounding wing nut (Figure 1) is provided for this purpose.

decking

or steel work).

• Never use worn, bare, frayed or otherwise damaged electrical cords with the generator. Death, serious injury and property damage from 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 overfill the fuel tank. Always allow room for fuel expansion.

If tank is overfilled, 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 engine-generator 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 least 2 feet of

clearance on all sides of generator while operating 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. You could damage the unit or injure yourself.

Grounding

Wing Nut

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. However, local codes may vary widely. Consult with a local electrician for grounding requirements in your area. Be sure to keep the ground wire attached while you connect the electrode.

Properly grounding the generator helps prevent electrical shock if ground fault conditions exists in the generator or in connected electrical devices. Proper grounding also helps dissipate static electricity, which often builds up in ungrounded devices.

for useafterit hasbeenproperlyservicedwiththe oilandfuel.

1-800-270-1408.

IMPORTANT: Any attempt to run the engine before it

has been serviced with the recommended

oil will result in an engine failure

TO REMOVE GENERATOR

FROM CARTON

• Set the palleted carton on a rigid fiat surface

• Carefully cut bands around the shipping carton

• Lift carton off the generator.

• Remove all packing material, carton fillers, etc.

• Remove the generator from the shipping pallet.

CARTON CONTENTS

Check all contents. If any parts are missing or damaged, call the generator helpline at

1-800-270-1408.

Contents include:

9,000 Watt generator

Owner's manual

Engine manual

Owner's registration card

2 Bottles of engine oil (28 oz.)

125 Volt, 30 Amp plug

125 Volt, 20 Amp plug

240 Volt, 30 Amp plug

Oil fill funnel

Wheel kit

ASSEMBLE

WHEEL

KIT

IMPORTANT: This wheel kit is not intended for

over-the-road use.

To install your wheel kit you need the following toot

• 13mm box, open end, or socket wrench

Install Wheel Kit as follows: (See Figure 2)

Place the bottom of the generator cradle on a flat,

even surface Temporarily elevate cradle on blocks to ease assembly

Slide axle through both axle mounting brackets on

cradle frame

Slide a wheel spacer over each end of the axle.

Install a wheel as shown. Slide a fiat washer over

the axle, then secure the wheel with a retaining pin

NOTE

Be sure to install each wheel with the air

pressure valve on the outboard side.

Install the other wheel in the same manner

Secure the vibration mount to the support leg with

a lock nut, a flat washer, and a 30 mm cap screw.

Secure the support leg assembly to the cradle

with 20 mm capscrews, flat washers, and lock

washers Remove the temporary blocks

Position the handle on the cradle end opposite from the control panel Attach the handle with

45 mm cap screws and lock nuts.

Tighten all lock nuts with 13mm wrench Make sure all components are secure.

GeneracPortableProducts9,000WattGenerator

HANDLE

Cap Screw, 45 mm

MOUNT,

Vibration

AXLE

Wheel

WHEEL

;HER,

Wheel

PiN, Retaining

CHECK BATTERY / ATTACH

NEGATIVE

BATTERY WIRE

The battery on the generator is fully charged, sealed

and pre-instalted except for the negative (black) battery cable.

To install:

• Cut off tie wrap on negative (black) cable attached

to the battery hold down.

• Remove nut on the negative battery terminal

• Slide the negative battery cable over the screw on

the negative terminal (Figure 3)

• Reattach nut and tighten.

• Ensure the connections to the battery and generator

and tight and secure

LEG, Mounting Support

WASHER

FLAT WASHER

,,--WASHER, Lock

_Cap Screw, 20 mm

Screw,

30 mm

KNOW YOUR 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

Circuit Breakers (AC)

120 Volt AC, 20 Amp

Duplex Receptacle

120 Volt AC, 20 Amp

Locking Receptacle

120 Volt AC

Locking Receptacle

Air Cleaner

Switch

Choke Lever

Spark Arrestor Muffler

120/240 Volt AC,

50 Amp Receptacle

120/240 Volt AC, 30 Amp

Locking Receptacle Grounding Wing Nut

120 Volt AC, 20 Amp Duplex Receptacle -- May be used to supply electrical power for the operation of

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

120 Volt AC, 20 Amp Locking Receptacle -- May be used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase, 60 Hz electrical lighting, appliance, tool and motor loads.

