Generac GP1200i G0076710 Portable Generator Owner's Manual

1200W Inverter

Owner’s Manual

®

MODEL:________________________

SERIAL:________________________

DATE PURCHASED:______________

WARNING

Loss of life. This product is not intended to be used in a critical life support application.

Failure to adhere to this warning could result in death or serious injury.

(000209b)

Register your Generac product at:

WWW.GENERAC.COM

1-888-GENERAC

(1-888-436-3722)

SAVE THIS MANUAL FOR FUTURE REFERENCE

Table of Contents

Section 1 Introduction and Safety 1

Introduction ..................................... 1

Safety Rules .................................... 1

Safety Symbols and Meanings ........ 1

Exhaust and Location Hazards ....... 2

Electrical Hazards ........................... 3

Fire Hazards .................................... 3

Standards Index .............................. 3

Section 2 General Information and Setup ....................................... 4

Know Your Generator ..................... 5

Emissions ........................................ 5

Connection Plugs ............................ 6

Run/Choke Switch ........................... 6

USB Outlets .................................... 6

Economy Switch .............................. 6

Generator Status Lights .................. 6

Circuit Protectors ............................. 6

Remove Contents from Carton ....... 7

Add Engine Oil ................................ 7

Fuel ................................................. 7

Section 3 Operation .......................9

Operation and Use Questions .........9

Before Starting Engine ....................9

Prepare Generator for Use ..............9

Grounding the Generator When In

Use ..................................................9

Know Generator Limits ....................9

Transporting/Tipping of the Unit ....10

Starting Pull Start Engines .............10

Starting Hot Engines ......................11

Low Oil Level Shutdown System ...11

Section 4 Maintenance and

Troubleshooting ..........................12

Maintenance ..................................12

Maintenance Schedule ..................12

Preventive Maintenance ................12

Engine Maintenance ......................12

Storage ..........................................15

Troubleshooting .............................17

Section 5 Exploded Views and

Parts Lists ....................................18

WARNING

Operating, servicing and maintaining this equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the

State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing your equipment.

For more information go to

www.P65Warnings.ca.gov.

(000393)

Section 1 Introduction and Safety

Introduction

Thank you for purchasing a Generac Power

Systems Inc. product. This unit has been designed to provide high-performance, efficient operation, and years of use when maintained properly.

WARNING

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

(000100a)

If any section of the manual is not understood, contact your nearest Independent Authorized

Service Dealer (IASD), or contact Generac

Customer Service at 1-888-GENERAC (1-

888-436-3722), or www.generac.com with any questions or concerns.

The owner is responsible for proper maintenance and safe use of the equipment. Before operating, servicing or storing this generator:

• Study all warnings in this manual and on the product carefully.

• Become familiar with this manual and the unit before use.

• Refer to the Assembly section of the manual for instructions on final assembly procedures. Follow the instructions completely.

Save these instructions for future reference.

ALWAYS supply this manual to any individual that will use this machine.

The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice.

Safety Rules

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, verify that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the equipment unsafe.

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:

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

(000001)

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

(000002)

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

(000003)

NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

Safety Symbols and Meanings

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

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

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

000657

DANGER

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas.

Carbon monoxide, if not avoided, will result in death or serious injury.

(000103)

• If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon monoxide poisoning.

Owner’s Manual for Portable Generator 1

2

DANGER

Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury.

(000179b)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000104)

DANGER

Electrocution. Turn utility and emergency power supplies to OFF before connecting power source and load lines. Failure to do so will result in death or serious injury. (000116)

WARNING

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

(000146)

WARNING

Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer’s instructions. Failure to do so could result in death or serious injury.

(000178a)

WARNING

Equipment and property damage. Do not operate unit on uneven surfaces, or areas of excessive moisture, dirt, dust or corrosive vapors. Doing so could result in death, serious injury, property and equipment damage.

(000250)

WARNING

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

(000111)

WARNING

Hot Surfaces. When operting machine, do not touch hot surfaces. Keep machine away from combustables during use. Hot surfaces could result in severe burns or fire.

(000108)

WARNING

Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage.

(000142a)

WARNING

Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to service this equipment and could result in death or serious injury.

(000215)

WARNING

Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury.

(000216)

Equipment damage. Do not attempt to start or operate a unit in need of repair or scheduled maintenance.

Doing so could result in serious injury, death, or equipment failure or damage.

