GENERAC GP2500i Portable Generator Owner’s Manual

GENERAC GP2500i Portable Generator

Specifications

• Model: GP2500i
• Serial   Number: 013915
• Date Purchased: [To be filled by user]

Product Usage Instructions

• Introduction and Safety
  • Read the manual thoroughly before using the generator. Failure to do so could result in serious injury or death.
• Safety Rules
  • It is crucial to adhere to the safety rules provided in the manual to prevent any accidents or injuries. Pay attention to the safety symbols and their meanings.
• Safety Symbols and Meanings
  • DANGER: Indicates a hazardous situation that will result in death or serious injury.
  • WARNING: Indicates a hazardous situation that could result in death or serious injury.
  • CAUTION: Indicates a hazardous situation that could result in minor or moderate injury.
  • Ensure proper ventilation when using the generator to prevent carbon monoxide poisoning.
• Maintenance and Troubleshooting
  • Regular maintenance is essential for the proper functioning of the generator. Follow the maintenance schedule provided in the manual.
• Maintenance Schedule
  • Refer to the maintenance schedule in the manual for detailed instructions on preventive maintenance and engine maintenance.
• Storage
  • Properly store the generator when not in use to prevent damage and ensure longevity.
• Troubleshooting
  • Refer to the troubleshooting section if you encounter any issues with the generator. The wiring diagram can also help in diagnosing problems.

FAQs

• Q: Can I use the generator indoors?
  • A: No, using the generator indoors can be fatal due to carbon monoxide poisoning. Always operate the generator outdoors in a well-ventilated area.
• Q: What should I do before using the generator?
  • A: Before using the generator, read the manual thoroughly, understand the safety rules, ensure proper ventilation, and perform any required maintenance as outlined in the manual.

Introduction and Safety

Introduction Read This Manual Thoroughly

WARNING Consult Manual. Read and understand the manual completely before using the product. Failure to completely understand the manual and product could result in death or serious injury. (000100a)

• If any section of this manual is not understood, contact the nearest Independent Authorized Service Dealer (IASD) or Generac Customer Service at 1-888-436-3722 (1-888-GEN-ERAC), or visit www.generac.com for starting, operating, and servicing procedures. The owner is responsible for proper maintenance and safe use of the unit.
• SAVE THESE INSTRUCTIONS for future reference. This manual contains important instructions that must be followed during the placement, operation, and maintenance of the unit and its components. Always supply this manual to any individual that will use this unit, and instruct them on how to correctly start, operate, and stop the unit in case of emergency.
• 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 alerts in this manual, and on tags and decals affixed to the unit, are 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 and does not render the equipment unsafe.
• Throughout this publication, and on tags and decals affixed to the unit, 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.

Alert definitions are as follows:

• DANGER: Indicates a hazardous situation that, if not avoided, will result in death or serious injury.
• WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
• NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual. These safety alerts 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 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 Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system to render it unsafe or make it non-compliant with local codes and/or standards. Failure to do so will result in death or serious injury. (000179b)
• 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.
• 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 the 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 the construction of, installation, or block ventilation for the 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 install it 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 the 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 operating the machine, do not touch hot surfaces. Keep the machine away from combustible 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. Generators 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 operate or service this equipment and could result in death or serious injury. (000215a)
• WARNING Injury and equipment damage. Do not use the generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury.  (000216)
• WARNING 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 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)
• WARNING Equipment and property damage. Do not alter the construction of, installation, or block ventilation for the 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 install it according to the manufacturer’s instructions. Failure to do so could result in death or serious injury. (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 a garage.
  • 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.