120 Volt AC, 30 Amp Locking Receptacle -- May

be used to supply electrical power for the operation

of 120 Volt AC, 30 Amp, single phase, 60 Hz

electrical lighting, appliance, tool 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.

120/240 Volt AC, 50 Amp Receptacle -- May be used to supply electrical power for the operation of

120/240 Volt AC, 50 Amp, single phase, 60 Hz electrical loads.

Air Cleaner -- Used to limit the amount of dirt and dust that gets in the engine.

Choke Lever-Used when starting a cold engine.

Circuit Breakers (6 AC) -- Each receptacle is provided with a circuit breaker to protect the generator against electrical overload. Breakers are

"push to reset" type.

Grounding Wing Nut -- Use this connection to properly ground the generator. See "Grounding the

GeneratoK' on page 3.

Spark Arrestor Muffler -- Exhaust muffler lowers engine noise and is equipped with a spark arrestor screen.

Start Switch -- Turn to Start position to start generator. Set switch to Run position when operating. Set to Stop position when stored or idle.

GeneracPortableProducts9,000WattGenerator

BEFORE STARTING THE

ENGINE

• Clean area around fuel fill cap; remove cap.

• Fill fuel tank with clean, fresh, unleaded gasoline.

Be careful not to overfill Allow 1/2" of tank space for fuel expansion (Figure 4).

Add Engine Oil

Note: When adding oil to the engine crankcase in the

future, use only high quality detergent oil rated with

API service classification SE or higher. Use no special

additives. Select the oil's viscosity grade according to instructions given in the engine owner's manual.

To add oil to the generator:

• Make sure unit is on a level surface.

• Clean around oil fill cap and remove it

• Remove oil dipstick, wipe clean and fully reinsert in

engine block.

• Slowly fill engine with oil until it reaches the full mark on the dipstick

Stop occasionally to check oil

level Do not overfill.

• Install oil dipstick.

• Install oil fill cap. Hand tighten securely.

,_.

CAUTION!

Any attempt to crank or start the with the recommended oil results in an engine failure.

NOTE: The generator's revolving field rides on a pre-iubricated and sealed bali bearing that requires no additional lubrication for the life of the bearing.

Add Gasoline

DANGER!

NEVER fill fuel tank indoors.

NEVER fill fuel tank when engine is running or hot. DO NOT light a cigarette or smoke when filling the fuel tank.

1_" AirSpace

To Start The Engine

_nk

• 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 gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer. See "Storage" on page 13. Never use engine or carburetor cleaner products in the fuel tank or permanent damage may occur.

OPERATING

THE

GENERATOR

DANGER!

Do not overfill the fuel tank.

• Use regular UNLEADED gasoline in the generator.

DO NOT use premium gasoline. DO NOT mix oil with gasoline. DO NOT overfill the gas tank.

WARNING!

Never start or stop engine with receptacles and turned on. You could damage both the generator and the electrical devices.

• Unplug all electrical loads from generator receptacles before starting the engine

• Make sure the unit is in a level position.

• Open the fuel shut-off valve (Figure 5)

Jl'*""'_

Fuel Tank

Start

• Pull the choke knob to close. If the engine is warm, or the ambient temperature is high, pull the choke handle half-way, or keep it fully open (Figure 6).

Close

A DANGER!

Engine exhaust contains carbon causes unconsciousness and death. Never run engine indoors or in poorly ventilated areas.

DANGER!

Burn hazard Temperature of muffler and nearby areas may exceed 150°F

(65°C). Do not touch these areas on the generator.

• Turn key switch to the "Start" position (Figure 7)

IMPORTANT: Do not operate the electric starter continuously for more than 5 seconds, even if the engine does not start. Extended cranking can damage the starter motor.