(000291)

• For safety reasons, it is recommended that the maintenance of this equipment be performed by an IASD. Inspect the generator regularly, and contact the nearest IASD for parts needing repair or replacement.

Exhaust and Location Hazards

DANGER

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas.

Carbon monoxide, if not avoided, will result in death or serious injury.

(000103)

DANGER


(000179b)

WARNING

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

(000146)

WARNING


(000178a)

• If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon monoxide poisoning.

• NEVER run a generator indoors or in a partly enclosed area such as garages.

• ONLY use outdoors and far away from windows, doors, vents, crawl spaces and in an area where adequate ventilation is available and will not accumulate deadly exhaust gas.

• Using a fan or opening a door will not provide sufficient ventilation.

• Point muffler exhaust away from people and occupied buildings.

Owner’s Manual for Portable Generator

Electrical Hazards

DANGER

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

(000144)

DANGER

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

(000104)

DANGER

Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury .

(000145)

• The National Electric Code (NEC) 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.

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

• Once generator has been started outside, connect electrical loads to extension cord(s) inside.

Fire Hazards

DANGER

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000105)

DANGER

Explosion and Fire. Do not overfill fuel tank. Fill to

1/2 inch from top of tank to allow for fuel expansion.

Overfilling may cause fuel to spill onto engine causing fire or explosion, which will result in death or serious injury.

(000166b)

WARNING


(000142a)

WARNING

Fire risk. Fuel and vapors are extremely flammable. Do not operate indoors. Doing so could result in death, serious injury, or property or equipment damage.

(000281)

WARNING

Explosion and fire risk. Do not smoke near unit.

Keep fire and spark away. Failure to do so could result in death, serious injury, or property or equipment damage.

(000282)

WARNING

Explosion and Fire. Do not smoke while refueling unit. Failure to do so could result in death, serious injury, or property or equipment damage.

(000284a)

• Allow at least 5 feet of clearance on all sides of the generator when operating to prevent overheating and fire.

• Do not operate the generator if connected electrical devices overheat, if electrical output is lost, if engine or generator sparks, or if flames or smoke are observed while unit is running.

• Keep a fire extinguisher near the generator at all times.

Standards Index

1. National Fire Protection Association

(NFPA) 70: The NATIONAL ELECTRIC

CODE (NEC) available from www.nfpa.org

2. National Fire Protection Association

(NFPA) 5000: BUILDING CONSTRUC-

TION AND SAFETY CODE available from www.nfpa.org

3. International Building Code available from www.iccsafe.org

4. Agricultural Wiring Handbook available from www.rerc.org, Rural Electricity

Resource Council P.O. Box 309 Wilmington, OH 45177-0309

5. ASAE EP-364.2 Installation and Maintenance of Farm Standby Electric Power available from www.asabe.org, American

Society of Agricultural & Biological Engineers 2950 Niles Road, St. Joseph, MI

49085

6. CSA C22.2 100-14 Electric motors and generators for installation and use, in accordance with the Rules of the Canadian Electrical Code

7. ANSI/PGMA G300 Safety and Performance of Portable Generators. Portable

Generator Manufacturer’s Association, www.pgmaonline.com

This list is not all inclusive. Check with the

Authority Having Jurisdiction (AHJ) for any local codes or standards which may be applicable to your jurisdiction.


4

Section 2 General Information and Setup

5

1

2

6

3

4

7

006674

Figure 2-1. Features and Controls

TABLE 1. Generator Components

14

7

8

5

6

3

4

1

2

Control Panel

Spark Plug Access Cover

Recoil Handle

Engine Control Switch

Fuel Cap and Vent

Engine Service Panel

Muffler and Spark Arrestor

120V, 20A Receptacle

9 1 Amp USB Outlet

10 Economy Mode Switch

11 Grounding Location

12 Output Ready LED

13 Overload LED

14 Low Oil LED

15 AC Breaker

16 2.1 Amp USB Outlet

13

12

15

10

9

16

Figure 2-2. Control Panel

8

11

006675


Know Your Generator

WARNING

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

(000100a)

Replacement owner’s manuals are available at www.generac.com.

Emissions

The United States Environmental Protection

Agency (US EPA) (and California Air

Resources Board (CARB), for engines/equipment certified to California standards) requires that this engine/equipment complies with exhaust and evaporative emissions standards. Locate the emissions compliance decal on the engine to determine applicable standards. For emissions warranty information, please reference the included emissions warranty. It is important to follow the maintenance specifications in the manual to ensure that the engine complies with the applicable emissions standards for the duration of the product’s life.