Electrical Hazards

• DANGER Electrocution. Contact with bare wires, terminals, and connections while the 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 an electrical accident, immediately shut the power OFF. Use non-conductive implements to free a victim from the 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 to 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 steelwork).
• Once a generator has been started outside, connect electrical loads to an 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 the fuel tank. Fill to 1/2 inch from the top of the tank to allow for fuel expansion. Overfilling may cause fuel to spill onto the engine causing fire or explosion, which will result in death or serious injury. (000166b)
• WARNING Personal injury. Do not insert any object through the air cooling slots. Generators can start at any time and could result in death, serious injury, and unit damage. (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 the 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 the unit. Failure to do so could result in death, serious injury, or property or equipment damage. (000284a)
• Allow at least five (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 the electrical output is lost, if the engine or generator sparks, or if flames or smoke are observed while the 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) is available from www.nfpa.org.
2. National Fire Protection Association (NFPA) 5000: BUILDING CONSTRUCTION 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 Mainte-nance 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, per 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 that may apply to your jurisdiction.

General Information and Setup

TABLE 1. Generator Components

Know Your Generator

WARNING: Consult Manual. Read and understand the manual completely before using the product. Failure to completely understand the 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/equip-ment certified to California standards) require this engine/equipment to comply with exhaust and evaporative emissions standards. Locate the emissions compliance decal on the engine to determine applicable standards. See the included emissions warranty for emissions warranty information. Follow the maintenance specifications in this manual to ensure the engine complies with applicable emissions standards for the duration of the product’s life.

TABLE 2. Product Specifications

Operating Temperature Range: -5 °C (23 °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 every 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| 2500i
Engine Type| Single Cylinder, 4-stroke
Displacement| 98 cc
Spark Plug Part Number| 10000006844
Spark Plug Type| E6RTC / BPR6HS or equivalent
Spark Plug Gap (in/mm)| 0.028-0.031 (0.7-0.8)
Fuel Capacity / Type| 3.75 L (1.0 U.S. gallons) / Unleaded
Oil Type| See Add Engine Oi l
Oil Capacity| 0.35 L (0.36 qt.)
Run Time at 50% Load| 4.5 Hours
Run Time at 25% Load| 8 Hours

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

Connection Plugs

120 VAC, Duplex Receptacle: See Figure 2-3. The 120 Volt outlet is overload protected by the 20 Amp push button circuit protector. Each receptacle will power 120 Volt AC, single phase, 60 Hz electrical loads requiring up to 2200 watts (2.2 kW).

Off/Run/Choke Switch
See Figure 2-4. This controls the ON/OFF functions, choke, and fuel valve operation.

• The OFF position (1) stops the engine and shuts off fuel flow.
• The RUN position (2) is for normal opera-tion and to gradually reduce the use of the choke.
• The CHOKE position (3) switches the fuel valve on to start the engine.
  • NOTE: The CHOKE is not required to start a warm engine.

USB Outlet

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

Generator Status Lights
See Figure 2-5.

• Low Oil Level LED (red): Illuminates when oil level is below safe operating level. Engine shuts down (1).
• Overload LED (red): Indicates system overload (2). During motor starting it is normal for the overload LED to illuminate for a few seconds. If the 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 the attached devices exceed the recommended output power. Check for faulty or shorted connec-tions. To restore electrical output, turn the dial OFF to reset. Start engine. If the condition is corrected, the red LED will not illuminate and electrical output will be restored. Loads can be applied once the green LED illuminates. If the red LED returns, contact an IASD.
• Power LED (green): Indicates output from a generator (3) (unless there is a low oil or overload condition).

COsense® Carbon Monoxide (CO) Detection and Shut-off System (if equipped)

• The COsense module monitors for the accumulation of poisonous CO gas found in engine exhaust when the generator is running. If COsense detects increasing levels of CO gas, it automatically shuts off the engine. COsense only monitors when the engine is running.

• Generators are intended to be used outdoors, far from occupied buildings and the exhaust pointed away from personnel and buildings. However, if misused and operated in a location that results in the accumulation of CO, like indoors or in a partially enclosed area, COsense shuts off the engine, notifies the user of what has happened, and directs the user to read the instruction action label for
  steps to take. See Figure 2-6. COsense is not a substitute for an indoor carbon monoxide alarm.