NOTE: If the engine failed to start, set the key to the

"Run" position and wait for about 10 seconds before retrying.

IMPORTANT: Never turn the key switch to the "Start" position while the engine is running. You could damage the starter motor.

• When the engine starts, gradually open choke by pushing the choke knob in and keep it fully opened while running.

IMPORTANT!

Do not overload the generator!

Do not overload individual panel receptacles!

These outlets are protected against overload with push-toreset-type circuit breakers. If amperage rating of any circuit breaker is exceeded, that breaker opens and electrical output to that receptacle is lost. Read "Don't

Overload the Generator" on page 12 carefully.

If the Engine Will Not Start:

Refer to the engine owner's manual

GeneracPortableProducts9,000WattGenerator

Stopping the Engine

• Remove all electrical loads connected to generator panel receptacles.

Never start or stop engine with

devices plugged in and turned on.

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

the internal temperatures of engine and generator.

• Turn the key switch to the "Stop" position.

• Close the fuel shut-off valve

Stopping the Engine with the Fuel Valve

This procedure eliminates fuel from the carburetor.

Use this method to stop the generator if you plan to store the generator over a long period. Fuel will clog the internal passages of carburetor if allowed to remain for an extended period.

• Unplug (or turn OFF) all electrical loads connected to generator panel receptacles.

Never start or stop

engine with devices plugged in and turned on.

• Let engine run at no-load for 30 seconds to stabilize the internal temperatures of engine and generator.

• Close the fuel shut-off valve while the engine is running and wait until the engine stops.

• Set the key switch to the "Stop" position after the engine quits.

Applying Electrical Loads

• Let engine stabilize and warm up for about two minutes after starting

• Plug in and turn on the desired 120 or 240 Volt AC, single phase, 60 Hz electrical loads. DO NOT

OVERLOAD THE GENERATOR.

Add up the rated watts (or amps) of all loads to be connected at one time. This total should not be greater than the rated wattage/amperage capacity of the generator. See page 12, "Don't Overload the Generator" for details.

RECEPTACLES

This generator is equipped with the following receptacles:

120 Volt AC, 20 Amp, Duplex

Receptacle

Each of these outlets is protected against overload by

20 Amp push-to-reset type circuit breakers. Use each outlet to operate 120 Volt AC, 60 Hz, single phase loads requiring 2400 (2.4 kW) watts at 20 Amps of current (Figure 8).

120 Volt AC, 20 Amp Locking

Receptacle

Use a NEMA L5-20 plug with this receptacle.

Connect a 3-wire cord set rated for 125 Volts AC at

20 Amps to the plug (Figure 9).

3-Wire Cord Set

120 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L5-30 plug with this receptacle.

Connect a 3-wire cord set rated for 125 Volts AC at

30 Amps to the plug (Figure 10).

3-Wire Cord Set

Neutml

120V

Hot

(_l

[ _--Neutral

120V

NEMA L5-20

,_ Greund

(Green)

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 2400 watts

(2.4 kW) of power at 20 Amps. The outlet is protected by a 20 Amp push-to-reset circuit breaker.

Hot

NEMA L5-30

/-!-TGreund

(Green)

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts

(3.6 kW) of power at 30 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker.

GeneracPortableProducts9,000WattGenerator

120/240 Volt AC, 30 Amp Locking

Receptacle

Use a NEMA L14-30 plug with this receptacle.

Connect a 4-wire cord set rated for 250 Volts at

30 Amps (or greater) (Figure 11). You can use the same 4-wire cord if you plan to run a 120 Volt load.

4-Wire CordSet

240 Volt AC, 50 Amp Receptacle

Use a NEMA 14-50 plug with this receptacle.

Connect a 4-wire cord set rated for 250 Volts AC at

50 Amps to the plug (Figure 12)

240 Volts AC --

Y (Hot)

X (Hot)

This receptacle powers 120/240 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts of power (3.6 kW) at 30 Amps for 120 Volts; 7200 watts of power (7.2 kW) at 30 Amps for 240 Volts. The outlet is protected by a 30 Amp push-to-reset circuit breaker.

w (Neutral)

NEMA 14-50

Use this receptacle to operate 240 Volts AC, 60 Hz, single phase loads requiring up to 9,000 watts

(9.0 kW) of power.