TABLE 2. Product Specifications

Generator Specifications

Rated Power

Starting Power

Rated AC Voltage

Rated AC Load at 120V

Rated Frequency

Dimensions L x W x H (in/mm)

Weight (dry)

GP1200i

1000 W

1200 W

120V

8.33 Amps**

60 Hz

18.5 x 10.2 x 7.9 (470 x 260 x 200)

33 lb. (15 kg)

** Operating Temperature Range: -17.8° C (0° F) to 40° C (104° F). When operated above 25° C (77°

F) there may be a decrease in power.

** 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.

Engine Specifications GP1200i

Engine Type

Displacement

Spark Plug Part Number

Spark Plug Type

Spark Plug Gap (in/mm)

Fuel Capacity / Type

Oil Type

Single Cylinder, 4-stroke

54 cc

10000031505

Torch A5RTC, Champion RZ10YC, Bosch

U4BC, Autolite 2795 or equivalent

0.032 (0.8)

3.0 L (0.8 U.S. gallons) / Unleaded

10W30

Oil Capacity

Run Time at 50% Load

0.25 L (0.26 qt.)

5.5 Hours

* Go to www.generac.com or contact an IASD for replacement parts.


Connection Plugs

120 VAC, Duplex Receptacle

The 120 Volt outlet is overload protected by the 20 Amp push button circuit protector. See

Figure 2-3 .

001630

Figure 2-3. 120 VAC, Duplex Receptacle

Run/Choke Switch

This controls the choke operation. See Figure

2-4 .

• The RUN position (1) is for normal operation and to gradually reduce the use of the choke.

• The CHOKE position (2) switches the fuel valve on to start the engine.

NOTE: The CHOKE is not required to start a warm engine.

are turning on and off (example: RV, air conditioner, hairdryer).

See Figure 2-2 for location of the economy switch.

Generator Status Lights

See Figure 2-5 .

• Overload LED ( red ): Indicates system overload (2). During motor starting it is normal for the overload LED to illuminate for a few seconds. If LED stays illuminated and the ready LED turns off, the engine will continue to run without output power. Remove all applied loads and determine if attached devices exceed recommended output power. Check for faulty or shorted connections. To restore electrical output, turn dial

OFF to reset. Start engine. If condition was corrected, the orange LED will not illuminate and electrical output will be restored.

Loads can be applied once the green LED illuminates. If the orange LED returns, contact an IASD.

• Low Oil Level LED (yellow): Illuminates when oil level is below safe operating level.

Engine shuts down (1).

• Power LED (green): Indicates output from generator (3) (unless there is a low oil or overload condition).

3

2

1

1 2

6

Figure 2-4. Switch (example)

006676

USB Outlets

The 5 VDC, 1/2.1 Amp USB outlet allows charging of compatible electronic devices.

See Figure 2-2 for location of the UBS outlets.

Economy Switch

The economy switch has 2 modes of operation:

• On: The quietest mode and best when running appliances or equipment that are resistive loads (non-motor starting), (example: TV, video game, light, radio).

• Off: Best when running a both inductive

(motor-starting) and resistive (non-motor starting) loads, especially when these loads

OVERLOAD OUT

PUT

005483

Figure 2-5. Status Indicators

Circuit Protectors

The AC receptacles are protected by an AC circuit protector. If the generator is overloaded or an external short circuit occurs, the circuit protector will trip. If this occurs, disconnect all electrical loads to determine the cause of the problem before using the generator again.

Reduce the load if the circuit protector is tripped.

NOTE: Continuous tripping of the circuit protector may cause damage to generator or equipment.

Push the button of the protector to reset the circuit protector.


Remove Contents from Carton

1. Open carton completely by cutting each corner from top to bottom.

2. Remove and verify carton contents prior to assembly. Carton contents should contain the following:

TABLE 3. Accessories

Item

Main Unit

Owner’s Manual

Quick Start Guide

Oil Funnel

Spark Plug Wrench

Service Warranty

Emissions Warranty

1

1

1

1

Qty.

1

1

1

3. Call Generac Customer Service at 1-888-

GENERAC (1-888-436-3722) with the unit model and serial number for any missing carton contents.

4. Record model, serial number, and date of purchase on front cover of this manual.

Add Engine Oil

CAUTION

Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage.

(000135)

NOTE: The generator is shipped without oil and must be purchased separately. Add oil slowly and verify oil level often during filling process to ensure overfilling does not occur.