• See Figure 2-7. After a shut-off, a blinking RED light in the COsense badge on the side of the generator provides a notification that the generator was shut off due to an accumulating CO hazard. The RED light will blink for at least five minutes after a CO shuts off.

• Move the generator to an open, outdoor area and point the exhaust away from people and occupied buildings. Once relocated to a safe area, the generator can be restarted and the proper electrical connections made to supply electri-cal power. The RED light will stop blinking automatically upon engine re-start. Introduce fresh air and ventilate the location where the generator had shut down.

• See Figure 2-7. If a COsense system fault has occurred and no longer provides protection, the portable generator is shut off automatically and the YELLOW light will blink for at least five minutes in the COsense badge to notify the user of the fault.

• The COsense module can only be diagnosed and repaired by a trained technician at the dealer. The generator can be restarted but may continue to shut off.

• COsense will detect the accumulation of Carbon Monoxide from other fuel-burning sources such as engine-powered tools or propane heaters used in the area of operation. For example, if another generator is used and the exhaust is pointed at a COsense-equipped generator, COsense may initiate a shut-off due to rising CO levels. This is not an error. Hazardous Carbon Monoxide has been detected. The user must take action to move and re-direct these devices to better dissipate Carbon Monoxide far away from personnel and occupied buildings.

Circuit Protectors

• The AC receptacles are protected by an AC circuit protector. The DC receptacles are pro-tected by a DC 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 the generator or equipment.
• Push the button of the protector to reset the circuit protector.

Remove Contents from Carton

1. Open the carton completely by cutting each corner from top to bottom.
2. Remove and verify carton contents before assembly. Carton contents should contain the following:
   • TABLE 3. Accessories
     Item| Qty.
     ---|---
     Main Unit| 1
     Owner’s Manual| 1
     Engine Oil| 1
     Oil Funnel| 1
     DC Charging Cable| 1
     Tool Kit| 1
     Service Warranty| 1
     Emissions Warranty| 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 the model, serial number, and date of purchase on the front cover of this manual.

Add Engine Oil

• CAUTION: Engine damage. Verify the proper type and quantity of engine oil before starting the engine. Failure to do so could result in engine damage. (000135)
• NOTE: The generator is shipped without oil in the engine. Add oil slowly and verify the oil level often during the filling process to ensure overfilling does not occur.

1. Place the generator on a level surface.
2. See Figure 2-8. Remove screws and side cover.
3. Clean the area around the oil fill cap.
4. See Figure 2-9. Remove the oil fill cap and wipe the dipstick clean.
5. Insert the funnel into the oil fill opening. Add recommended engine oil as necessary. Climate determines proper engine oil viscosity. See the chart to select the correct viscosity.
   • NOTE: Use petroleum-based oil (supplied) for engine break-in before using synthetic oil.
6. See Figure 2-10. To check the oil level, remove the funnel and insert the dipstick into the oil filler neck without screwing it in.
7. Remove the dipstick and verify oil level is within a safe operating range.
   • NOTE: Verify oil level often during the filling process to ensure overfilling does not occur.
8. Install oil fill cap/dipstick and hand-tighten.
9. Replace the side cover and screws.

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 the fuel tank. Fill to 1/2 inch from the top of the tank to allow for fuel expansion. Overfilling may cause fuel to spill onto the engine causing fire or explosion, which will result in death or serious injury. (000166b)
• 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)

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 (where available, non-ethanol fuel is recommended).
• DO NOT use E85.
• DO NOT use a gas oil mix.
• DO NOT modify the engine to run on alternate fuels. Stabilize fuel before storage.

1. Verify unit is OFF and cooled entirely before fueling.
2. Place the unit on level ground in a well ventilated area.
3. Clean the area around the fuel cap.
4. Turn the cap slowly to remove it.
5. Slowly add the recommended fuel. Do not overfill.
   • NOTE: See Figure 2-11. Fill to red and insert inside the filler neck.
6. Install fuel cap.
   • NOTE: Allow spilled fuel to evaporate before starting the 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. Alcohol-blended fuels (called gasohol, ethanol, or methanol) can attract moisture, which leads to the 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 for 30 days or longer. See the Storage section. Never use engine or carburetor cleaner products in the fuel tank as permanent damage may occur.