CAUTION!

Although this outlet states it has a the generator is only rated for 9,000 watts.

Powering loads that exceed the wattage/ amperage capacity of the generator can damage it or cause serious injuries.

DON'T OVERLOAD

THE

GENERATOR

Overloading a generator in excess of its rated wattage capacity can result in damage to generator and to connected electrical devices. Observe the following, to prevent overloading the unit:

• Add up the total wattage of all electrical devices to be connected at one time. This total should NOT be greater than the generator's wattage capacity.

• The rated wattage of lights can be taken from light bulbs The rated wattage of tools, appliances and motors can usually be found on a data plate or decal affixed to the device.

• If the appliance, tool or motor does not give

wattage, multiply volts times ampere rating to determine watts (volts x amps = watts).

• Some electric motors, such as induction types, require about three times more watts of power for starting than for running. This surge of power lasts for only a few seconds when starting such motors.

Be sure you allow for this high starting wattage when selecting electrical devices to connect to your generator. First figure the watts needed to start the largest motor. Add to that figure the running watts of all other connected loads.

• Items in the guide shown in Figure 13 are provided to help you to determine how many items the generator can operate at one time.

Device .......................

*Air Conditioner (12,000 Btu) .......

*Air Conditioner (24,000 Btu) ..............

*Air Conditioner (40,000 Btu) ..............

Battery Charger (20 Amp) ..................

Belt Sander (3") .........................

Chain Saw .............................

Running Watts

1700

3800

6000

500

1000

1200

Circular Saw (6-1/2") ...............

*Clothes Dryer (Electric) ..................

*Clothes Dryer (Gas) ......................

*Clothes Washer ........................

Coffee Maker ...........................

*Compressor (1 HP) .....................

*Compressor (3/4 HP) ....................

*Compressor (1/2 HP) ....................

Curling Iron .............................

*Freezer ................................

*Dehumidifier ............................

Disc Sander (9") ........................

Edge Trimmer ...........................

Electric Blanket ..........................

Electric Nail Gun ........................

800 to 1000

5750

700

1150

1750

2000

1800

1400

700

650

1200

500

400

1200

Electric Range (per element) ...............

Electric Skillet ..........................

*Furnace Fan (3/5 HP) ....................

*Garage Door Opener ...............

Hair Dryer .............................

Hand Drill ........................

1500

1250

875

500 to 750

1200

250 to 1100

Device .......................

Hedge Trimmer ..........................

Impact Wrench ..........................

Iron ..................................

*Jet Pump ..............................

Lawn Mower ...........................

Light Bulb ..............................

Microwave Oven ...................

*Milk Cooler ............................

Oil Burner on Furnace .....................

Running Watts

450

500

1200

800

1200

100

700 to 1000

1100

300

Oil Fired Space Heater (140,000 Btu) .........

Oil Fired Space Heater (85,000 Btu) ..........

Oil Fired Space Heater (30,000 Btu) ..........

*Paint Sprayer, Aidess (1/3 HP) .............

Paint Sprayer, Airless (handheld) ............

Radio .............................

400

225

180

600

150

50 to 200

*Refrigerator ............................

Slow Cooker ............................

700

200

*Submersible Pump (1-1/2 HP) ............

*Submersible Pump (1 HP) ................

*Submersible Pump (1/2 HP) ..............

*Sump Pump .....................

*Table Saw (10") ..................

Television .........................

Toaster .........................

Weed Trimmer ...........................

2800

2000

1500

800 to 1050

1750 to 2000

200 to 500

1000 to 1650

500

* Allow 3 times the listed watts for starting these devices.

GeneracPortableProducts

_ _1

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 your engine owner's manual for information needed to maintain and service the engine

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.