1. Place generator on a level surface.

2. Clean area around oil fill and oil drain plug.

3. Remove oil fill cap and wipe dipstick clean.

See Figure 2-6 .

000115

Figure 2-6. Remove Dipstick

4. Insert funnel into oil fill opening. Add recommended engine oil as necessary. Climate determines proper engine oil viscosity. See chart to select correct viscosity.


NOTE: Use petroleum based oil for engine break-in before using synthetic oil.

S y n t h e t i c 5 W- 3 0

1 0 W- 3 0

S A E 1 5 W- 4 0

5. To check oil level, remove funnel and insert dipstick into oil filler neck. See Figure 2-7 .

000116

Figure 2-7. Safe Operating Range

6. Remove dipstick and verify oil level is within safe operating range.

NOTE: Verify oil level often during filling process to ensure overfilling does not occur.

7. Install oil fill cap/dipstick and hand-tighten.

Fuel

DANGER

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000105)

DANGER

Explosion and Fire. Do not overfill fuel tank. Fill to

1/2 inch from top of tank to allow for fuel expansion.

Overfilling may cause fuel to spill onto engine causing fire or explosion, which will result in death or serious injury.

(000166b)

Fuel requirements are as follows:

• Clean, fresh, unleaded gasoline.

• Minimum rating of 87 octane/87 AKI (91

RON).

• Up to 10% ethanol (gasohol) is acceptable.

• DO NOT use E85.

• DO NOT use a gas oil mix.

• DO NOT modify engine to run on alternate fuels. Stabilize fuel prior to storage.

1. Verify unit is OFF and cooled entirely prior to fueling.

2. Place unit on level ground in a well ventilated area.

7

WARNING

Explosion and Fire. Verify fuel cap vent is set to

ON for operation, and OFF for transportation and storage. Failure to do so could result in poor unit performance, death, or serious injury.

(000362)

3. Clean area around fuel cap.

4. Turn cap slowly to remove.

5. Slowly add recommended fuel. Do not overfill.

6. Install fuel cap.

NOTE: Allow spilled fuel to evaporate before starting unit.

IMPORTANT NOTE: It is important to prevent gum deposits from forming in fuel system parts such as the carburetor, fuel hose or tank during storage. Alcoholblended 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 or treated 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.

8 Owner’s Manual for Portable Generator

Section 3 Operation

Operation and Use Questions

Call Generac Customer Service at 1-888-

GENERAC (1-888-436-3722) with questions or concerns about equipment operation and maintenance.

Before Starting Engine

1. Verify engine oil level is correct.

2. Verify fuel level is correct.

3. Verify unit is secure on level ground, with proper clearance and is in a well ventilated area.

Prepare Generator for Use

DANGER

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

(000103)

DANGER


(000179b)

WARNING

Risk of fire. Do not use generator without spark arrestor installed. Failure to do so could result in death or serious injury.

(000118a)

WARNING


(000178a)

WARNING

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire could result in death or serious injury.

(000110)

WARNING

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

(000108)

CAUTION

Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.

(000136)

Grounding the Generator When

In Use

The generator is equipped with an equipment ground connecting the generator frame and the ground terminals on the AC output receptacles (see NEC 250.34 (A). This allows the generator to be used as a portable without grounding the frame of the generator as specified in NEC 250.34. See Figure 2-2 for grounding location.

The generator (stator winding) is isolated from the frame and from the AC receptacle ground pin. Electrical devices that require a grounded receptacle pin connection will not function if the receptacle ground pin is not functional.

Know Generator Limits

Overloading a generator can result in damage to the generator and connected electrical devices. Observe the following to prevent overload:

• 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 be found on a data label 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 only a few seconds when starting such motors. Make sure to allow for high starting wattage when selecting electrical devices to connect to the generator:

1. Figure the watts needed to start the largest motor.

2. Add to that figure the running watts of all other connected loads.


Wattage Reference Guide is provided to assist in determining how many items the generator can operate at one time.

NOTE: All figures are approximate. See data label on appliance for wattage requirements.

