Generac Power Systems GP Series Manuel utilisateur

GP Series Portable Generator

Owner’s Manual

MODEL:________________________

SERIAL:________________________

DATE PURCHASED:______________

WWW.GENERAC.COM

1-888-GENERAC

(1-888-436-3722)

SAVE THIS MANUAL FOR FUTURE REFERENCE

000381

(000209a)

WARNING

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.

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

Hour Meter ...................................... 6

Connection Plugs ............................ 7

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

Assembly ......................................... 8

Battery Cable Connection (electric

start only) ........................................ 9

Add Engine Oil ................................ 9

Fuel ................................................. 9

Section 3 Operation .................... 11

Operation and Use Questions ....... 11

Before Starting Engine .................. 11

Prepare Generator for Use ............ 11

Grounding the Generator When Used

as a Portable ................................. 11

Know Generator Limits .................. 11

Transporting/Tipping of the Unit .... 12

Starting Pull Start Engines ............ 12

Starting Electric Start Engines ...... 13

Low Oil Level Shutdown System ... 14

Charging the Battery (electric start

units only) ...................................... 14

Section 4 Maintenance and

Troubleshooting ..........................15

Maintenance ..................................15

Maintenance Schedule ..................15

Preventive Maintenance ................15

Engine Maintenance ......................15

Battery Replacement (if applicable) 17

Inspect Muffler and Spark Arrester 17

Valve Clearance ............................18

Storage ..........................................18

Troubleshooting .............................19

Notes .............................................20

(000004)

WARNING

California Proposition 65. Engine exhaust and some

of its constituents are known to the state of California

to cause cancer, birth defects, and other reproductive

harm.

(000005)

WARNING

California Proposition 65. This product contains or

emits chemicals known to the state of California to

cause cancer, birth defects, and other reproductive

harm.

Owner’s Manual for Portable Generator 1

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, effi-

cient operation, and years of use when main-

tained properly.

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 mainte-

nance 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 man-

ual for instructions on final assembly proce-

dures. 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, there-

fore, not all inclusive. If using a procedure,

work method or operating technique that the

manufacturer does not specifically recom-

mend, 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 haz-

ardous if performed incorrectly or carelessly.

Observe them carefully. Their definitions are

as follows:

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 instruc-

tions while performing the action or service

are essential to preventing accidents.

Safety Symbols and Meanings

• The engine exhaust fumes contain carbon

monoxide, which you cannot see or smell.

This poisonous gas, if breathed in sufficient

concentrations, can cause unconscious-

ness or even death.

• Adequate, unobstructed flow of cooling and

ventilating air is critical to correct generator

operation. Do not alter the installation or

permit even partial blockage of ventilation

provisions, as this can seriously affect safe

operation of the generator. The generator

MUST be operated outdoors.

(000100a)

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.

(000001)

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious injury.

(000002)

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

(000003)

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

000657

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.

2 Owner’s Manual for Portable Generator

• This exhaust system must be properly

maintained. Do nothing that might render

the exhaust system unsafe or in noncompli-

ance with any local codes and/or stan-

dards.

• Always use a battery operated carbon

monoxide alarm indoors, installed accord-

ing to the manufacturers instructions.

• 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 poison-

ing.

• For safety reasons, it is recommended that

the maintenance of this equipment be per-

formed by an IASD. Inspect the generator

regularly, and contact the nearest IASD for

parts needing repair or replacement.

• Operate generator only on level surfaces

and where it will not be exposed to exces-

sive moisture, dirt, dust or corrosive vapors.

• When working on this equipment, remain

alert at all times.

• Never work on the equipment when physi-

cally or mentally fatigued.

• Never use the generator or any of its parts

as a step. Stepping on the unit can stress

and break parts, and may result in danger-

ous operating conditions from leaking

exhaust gases, fuel leakage, oil leakage,

etc.

Exhaust and Location Hazards

• This exhaust system must be properly

maintained. Do nothing that might render

the exhaust system unsafe or in noncompli-

ance with any local codes and/or stan-

dards.

• 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 poison-

ing.

• Point muffler exhaust away, downwind from

occupied buildings.

• Place generator at least 20 feet from occu-

pied buildings.

(000103)

DANGER

Asphyxiation. Running engines produce carbon

monoxide, a colorless, odorless, poisonous gas.

Carbon monoxide, if not avoided,

will result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power source,

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

(000116)

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.

(000111)

WARNING

Moving Parts. Keep clothing, hair, and appendages

away from moving parts. Failure to do so could

result in death or serious injury.

(000108)

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.

(000146)

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.

(000142)

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.

WARNING

000406

(000103)

DANGER

Asphyxiation. Running engines produce carbon

monoxide, a colorless, odorless, poisonous gas.

Carbon monoxide, if not avoided,

will result in death or serious injury.

(000146)

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.

(000178a)

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.

WARNING

Owner’s Manual for Portable Generator 3

Electrical Hazards

• The National Electric Code (NEC) requires

the frame and external electrically conduc-

tive parts of the generator be properly con-

nected 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

• Wipe up any fuel or oil spills immediately.