Make sure the cooling air slots in the generator do not become clogged with snow, leaves or other foreign material.

Check cleanliness of the generator frequently and clean when dust, dirt, oil, moisture or other foreign substances are visible on its exterior surface.

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 the cooling air slots, some water will be retained in the voids and cracks 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.

To Clean the Generator

• Use a damp cloth to wipe exterior surfaces clean.

• 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.

STORAGE INSTRUCTIONS

The generator should be started at least once every seven days and 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 the cooling air slots and openings on the generator are open and unobstructed.

• Drain fuel and run engine until the fuel system is empty.

• Remove spark plugs and pour about 1 ounce of clean engine oil into spark plug holes. Crank engine over slowly several times, to distribute oil. Install and tighten spark plugs.

• Change engine oil and filter, as described in engine owner's manual.

• Remove the negative battery cable from the battery

to prevent the battery from being depleted

• Store the unit in a clean dry place

DANGER!

Storage covers can be flammable generator. Let the unit cool for 10 minutes before placing cover on the unit.

SPECIFICATIONS

Rated Maximum Continuous

AC Power Output ........................ 9,000 watts

(9.0kW)

Rated Voltage ..................................

120/240 Volts

Rated Maximum Current: at 240 Volts ...................................

37.5 Amperes at 120 Volts ...................................

75 Amperes

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

Rated AC Frequency ....................... 60 Hertz

Number of Rotor Poles .................... 2

Driven Speed of Rotor ..................... 3600 rpm

GeneracPortableProducts9,000WattGenerator

TROUBLESHOOTING

Problem

Engine is running, but no

AC output is available.

Cause

1. One of the circuit breakers is open.

2, Fault in generator.

3. Poor connection or defective cord set.

4. Connected device is bad.

Engine runs good at no-load but "bogs down" when loads are connected.

1. Short circuit in a connected load.

2, Engine speed is too slow.

3. Generator is overloaded.

4. Shorted generator circuit.

Engine will not start; or starts and runs rough.

Run/Stop Switch set to STOE

Dirty air cleaner.

Out of gasoline.

Stale gasoline.

Spark plug wire not connected to spark plug,

Bad spark plug.

Water in gasoline.

8, Overchoking.

9, Excessively rich fuel mixture.

10, Intake valve stuck open or closed.

11, Engine compression lost.

12. Failed battery.

Engine shuts down during operation.

1. Out of gasoline.

2. Low oil level,

Engine lacks power.

Engine "hunts" or falters.

1. Load is too high.

2. Dirty air filter.

1. Choke is opened too soon.

2. Carburetor is running too rich or too lean.

Correction

1. Reset circuit breaker.

Contact Generac service facility.

Check and repair.

Connect another device that is in good condition.

1. Disconnect shorted electrical load,

2. Contact Generac service facility.

See "Don't Overload the

Generator" on page 12.

Contact Generac service facility.

1. Set switch to RUN,

Clean or replace air cleaner.

3, Fill fuel tank.

Drain gas tank; fill with fresh fuel.

Connect wire to spark plug,

Replace spark plug.

7, Drain gas tank; fill with fresh fuel.

8, Open choke fully and crank engine.

Contact Generac service facility.

10, Contact Generac service facility.

11, Contact Generac service facility.

12. Replace battery,

1. Fill fuel tank,

Fill crankcase to proper level,

1. See "Don't Overload the Generator" on page 12,

Replace air filter.

1. Move choke to halfway position until engine runs smoothly.

Contact Generac service facility.