Wattage Reference Guide

Device

*Air Conditioner (12,000 Btu)



Battery Charger (20 Amp)

Belt Sander (3")

Chain Saw

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

*Dehumidifier

Disc Sander (9")

Edge Trimmer

Electric Blanket

Electric Nail Gun

Electric Range (per element)

Electric Skillet

*Freezer

*Furnace Fan (3/5 HP)

*Garage Door Opener

Hair Dryer

Hand Drill

Hedge Trimmer

Impact Wrench

Iron

*Jet Pump

Lawn Mower

Light Bulb

Microwave Oven

*Milk Cooler

Oil Burner on Furnace

Oil Fired Space Heater (140,000

Btu)

Oil Fired Space Heater (85,000 Btu)

Running

Watts

1700

500

400

1200

1500

1250

700

875

500 to 750

1200

250 to 1100

450

500

1200

800

1200

100

700 to 1000

1100

300

400

1150

1750

2000

1800

1400

700

650

1200

3800

6000

500

1000

1200

800 to 1000

5750

700

225

10

Oil Fired Space Heater (30,000 Btu)

*Paint Sprayer, Airless (1/3 HP)

Paint Sprayer, Airless (hand-held)

Radio

*Refrigerator

Slow Cooker

*Submersible Pump (1-1/2 HP)

*Submersible Pump (1 HP)

150

600

150

50 to 200

700

200

2800

2000

*Submersible Pump (1/2 HP)

*Sump Pump

*Table Saw (10")

Television

1500

800 to 1050

1750 to 2000

200 to 500

Toaster

Weed Trimmer

1000 to 1650

500

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

Transporting/Tipping of the Unit

Do not store or transport the unit at an angle greater than 15 degrees.

Starting Pull Start Engines

WARNING

Recoil Hazard. Recoil could retract unexpectedly.

Kickback could result in death or serious injury.

(000183)

CAUTION


(000136)

1. See Figure 3-1 . Turn fuel vent ON.

006677

Figure 3-1.Turn Fuel Vent ON

2. See Figure 3-2 . Turn engine control switch

ON.


1

ON

2

OFF

006678

Figure 3-2.Turn Engine Switch ON

3. See Figure 3-3 . Move the Run/Choke lever to CHOKE (2).

4. Switch Economy switch to OFF.

5. Firmly grasp recoil handle and pull slowly until increased resistance is felt. Pull rapidly up and away.

006676

Figure 3-3.Off/Run/Choke Positions

6. See Figure 3-3 . When engine starts, move

Run/Choke lever to RUN (1).

NOTE: If engine fires, but does not continue to run, move Run/Choke lever to CHOKE (2) and repeat starting instructions.

.

IMPORTANT NOTE: Do not overload generator or individual panel receptacles. See

Figure 3-4 . If an overload occurs, the overload LED (A) will illuminate and AC output ceases. To correct, see Generator Status

Lights . Read Know Generator Limits carefully.

A B

Generator Shut Down

CAUTION


(000136)

1. Shut off all loads and unplug electrical loads from generator panel receptacles.

2. Let engine run at no-load for several minutes to stabilize internal temperatures of engine and generator.

3. See Figure 3-2 . Turn engine control switch

OFF.

4. See Figure 3-1 . Turn fuel vent OFF.

Starting Hot Engines

CAUTION


(000136)

1. See Figure 3-3 . Move Run/Choke lever to

RUN. This will open the fuel valve and permit starting.

2. Firmly grasp recoil handle and pull slowly until increased resistance is felt. Pull rapidly up and away.

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 to prevent engine damage. See

Figure 3-4 (B). The engine will not run until the oil has been filled to the proper level.

If the engine shuts down and there is sufficient fuel, check engine oil level.

OVERLOAD OUT

PUT

005483

Figure 3-4.Shutdown Fault


Section 4 Maintenance and Troubleshooting

Maintenance

Regular maintenance will improve performance and extend engine/equipment life.

Generac Power Systems, Inc. recommends that all maintenance work be performed by an

Independent Authorized Service Dealer

(IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing. To obtain emissions control warranty service free of charge, the work must be performed by an

IASD. See the emissions warranty.

NOTE: Call 1-888-GENERAC (1-888-436-

3722) with questions about component replacement.

Maintenance Schedule

Follow maintenance schedule intervals, whichever occurs first according to use.

NOTE: Adverse conditions will require more frequent service.

NOTE: All required service and adjustments should be each season as detailed in the following chart.

Before Each Use

Check engine oil level

Check and clean cooling features

Check air filter

After First 20 Hours or First Month

Change engine oil

After 50 Hours or Every 6 Months

Change engine oil

Clean air filter*

After 100 Hours or Every 6 Months

Check and clean spark plug

Check and clean spark arrestor

After 300 Hours or Every Year

Replace air filter

Replace spark plug

* Service more frequently if operating in dry or dusty conditions.