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 sufficient.
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 Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system to render it unsafe or make it non-compliant with local codes and/or standards. Failure to do so will result in death or serious injury. (000179b)
• WARNING Risk of fire. Do not use the generator without a spark arrestor installed. Failure to do so could result in death or serious injury. (000118a)
• WARNING Asphyxiation. Always use a battery-operated carbon monoxide alarm indoors and install it according to the manufacturer’s instructions. Failure to do so could result in death or serious injury. (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 the machine, do not touch hot surfaces. Keep the machine away from combustibles during use. Hot surfaces could result in severe burns or fire. (000108)
• CAUTION Equipment and property damage. Disconnect electrical loads before starting or stopping the unit. Failure to do so could result in equipment and property damage. (000136)

Grounding the Generator When In Use
See Figure 3-1. 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.

• Neutral Floating
• The generator (stator winding) is isolated from the frame and 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.

Special Requirements
There may be Federal or State Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Consult a qualified electrician, electrical inspector, or the local agency having jurisdiction:

• In some areas, generators are required to be registered with local utility companies.
• If the generator is used at a construction site, there may be additional regulations that must be observed.

Know Generator Limits

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

• Add 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 approximately 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. Calculate the watts needed to start the largest motor.
2. Add to that figure the running watts of all other connected loads. The Wattage Reference Guide is provided toassist in determining how many items the generator can operate at one time.
   • NOTE: All figures are approximate. See the data label on the appliance for wattage requirements.

Wattage Reference Guide

• 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.
• Two (2) people are needed to lift the unit.
• Allow the unit to cool off before transporting or storing in an enclosed space.
• DO NOT move the unit during operation.

Starting Cold Engines

WARNING Recoil Hazard. Recoil could retract unexpectedly. Kickback could result in death or serious injury. (000183)
CAUTION Equipment and property damage. Disconnect electrical loads before starting or stopping unit. Failure to do so could result in equipment and property damage. (000136)

1. See Figure 3-2. Rotate the Off/Run/Choke dial to CHOKE (1).
2. Switch the Economy switch to OFF.
3. Firmly grasp the recoil handle and pull slowly until increased resistance is felt. Pull rapidly up and away.
4. See Figure 3-2. When the engine starts, rotate the Off/Run/Choke dial to RUN (2). Choke operation is reduced as the Off/Run/Choke dial is rotated towards RUN.
   • NOTE: If the engine fires, but does not continue to run, rotate the Off/Run/Choke dial to OFF and repeat the starting instructions.
   • IMPORTANT NOTE: See Figure 3-3. Do not overload the generator or individual panel receptacles. If an overload occurs, the overload LED (A) will illuminate and AC output ceases. To correct this, see Generator Status Lights. Read Know Generator Limits carefully.

Generator Shut Down

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)

1. Shut off all loads and unplug electrical loads from generator panel receptacles.
2. Let the engine run at no load for several minutes to stabilize the internal temperatures of the engine and generator.
3. See Figure 3-2 Rotate Off/Run/Choke dial to OFF (3).

Starting Hot Engines

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)

1. See Figure 3-2. Turn Off/Run/Choke dial from STOP to RUN. This will open the fuel valve and permit starting.
2. Firmly grasp the 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 to shut down the engine automatically when the oil level drops below a specified level. The engine will not run until the oil has been filled to the proper level.
• IMPORTANT NOTE: Verify proper engine oil and fuel levels before use.

Charging a 12 VDC Battery

• WARNING Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury. (000137a)
• WARNING Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.  (000138a)

NOTE: A battery may lose some of its charge when not in use for prolonged periods. The DC charging output is not regulated. The circuit protector does not prevent overcharging a battery. Battery charging should be done in a dry location.