NOTES

Generac Portable Products 9,000 Watt Generator

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GENERATOR PARTS LIST

Item Part #

1 NSP

2 BB4509

A77304

BB4811

80270

78299

B4325

38353

78831B

B1696

AB4426

83465

B5177

B5176

78817

77816

B4826

B4824

79552

73054

B4268

BB4481

20441

23152

22237

22241

22746

22131

BB5228

B4425

19553621 1

38750 1

B4502

22145

26850

20566

B4986

92982

Qty

Description

ENGINE, Robin 18HP

SHIELD, Heat

SUPPORT, Engine

SHIELD, Heat

VALVE, Fuel Shut-Off

BUSHING, Fuel Valve

CAP, Fuel Tank

MOUNTS, Vibration

CAPSCREW, M6-1.0 x 60mm

TANK, Fuel 10 Gal

CRADLE

GROMMET, Fuel Tank

Mounting

CAPSCREW, 3/8-16 x 3/4"

WASHER, 3/8" Lock

NUT, 3/8"-16 Hex

CAPSCREW, 3/8-16 x 1-3/4"

WASHER, 3/8" Flat

SHIELD, Heat

ASSEMBLY, Control Panel

WIRE ASSEMBLY, Ground

HHCS, M6 - 1.0 x 30

SWITCH, Key Ignition

WASHER, M8 Flat

WASHER, M6 Shakeproof

DECAL 1-800

DECAL Ground

DECAL Danger

DECAL Side Panel

DECAL Control Panel

DECAL Data Plate

DECAL Caution Hot Muffler

DECAL Start Instructions

DECAL Start - Run - Stop

DECAL Ovedaminate

DECAL Fuel Shut-Off

ALTERNATOR, 10KW

GUARD, Muffler

SCREW, 1/4" x 3/4" Self

Driller

Item Part #

40 NSP

B4627

AB4682

A96925

96924

Qty

Description

BATTERY

1 KEY, Ignition Switch

1 BRACKET, Ignition Switch

1 BRACKET, Battery Tie Down

2 J-BOLT, M8 - 1.25

19353621 1 CABLE, Battery Positive

19453621 1 CABLE, Battery Negative

52618

49226

2 HHCS, M5 - 0.8 x 12

1 WASHER, M5 Lock

52856

49820

39253

NSP

45771

27482

47411

22473

B4948

2 NUT, M5 Flange Lock

2 NUT, Nylok M8 - 1.25

1 CAPSCREW, M8 - 1.25 x 20

SUPPLIED WITH ENGINE

1 NUT, M8 - 1.25

1 WASHER, 5/16" Shakeproof

2 CAPSCREW, M6 - 1.0 X 16

2 WASHER, Flat M6

1 CLAMP, Hose

55934G

22511

B4803

52618

B4794

B2153

B4988

52857

87680

23897

49813

3 CLAMP, Hose

4 CAPSCREW, 3/8 x 1-1/4"

1 CONNECTOR, 5-Way

1 HHCS, M5 - 0.8 x 12

1 GROMMET, Generator Cover

20 SCREW, #12 Self Driller

1 DECAL, Oil Fill

1 NUT, Locking M6 - 1.0

1 WING NUT, M6 - 1.0

2 WASHER, M5 Lock

1 NUT Hex M6 - 1.0

Items Not Shown:

B4428

37806

43438

93568

BB3061

1 Generator Owner's Manual

1 125V 30 Amp plug

1 120/240V 30 Amp plug

1 125V 30 Amp plug

2 Oil Bottle (28oz)

Available Accessories:

B4767

84883

Storage Cover

Cord Wrap

j/_ I

Generac Portable Products 9,000 Watt Generator

ALTERNATOR EXPLODED VIEW AND PARTS LIST

9 lO

Nx\

Item

Pa_ #

B4906

B4907

B4908

B4909

B4910

B4911

B4912

B4913

B4914

B4915

B4916

B4917

B4918

B4919

B4920

49820

Qty Description

1 SHIELD, Front

2 GRID, Front

1 BOLT, Shaft Stay

4 STAY BOLT, M8 x 30

1 ASSEMBLY, Housing

1 CAP

1 COVER, Blind End

1 COVER, Top Black

2 CAPACITOR, 25mF 450V

1 BEARING, 62052RS C3

1 CAPACITOR, Diode + Varistor + EMC

1 ROTOR, (Includes Item 13)

1 FAN

2 SCREW, M6 - 1.0 x 10mm

8 SCREW, M5 - 0.8 x 10mm

1 LOCK NUT, M8 - 1.25

GeneracPortableProducts9,000WattGenerator

l/!