Preventive Maintenance

Dirt or debris can cause improper operation and equipment damage. Clean generator daily or before each use. Keep area around and behind muffler free from combustible debris. Inspect all cooling air openings on generator.

WARNING


(000142a)

• Use a damp cloth to wipe exterior surfaces clean.

• Use a soft bristle brush to loosen caked on dirt, oil, etc.

• Use a vacuum 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 generator.

These openings must be kept clean and unobstructed.

NOTE: DO NOT use a garden hose to clean generator. Water can enter engine fuel system and cause problems. If water enters generator through cooling air slots, some water will be retained in voids and crevices of rotor and stator winding insulation. Water and dirt buildup on generator internal windings will decrease insulation resistance of windings.

Engine Maintenance

WARNING

Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.

(000141)

Engine Oil Recommendations

To maintain the product warranty, the engine oil should be serviced in accordance with the recommendations of this manual. For your convenience, maintenance kits designed and intended for use on this product are available from the manufacturer that include engine oil, oil filter, air filter, spark plug(s), a shop towel and funnel. These kits can be obtained from an Independent Authorized Service Dealer

(IASD).


S y n t h e t i c 5 W- 3 0

1 0 W- 3 0

S A E 1 5 W- 4 0

Inspect Engine Oil Level

WARNING

Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.

(000139)

Inspect engine oil level prior to each use, or every 8 hours of operation.


2. Clean area around oil fill, and oil drain plug.


See Figure 4-1 .

7. Replace oil fill cap and hand-tighten.

NOTE: Some units have more than one oil fill location. It is only necessary to use one oil fill point.

Change Engine Oil

WARNING

Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.

(000141)

When using generator under extreme, dirty, dusty conditions, or in extremely hot weather, change oil more frequently.

NOTE: Don’t pollute. Conserve resources.

Return used oil to collection centers.

Change oil while engine is still warm from running, as follows:


2. Disconnect the spark plug wire from the spark plug and place the wire where it cannot contact spark plug.

3. Clean area around oil fill and oil drain plug.


5. Tip unit and drain oil completely into a suitable container.

6. Once oil is sufficiently drained from unit, tip unit back to a level position.

7. Insert funnel into oil fill opening. See Figure 4-3 . Add recommended engine oil as necessary.

000115

Figure 4-1.Engine Oil Fill

4. To check oil level, insert dipstick into oil filler neck without screwing it in. See Figure 4-2 .

000116

Figure 4-2.Safe Operating Range


6. Add recommended engine oil as necessary.



002404

Figure 4-3.Oil Fill Opening With Funnel

8. To check oil level, remove funnel and insert dipstick into oil filler neck without screwing it in. See Figure 4-2 .



10. Replace oil fill cap and hand-tighten.

11. Wipe up any spilled oil.

12. Properly dispose of oil in accordance with all applicable regulations.

13

Air Filter

Engine will not run properly and may be damaged if run with a dirty air filter. Service air filter more frequently in dirty or dusty conditions.

To service air filter:

1. Remove the engine service panel to access the air filter.

2. Release tabs for the air cleaner cover and tip the cover down.

3. See Figure 4-4 . Remove foam element from air cleaner housing and wash in soapy water. Squeeze dry in clean cloth

(DO NOT TWIST)

4. Clean air filter cover before installation.

5. Replace side cover and screws.

NOTE: To order a new air filter, contact the nearest authorized service center at 1-888-

436-3722.

006680

Figure 4-5.Float Bowl Hose

3. Loosen the float bowl drain screw until fuel is seen draining from the float bowl.

4. Allow fuel to drain into the container, and then tighten the float bowl drain screw.

5. Install the engine service panel.

Service Spark Plug

To service spark plug:

1. Remove spark plug cover. See Figure 2-1 .

2. Clean area around spark plug.

3. Remove and inspect spark plug.

4. Inspect electrode gap with wire feeler gauge and reset spark plug gap to 0.8 mm

(0.032 in). See Figure 4-6 .

Figure 4-4.Air Filter Assembly

006673

Drain Float Bowl

To drain the float bowl:

1. Remove the engine service panel to access the carburetor.

2. See Figure 4-5 . Locate the clear plastic hose from the float that is exiting out the bottom of the inverter, and place a suitable container under it to catch the drained fuel.

14

000211

Figure 4-6.Spark Plug

NOTE: Replace spark plug if electrodes are pitted, burned or porcelain is cracked. Use

ONLY recommended replacement plug. See

Product Specifications .