1. Start the generator and turn the Economy switch OFF.
2. See Figure 3-4. Plug the Battery Charging Cable into the Battery Charger Output jack, located on the control panel.
3. Connect positive (+) battery clamp (red wire) to battery FIRST.
4. Connect negative (-) battery clamp (black wire) to battery SECOND.
   • NOTE: This receptacle can not recharge 6-volt batteries and can not be used to crank an engine having a discharged battery.

Parallel Operation

For output power up to 4180W, two inverters can operate in parallel using Generac’s Parallel Kit (optional). See the Parallel Kit Operator’s Manual or contact an IASD.
NOTE: All connections to the parallel kit should be made while both inverters are turned off and all loads disconnected.

1. Make sure the Engine Economy Switch is in the same position on both generators.
2. Make appropriate parallel connections to the outlets on each Generac inverter as outlined in the owner’s manual supplied with the kit.
   • NOTE: Do not disconnect any parallel kit connections once the units are running.
3. Start both units per starting instructions. Once the green output indicator illuminates, devices can be connected and turned on using the parallel kit outlet.
4. Follow Generator Shut Down instructions.
   • NOTE: For inverters, the load applied to the parallel kit is not to exceed 4180 watts due to a 5% power loss when paralleling. See manual.
   • NOTE: Only use Generac Generac-approved parallel kit.

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 services and adjustments should be each season as detailed in the following chart.

At Each Use

Check Engine Oil Level
Every 50 Hours
Inspect/Clean Air Filter*
Change Oil ǂ
Every 100 Hours or Every 6 Months*
Replace Spark Plug
Clean Spark Arrestor
Valve Clearance Adjustment*
Every 200 Hours or Every Year
Clean/Replace Air Cleaner Filter
Replace Fuel Filter +
ǂ Change oil after the first 30 hours of operation, then every 50 hours.

+ To be performed by IASD.

• Change oil every month when operating under heavy load or in high temperatures.

** Clean more often under dirty or dusty operating conditions. Replace air filter parts if they cannot be adequately cleaned.

*** Check valve clearance and adjust if necessary after the first 50 hours of operation and every 100 hours thereafter.

Preventive Maintenance

WARNING Personal injury. Do not insert any object through the air cooling slots. Generators can start at any time and could result in death, serious injury, and unit damage. (000142a)

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

• 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 the generator. These openings must be kept clean and unobstructed.

NOTE: DO NOT use a garden hose to clean the generator. Water can enter the engine fuel system and cause problems. If water enters the 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 the generator’s internal windings will decrease the insulation resistance of windings.

Engine Maintenance

WARNING Accidental start-up. Disconnect spark plug wires when working on the 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 by the recommendations of this manual. For your convenience, maintenance kits designed and intended for use on this product are available from the manufacturer and 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).

Inspect Engine Oil Level

WARNING Risk of burns. Allow the engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury. (000139) Inspect engine oil level before each use, or every 8 hours of operation.

1. Place the generator on a level surface.
2. See Figure 4-3. Remove screws and side cover.
3. Clean the area around the oil fill cap.
4. See Figure 4-1. Remove oil fill cap and wipe the dipstick clean.
5. See Figure 4-2. To check oil level, insert the dipstick into oil filler neck without screwing it in.
6. Remove dipstick and verify oil level is within safe operating range.
7. Add recommended engine oil as necessary.