Verify that no combustible materials are left

on or near the generator. Keep the area

surrounding the generator clean and free

from debris and keep a clearance of five (5)

feet on all sides to allow for proper ventila-

tion of the generator.

• Do not operate the generator if connected

electrical devices overheat, if electrical out-

put 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 Wilming-

ton, OH 45177-0309

5. ASAE EP-364.2 Installation and Mainte-

nance of Farm Standby Electric Power

available from www.asabe.org, American

Society of Agricultural & Biological Engi-

neers 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 Cana-

dian Electrical Code

7. ANSI/PGMA G300 Safety and Perfor-

mance 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 appli-

cable to your jurisdiction.

(000144)

DANGER

Electrocution. Contact with bare wires,

terminals, and connections while generator

is running will result in death or serious injury.

(000104)

DANGER

Electrocution. Water contact with a power source,

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

(000145)

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.

(000130)

WARNING

Accidental Start-up. Disconnect the negative battery

cable, then the positive battery cable when working

on unit. Failure to do so could result in death

or serious injury.

(000105)

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.

(000166)

DANGER

Do not overfill fuel tank. Fill to 1/2 in. of 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.

(000142)

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.

WARNING

4 Owner’s Manual for Portable Generator

Section 2 General Information and Setup

Figure 2-1. Features and Controls

Generator Components

Figure 2-2. Unit Identification Label

Figure 2-3. Control Panel

000398

000381

18 7

1 120 Volt AC, 20 Amp, GFCI (if equipped)

Duplex Receptacle (NEMA 5-20R)

2 120/240 Volt AC, 30 Amp Locking

Receptacle (NEMA L14-30R)

3 Circuit Breakers (AC)

4OilDrain

5 Air Filter

6 Choke Knob

7 Fuel Tank

8 Grounding Lug

9 Run/Stop Switch (pull start models only)

10 Start Switch (electric start models only)

11 Muffler

12 Handle

13 Gas Cap

14 Fuel Gauge

15 Oil Fill

16 Recoil Starter

17 Fuel Shut Off

18 Roll Over Valve

19 Recovery Hose

20 Hour Meter

21 Battery Charger Input

22 Battery Location (if equipped)

23 Spark Arrestor

000601

000585

2120

103

Owner’s Manual for Portable Generator 5

Figure 2-4. Control Panel

Figure 2-5. Control Panel

Know Your Generator

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/equip-

ment certified to California standards) requires

that this engine/equipment complies with

exhaust and evaporative emissions stan-

dards. Locate the emissions compliance decal

on the engine to determine applicable stan-

dards. For emissions warranty information,

please reference the included emissions war-

ranty. 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.

000396

2 1 20

000885

2120

(000100a)

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.

6 Owner’s Manual for Portable Generator

Hour Meter

The Hour Meter tracks hours of operation for

scheduled maintenance. See Figure 2-6.

• The CHG OIL display will illuminate every

100 hours. The message will flash one hour

before and one hour after each 100 hour

interval, providing a two hour window to

perform service.

• The SVC display will illuminate every 100

hours. The message will flash one hour

before and one hour after each 200 hour

interval providing a two hour window to per-

form service.

When the hour meter is in flash alert mode,

the maintenance message will alternate with

elapsed time in hours and tenths. The hours

will flash four times, then alternate with the

maintenance message four times until the

meter automatically resets.

• 100 hours - CHG OIL — Oil Change Inter-

val (Every 100 hrs)

• 200 hours - SVC — Service Air Filter

(Every 200 hrs)

NOTE: The hour glass icon will flash when the

engine is running. This signifies the meter is

recording hours of operation.

Product Specifications

Generator Specifications GP5500 GP6500 GP7500 GP8000

Rated Power 5.5 kW** 6.5 kW** 7.5 kW** 8.0 kW**

Surge Power 6.875 KVA 8.125 KVA 9.375 KVA 10.0 KVA

Rated AC Voltage 120/240

Rated AC Load

Current @ 240V**

Current @ 120V** 22.9

45.8 27.1

54.2 31.3

62.5 33.3

66.6

Rated Frequency 60 Hz @ 3600 RPM

Phase Single Phase

Weight (dry)

Pounds (lb)

Kilograms (kg) 170.9-179.2

77.5-81.3 174.8-186

79.3-84.4 191.6-197.1

86.9-89.4 197.1

89.4

** Operating Temperature Range: -18 deg. C (0 deg. F) to 40 Deg. C (104 Deg. F). When operated

above 25 deg. C (77 deg. F) there may be a decrease in power.

** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambi-

ent 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.

5.5 / 6.5 Engine Specifications

Displacement 389 cc

Spark Plug Part No. 0J00620106

Spark Plug Gap 0.028-0.031 inch or (0.70-0.80 mm)

Gasoline Capacity 25.6 L (6.77 gal)

Oil Type See Chart in Add Engine Oil

Oil Capacity 1.0 L (1.06 qt.)