5. Install spark plug finger tight, and tighten an additional 3/8 to 1/2 turn using spark plug wrench.

Inspect Muffler and Spark Arrestor

NOTE: It is a violation of California Public

Resource Code, Section 4442, to use or operate the engine on any forest-covered, brushcovered, or grass-covered land unless the exhaust system is equipped with a spark


arrestor, as defined in Section 4442, maintained in effective working order. Other states or federal jurisdictions may have similar laws.

Contact original equipment manufacturer, retailer, or dealer to obtain a spark arrestor designed for exhaust system installed on this engine.

NOTE: Use ONLY original equipment replacement parts.

Inspect muffler for cracks, corrosion, or other damage. Remove spark arrestor, if equipped, inspect for damage or carbon blockage.

Replace parts as required.

Inspect Spark Arrestor Screen

WARNING

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

(000108)

Clean Spark Arrestor Screen

The engine exhaust muffler has a spark arrestor screen. Inspect and clean the screen every

50 hours of operation or every season, whichever comes first.

To service spark arrestor:

1. Stop the unit and let it cool for several minutes.

2. See Figure 4-7 . Remove the screws holding the muffler cover in place.

006672

Figure 4-7.Remove Screws

3. See Figure 4-8 . Remove the clamp to remove retainer.

4. Slide spark arrestor screens out from the muffler outlet tube.

5. Inspect screens and replace if torn, perforated or otherwise damaged. Do NOT use a defective screen. If screen is not damaged, clean with a commercial solvent.

6. Replace the screens, and retainer, and secure with clamp.

7. Replace muffler cover and install screws.

Valve Clearance

Important: Please contact an Independent

Authorized Service Dealer for service assistance. Proper valve clearance is essential for prolonging the life of the engine.

• Intake — 0.06 ± 0.10 mm (cold), (0.002 ±

0.004 in)

• Exhaust — 0.08 ± 0.12 mm (cold) (0.003 ±

0.005 in)

Storage

General

DANGER

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Store fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

(000143)

WARNING

Risk of Fire. Verify machine has properly cooled before installing cover and storing machine. Hot surfaces could result in fire.

(000109)

It is recommended to start and run the generator for 30 minutes, every 30 days. If this is not possible, refer to the following list to prepare unit for storage.

• DO NOT place a storage cover on a hot generator. Allow unit to cool to room temperature before storage.

• DO NOT store fuel from one season to another unless properly treated.

• Replace fuel container if rust is present.

Rust in fuel will cause fuel system problems.

• Cover unit with a suitable protective, moisture resistant cover.

• Store unit in a clean, dry area.

• Always store generator and fuel away from heat and ignition sources.

006774

Figure 4-8.Spark Arrestor Screen


Prepare Fuel System/Engine for

Storage

Fuel stored over 30 days can go bad and damage fuel system components. Keep fuel fresh, use fuel stabilizer.

If fuel stabilizer is added to the fuel system, prepare and run engine for long term storage.

Run engine for 10-15 minutes to circulate stabilizer throughout fuel system. Adequately prepared fuel can be stored up to 24 months.

NOTE: If fuel has not been treated with fuel stabilizer, it must be drained into an approved container. Run engine until it stops from lack of fuel. Use of fuel stabilizer in fuel storage container is recommended to keep fuel fresh.

1. Change engine oil.

2. Remove spark plug.

3. Pour tablespoon (5-10cc) of clean engine oil or spray a suitable fogging agent into cylinder.

WARNING

Vision Loss. Eye protection is required to avoid spray from spark plug hole when cranking engine.

Failure to do so could result in vision loss.

(000181)

4. Pull starter recoil several times to distribute oil in cylinder.

5. Install spark plug.

6. Pull recoil slowly until resistance is felt.

This will close valves so moisture cannot enter engine cylinder. Gently release recoil.

Change Oil

Change engine oil before storage. See,

Change Engine Oil .


Troubleshooting

PROBLEM

Engine won't start.

CAUSE

1. Dial turned off.

2. Out of fuel.

3. Defective spark plug.

4. Defective or stuck Dial assembly.

5. Incorrect engine oil level.

6. Defective ignition coil.

7. Fuel cap vent OFF.

8. Carb is flooded.

9. Throttle plate closed.

CORRECTION

1. Turn on Dial.

2. Fill fuel tank.

3. Replace spark plug.

4. Contact IASD.

5. Check/fill engine oil.

6. Contact IASD.

7. Turn fuel cap vent ON.

8. Drain carb.

9. Open throttle plate (push toward back of unit).

Engine starts, then shuts down.