NOTE: Verify oil level often during filling process to ensure overfilling does not occur. 8. Install oil fill cap/dipstick 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 a 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 the engine is still warm from running, as follows:

1. Place the generator on a level surface.
2. See Figure 4-3. Remove screws and side cover.
3. Disconnect the spark plug wire from the spark plug and place the wire where it cannot contact the spark plug.
4. Clean the area around the oil fill and oil drain plug.
5. Remove the oil fill cap and wipe the dipstick clean.
6. Tip the unit and drain the oil completely into a suitable container.
7. Once the oil is sufficiently drained from the unit, tip the unit back to a level position.
8. See Figure 4-4. Insert the funnel into the oil fill opening. Add recommended engine oil as necessary.
9. See Figure 4-2. To check the oil level, remove the funnel and insert a dipstick into the oil filler neck without screwing it in.
10. Remove the dipstick and verify oil level is within a safe operating range.
    • NOTE: Verify oil level often during the filling process to ensure overfilling does not occur.
11. Install oil fill cap/dipstick and hand-tighten.
12. Wipe up any spilled oil.
13. Replace the side cover and screws.
14. Properly dispose of oil by all applicable regulations.

Air Filter

The engine will not run properly and may be damaged if run with a dirty air filter. Service air filters more frequently in dirty or dusty conditions.
To service the air filter:

1. See Figure 4-3. Remove screws and side cover.
2. See Figure 4-5. Unscrew bolt (A) and remove the air filter cover.
3. Wash filter (B) in soapy water. Squeeze dry in a clean cloth (DO NOT TWIST).
4. Clean air filter cover before installation.
5. Replace the side cover and screws.
   • NOTE: To order a new air filter, contact the nearest authorized service center at 1-888- 436-3722.

Service Spark Plug
To service spark plug:

1. See Figure 2-1. Remove the spark plug cover.
2. Clean the area around the spark plug.
3. Remove and inspect the spark plug.
4. See Figure 4-6. Inspect the electrode gap with the feeler gauge and reset the spark plug gap to 0.7 – 0.8mm (0.028 – 0.031 in).
   • NOTE: Replace the spark plug if electrodes are pitted, or burned or the porcelain is cracked. Use ONLY the recommended replacement plug. See Product Specifications.
5. Install the spark plug finger tight, and tighten an additional 3/8 to 1/2 turn using a spark plug wrench.

Inspect Muffler and Spark Arrester

• NOTE: It is a violation of California Public
• Resource Code, Section 4442, to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order. Other states or federal jurisdictions may have similar laws.
• Contact the original equipment manufacturer, retailer, or dealer to obtain a spark arrester designed for the exhaust system installed on this engine.
• NOTE: Use ONLY original equipment replacement parts.
• Inspect the muffler for cracks, corrosion, or other damage. Remove spark arrester, if equipped, and inspect for damage or carbon blockage. Replace parts as required.

Inspect Spark Arrester Screen

WARNING Hot Surfaces. When operating the machine, do not touch hot surfaces. Keep the 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 100 hours of operation or every season, whichever comes first.

To service spark arrestor:

1. See Figure 4-7. Remove the clamp to remove the retainer.
2. Slide spark arrestor screens out from the muffler outlet tube.
3. Inspect screens and replace if torn, perforated, or otherwise damaged. Do NOT use a defective screen. If the screen is not damaged, clean it with a commercial solvent.
4. Replace the screens, and retainer, and secure with a clamp.

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.
• Check valve clearance after the first fifty hours of operation. Adjust as necessary.
• Intake — 0.10 ± 0.02mm (cold), (0.004″ ± 0.001″ inches)
• Exhaust — 0.15 ± 0.02mm (cold) (0.006″ ± 0.001″ inches)

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 the cover and storing the 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 the unit for storage.

• DO NOT place a storage cover on a hot generator. Allow the unit to cool to room temperature before storage.
• DO NOT store fuel from one season to another unless properly treated.
• Replace the fuel container if rust is present. Rust in fuel will cause fuel system problems.
• Cover the unit with a suitable protective, moisture-resistant cover.
• Store the unit in a clean, dry area.
• Always store the generator and fuel away from heat and ignition sources.

Prepare Fuel System/Engine for Storage

WARNING Vision Loss. Eye protection is required to avoid the spray from spark plug holes when cranking the engine. Failure to do so could result in vision loss.  (000181)

Fuel stored over 30 days can go bad and damage fuel system components. Keep fuel fresh, use a fuel stabilizer. If a fuel stabilizer is added to the fuel system, prepare and run the engine for long-term storage. Run the engine for 10-15 minutes to circulate the stabilizer throughout the fuel system. Adequately prepared fuel can be stored for up to 24 months.