m

CONTROL

PANEL EXPLODED VIEW AND PARTS LIST

3o 28

\\\\_

17 18

Item Part #

BB4504

23897

91526

49226

75207

23365

68759

38150

22264

51715

75207A

74190

68868

B4445

B4262

Qty Description

1 PANEL, Control

5 FLAT WASHER, #10 - M5

4 PPHMS, M5 - .08 x 12mm

5 LOCK WASHER, M5

3 CIRCUIT BREAKER, 20 Amp

12 WASHER, #8 Shakeproof

1 OUTLET, 120V, 20 Amp

Duplex

12 FLAT WASHER, #8

12 LOCK WASHER, #8

12 NUT, M4 -0.7

Hex

2 CIRCUIT BREAKER, 30 Amp

1 OUTLET, 120V/20A Locking

1 OUTLET, 120V, 30 Amp

Locking

2 CIRCUIT BREAKER, 45 Amp

1 OUTLET, 120/250V, 50 Amp

Item

Part #

43437

80077

92953

90576

84135

75477

B4894

43181

43182

77314

B4737

B95906

51716

B4893

B4892

51714

Qty Description

1 OUTLET, 120/240'7, 30 Amp

Locking

PPHMS, M4 x 20mm

1 BLOCK, 50 Amp, 3 - Terminal

1 GROMMET, Rubber

1 PPHMS, M5 - 0.8 x 20mm

1 RECTIFIER, Battery Charge

4 PHMS, M3 - 0.5 x 10mm

4 LOCK WASHER, M3

1 RELAY, Thermal

1 ASSEMBLY, Wire Harness

1 BOX, Control Panel

1 NUT, Hex M5 - 0.8

2 STAND OFF

1 RESISTOR, 2ohm 25 watt

1 NUT, Hex M3

? j/_ I

Generac Portable Products 9,000 Watt Generator

WHEEL

KIT EXPLODED VIEW AND PARTS LIST

Item

Pa_ #

93393B

39287

52858

93394

27007

22145

42909

39253

93693B

89635

89742

22247

87005

22129

Qty Description

1 HANDLE

4 HHCS, M8 - 1.25 x 45

5 NUT, Locking M8 - 1 25

1 LEG, Mounting Support

1 MOUNT, Vibration

3 FLAT WASHER, 5/16 - M8

1 HHCS, M8 - 1.25 x 30

2 HHCS, M8 - 1.25 x 20

1 AXLE

2 SPACER, Wheel

2 WHEEL

2 WASHER, Wheel

2 PIN, Retaining

2 WASHER, M8 Lock

NOTES

GeneracPortableProducts9,000WattGenerator

LIMITED WARRANTY

FOR OVERHEAD VALVE V-TWIN ENGINE-DRIVEN PORTABLE GENERATORS

GENERAC PORTABLE PRODUCTS (hereafter referred to as the COMPANY) warrants to the original purchaser that all components originally equipped with the generator, excluding the engine, for its portable generator will be free from defects in materials or workmanship for the items and period set forth below from the date of original purchase. This warranty is not transferable and applies only to portable generators driven by an overhead valve

V-Twin engine.

Alternator

Engine

Consumer* Commercial*

2 years (2nd year parts only) 1 year

Warranted solely by the engine manufacturer

With the exception of European Community

Countries, all units bound for export shall be warranted for

One (1) 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 warranty.

During said 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**. Starting batteries are not warranted by the COMPANY. All 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 use has exhausted the life of a part or generator.

THERE IS NO OTHER EXPRESS WARRANTY. THE COMPANY HEREBY DISCLAIMS ANY AND

ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY

AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW. THE

DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DISCLAIMED IS LIMITED TO

THE TIME PERIOD AS SPECIFIED iN 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 LOSS OF TIME OR THE USE OF THE POWER

EQUIPMENT, OR ANY COMMERCIAL LOSS DUE TO THE FAILURE OF THE EQUIPMENT: AND

ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This 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.

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.