Engine will not start; or starts and runs rough.*

1. Out of fuel.

2. Incorrect engine oil level.

3. Contaminated fuel.

4. Defective low oil level switch.

1. Choke is stuck or left on.

2. Dirty or clogged air filter.

3. Defective or dirty spark plug.

4. Dirty or gummed up carburettor.

5. Unit not warmed up.

6. Spark arrestor clogged.

1. Fill fuel tank.

2. Check engine oil level.

3. Contact IASD.

4. Contact IASD.

1. Turn choke off.

2. Clean or replace air filter.

3. Replace spark plug.

4. Clean carburetor.

5. Gradually adjust Dial and reduce choke until engine runs smoothly in RUN position.

6. Clean spark arrestor.

No AC output.

1. Generator is overloaded.

2. Inverter module is overheated.

3. Short circuit in electrical device.

4. Defective inverter assembly.

1. Disconnect all loads. Shut down generator to reset module. Reduce loads, restart generator.

2. Verify service door is ON. Let cool 15 minutes by running engine without AC output.

Press and hold Reset button on control panel, restart generator.

3. Verify condition of extension cords and items being powered. Press and hold Reset button on control panel.

4. Contact IASD.

Fuel leaks from drain hoses.

1. Carburetor drain in bowl is not closed.

1. Turn valve clockwise to close.

* Engine speed increases and decreases — This is normal as generator starts up and loads vary.


Section 5 Exploded Views and Parts Lists

NOTE: Only parts called out in the parts lists below will be supported.

14

13

15

19

12

7

19

23

24

25

4

8

22

5

22

9

6

11

10

20

22

21

19

18

19

19

1

2

3

3

2

16

17

19


Item

Number

1

2

Part Number

10000031542

10000006838

Description

Enclosure Base

Rubber Foot

3

4

5

6

10000031551

10000031496

10000031543

10000031514

Bolt (M6X20)

Left Side Enclosure

Fuel Valve Lever

Fuel Valve

7

8

10000031486

10000031553

9 10000031532

10 10000031523

11 10000031524

12 10000031515

13 10000031525

14 10000031516

Fuel Shut-Off Knob

Fuel Shut-Off Knob Gasket

Fuel Valve Upper Hose

Fuel Valve Lower Hose

Fuel Pump

Service Access Panel

Fuel Fill Cover

Fuel Fill Cap

15 10000031499

16 10000031517

17 10000031526

18 10000031527

19 10000031560

20 10000031488

21 10000031544

22 10000006942

23 10000031518

24 10000031507

25 10000031529

Filter Basket

Right Side Enclosure

Inspection Cover

Control Panel

Bolt (M5X12)

Exhaust Packing

Muffler End Enclosure Piece

Lock Clamps

Recoil Rope Handle Cover

Recoil Rope Handle

Recoil Rope Guide

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

4

1

1

4

1

1

1

1

1

13

1

1

6


11

13

14

12

18

20

19

21

7

8

17


9

10 16

15

4

6

5

3

2 1

20

Item

Number

1

2

Part Number

10000031471

10000031472

Description

Intake Plenum

Air Plenum to Carb Gasket

3

4

5

6

10000031504

10000031511

10000031466

10000031473

Carburetor Assembly

Stepper Motor

Carb to Spacer Gasket

Carburetor Spacer

7

8

10000031530

10000031505

9 10000031531

10 10000031483

11 10000031467

12 10000031484

13 10000031494

14 10000031469

Rocker Cover Gasket

Spark Plug

Intake Port Gasket

Breather Tube

Recoil Assembly

Air Cleaner Element

Ignition Coil

Recoil Cup

15 10000031506

16 10000031521

17 10000031540

18 10000031475

19 10000031513

20 10000031476

21 10000031522

Fuel Inlet Tube

Hose

Engine Oil Dipstick

Muffler Assembly

Muffler Gasket

Exhaust Pipe

Exhaust Port Gasket

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1


Part No. 10000028711 Rev. A 02/26/2018

©2018 Generac Power Systems, Inc.

All rights reserved

Specifications are subject to change without notice.

No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc.

Generac Power Systems, Inc.

S45 W29290 Hwy. 59

Waukesha, WI 53189

1-888-GENERAC (1-888-436-3722) www.generac.com

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