Run Time at 50% Load 11 Hours / 10 Hours

7.5 / 8.0 Engine Specifications

Displacement 420cc

Spark Plug Part No. 0J00620106

Spark Plug Gap 0.028-0.031 inch or (0.70-0.80 mm)

Gasoline Capacity 28.4 L (7.5 gal)

Oil Type See Chart in Add Engine Oil

Oil Capacity 1.0 L (1.06 qt.)

Run Time at 50% Load 11 Hours

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

Owner’s Manual for Portable Generator 7

Figure 2-6. Hour Meter

Connection Plugs

120 VAC, 20 Amp, Duplex Recepta-

cle

The 120 Volt outlet is overload protected by a

20 Amp push-to-reset circuit breaker. See Fig-

ure 2-7. Each receptacle will power 120 Volt

AC, single phase, 60 Hz electrical loads

requiring up to 2400 watts (2.4 kW) or 20

Amps of current. Use only high quality, well-

insulated, 3-wire grounded cord sets rated for

125 Volts at 20 Amps (or greater).

Figure 2-7. 120 VAC, 20 Amp, Duplex

Receptacle NEMA 5-20R

120 VAC, 20 Amp, GFCI Duplex

Receptacle (if equipped)

The 120 Volt outlet is overload protected by a

20 Amp push-to-reset circuit breaker. See Fig-

ure 2-8. Each receptacle will power 120 Volt

AC, single phase, 60 Hz electrical loads

requiring up to 2400 watts (2.4 kW) or 20

Amps of current. Use only high quality, well-

insulated, 3-wire grounded cord sets rated for

125 Volts at 20 Amps (or greater). It also pro-

vides protection with a Ground Fault Circuit

Interrupter with a press to TEST and RESET

button.

Figure 2-8. 120 VAC, 20 Amp, GFCI Duplex

Receptacle NEMA 5-20R

120/240 VAC, 30 Amp Receptacle

Use a NEMA L14-30 plug with this receptacle

(rotate to lock/unlock). Connect a suitable 4-

wire grounded cord set to plug and desired

load. The cord set should be rated 250 Volts

AC at 30 Amps (or greater). See Figure 2-9.

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 or 240

Volt AC, 60 Hz, single phase loads requiring

up to 7200 watts (7.2 kW) of power at 30

Amps. The outlet is protected by two 25 Amp

(5.5kW), or two 30 Amp (6.5kW) push-to-

reset, or one 30 Amp 2-pole circuit breaker or,

two 30 Amp push button to reset (6.5/7.5/8.0

kW) circuit breaker.

Figure 2-9. 120/240 VAC, 30 Amp Receptacle

NEMA L14-30R

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:

0000.0

000205

000424

000203

000204

8 Owner’s Manual for Portable Generator

Accessories

NOTE: The generator is shipped with only one

(1) hardware bag, assembly A or B.

3. Call Generac Customer Service 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.

Assembly

Call Generac Customer Service at 1-888-

GENERAC (1-888-436-3722) for any assem-

bly issues or concerns. Please have model

and serial number available.

The following tools are required to install the

accessory kit.

• Needle nose pliers

• 10mm socket

• 8mm and 13mm box wrenches (2 each)

NOTE: The wheels are not intended for over-

the-road use.

See Figure 2-10 and Figure 2-11.

Install wheels as follows:

1. Slide axle pin (E) through the wheel (B),

wheel bracket on frame, and 1/2” flat

washer (G).

2. Insert cotter pin (F) through axle pin (E).

Bend tabs (of cotter pins) outward to lock

into place.

Install frame foot and rubber bumpers as fol-

lows:

1. Slide hex head bolts (L) through rubber

bumper (D), then through frame foot (C).

2. Slide hex head bolts (K) through holes in

frame rail.

3. Slide frame foot (C) onto hex head bolts

(K). Install locking flange nuts (J).

Install handle as follows:

1. Slide long bolts (K) through handle bracket

and handle (A). Install hex nuts (J).

Figure 2-10. Wheel & Handle Assembly (A)

Figure 2-11. Wheel & Handle Assembly (B)

Item Qty.

Main Unit 1

Owner’s Manual 1

Liter Oil SAE 30 1

Handle Assembly (A) 1

Never-flat Wheel (B) 2

Frame Foot (C) 2

Product Registration Card 3

Service Warranty 1

Emissions Warranty 1

20’ Power Cord (if

equipped) 1

Battery Charger (electric

start models) 1

Hardware Bag Qty.

Assy. A

Qty.

Assy. B

Rubber Feet (D) 2 0

1/2” Axle Pin (E) 2 2

Cotter Pin (F) 2 2

1/2” Flat Washer (G) 2 2

Hex Flanged M6 Nut (H) 2 0

Hex Flanged M8 Nut (J) 6 5

M8 Bolt (Long) (K) 6 5

M6 Bolt (Long) (L) 2 0

(000100a)

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.

000916

JHK

000884

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