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

1. Change engine oil.
2. Remove the spark plug.
3. Pour a tablespoon (5-10cc) of clean engine oil or spray a suitable fogging agent into the cylinder.
4. Pull the starter recoil several times to distribute oil in the cylinder.
5. Install spark plug.
6. Pull recoil slowly until resistance is felt. This will close valves so moisture cannot enter the engine cylinder. Gently release recoil.

Change Oil
Change engine oil before storage. See, Change Engine Oil.

Troubleshooting

2.  Out of fuel.

3.  Defective spark plug.

4.  Plugged fuel filter.

5.  Defective or stuck Dial assembly.

6.  Incorrect engine oil level.

7.  Defective ignition coil.

8.  Carburetor is flooded.

9.  Throttle plate closed.

| 1.  Turn on Dial.

2.  Fill fuel tank.

3.  Replace spark plug.

4.  Replace fuel and fuel filter.

5.  Contact IASD.

6.  Check/fill engine oil.

7.  Contact IASD.

8.  Drain carburetor.

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

| |
The engine starts, then shuts down.| 1.   Out of fuel.

2.  Incorrect engine oil level.

3.  Contaminated fuel.

4.  Defective low oil level switch.

| 1.  Fill fuel tank.

2.  Check engine oil level.

3.  Contact IASD.

4.  Contact IASD.

| |
The engine will not start or starts and run rough.*| 1. The choke is stuck or left on.

2.  Dirty or clogged air filter.

3.  Defective or dirty spark plug.

4.  Dirty fuel filter.

5.  Dirty or gummed-up carburetor.

6. The unit is not warmed up.

7.  Spark arrestor clogged.

| 1.  Turn the choke off.

2.  Clean or replace the air filter.

3.  Replace spark plug.

4.  Replace fuel and fuel filter.

5.  Clean carburetor.

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

7.  Clean spark arrestor.

| |
No AC output.| 1.  Generator is overloaded.

2. The inverter module is overheated.

3.  Short circuit in an electrical device.

4.  Defective inverter assembly.

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

2.  Verify service door is ON. Let cool for 15 minutes by running the engine without AC output. Press and hold the Reset button on the control panel, and restart the generator.

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

4.  Contact IASD.

| |
Fuel leaks from drain hoses.| 1. The carburetor drain in the bowl is not closed.| 1. Turn the valve clockwise to close.
| |
PROBLEM| CAUSE| CORRECTION
---|---|---
The engine starts and shuts off right away.| 1.   CO PROTECT shut-off due to accumulating carbon monoxide if a RED light blinks on the side panel badge.

2.  CO PROTECT shut-off due to a system fault if a YELLOW light blinks on the side panel badge.

3.  Contaminated fuel.

4.  Defective low oil level switch.

5.  Fuel cap vent OFF.

| 1.  Follow all Safety Instructions and relocate the generator to an open area outside, far away from windows, doors, and vents.

2.  Start to confirm YELLOW light blinks when/if the generator shuts- off. If CO PROTECT continues to fail and shut off, contact IASD.

3.  Contact IASD.

4.  Contact IASD.

5.  Turn the fuel cap vent ON.

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

Wiring Diagram

SCHEMATIC – DIAGRAM / WIRING – DIAGRAM

WIRING DIAGRAM

MORE INFO

• 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)
• CALIFORNIA WARNING Can expose you to benzene, a carcinogen, and reproductive toxicant www.P65Warnings.ca.gov. (000759a)

CONTACT INFORMATION

• Part No. A0000680681 Rev. F 04/26/2024
• ©2024 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.

References

• Generac Power Systems | A total energy solutions company
• ICC - International Code Council - ICC
• NFPA | The National Fire Protection Association
• P65Warnings.ca.gov
• Rural Electricity Resource Council

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