Owner's Manual
50 Hz, GP Series Portable Generator
www.generac.com or 1-888-436-3722
DEADLY EXHAUST FUMES! ONLY use OUTSIDE
far away from windows, doors and vents!
NOT INTENDED FOR USE IN CRITICAL LIFE
SUPPORT APPLICATIONS.
SAVE this Manual. Provide this manual to any
operator of the generator.
Introduction ............................................................. 1
Read this Manual Thoroughly ................................. 1
Safety Rules ........................................................... 1
Registration ............................................................ 3
General Information ................................................ 4
1.1 Unpacking ...................................................................... 4
1.1.1 Accessory Box (Common) ................................. 4
1.2 Assembly ....................................................................... 4
1.2.1 Assembling the Accessory Kit............................4
1.2.2 Battery Cable Connection (Electric Start Only) ....6
Operation ................................................................ 6
2.1 Know the Generator .......................................................6
2.2 Hourmeter (GP5000/GP6000 Only) ................................8
2.3 Cord Sets and Connection Plugs ....................................8
2.3.1 230 VAC, 16 Amp, CEE 7/4, Type F
Receptacle ......................................................... 8
2.3.2 230 VAC, 30 Amp, Receptacle
(GP5000/GP6000 Only) .....................................9
2.3.3 Adapter Cable, 50 Hz (GP5000/GP6000 Only) ...9
2.4 How to Use the Generator ..............................................9
2.4.1 System Ground .................................................. 9
2.4.2 Connecting to a Building's Electrical System ....10
2.5 Don’t Overload the Generator ........................................10
2.6 Before Starting the Generator .......................................10
2.6.1 Adding Engine Oil ............................................10
2.6.2 Adding Gasoline ...............................................11
2.7 Starting Pull Start Engines ............................................11
2.8 Starting Electric Start Engines ......................................12
2.8.1 Manual Start .................................................... 12
2.9 Stopping the Engine .....................................................12
2.10 Low Oil Level Shutdown System ..................................12
2.10.1 Sensing Low Oil Level ......................................12
2.11 Charging the Battery (Electric Start Units Only) .............12
Maintenance ......................................................... 13
3.1 Performing Scheduled Maintenance .............................13
3.2 Maintenance Schedule .................................................13
3.2.1 GP5000/GP6000 Maintenance Schedule ..........13
3.2.2 GP2600 Maintenance Schedule .......................13
3.3 Product Specifications .................................................. 13
3.3.1 GP5000/GP6000 Generator Specifications .......13
3.3.2 GP2600 Generator Specifications .....................14
3.3.3 GP5000/GP6000 Engine Specifications ............ 14
3.3.4 GP2600 Engine Specifications .........................14
3.4 General Recommendations ........................................... 14
3.4.1 Generator Maintenance ....................................14
3.4.2 To Clean the Generator .....................................14
3.4.3 Engine Maintenance ......................................... 14
3.4.4 Checking Oil Level ...........................................14
3.4.5 Changing the Oil ..............................................15
3.4.6 Replacing the Spark Plug .................................15
3.4.7 Battery Replacement (if applicable) ..................15
3.4.8 Spark Arrestor .................................................15
3.5 Service Air Cleaner ....................................................... 16
3.5.1 GP5000/GP6000 Air Cleaner ............................16
3.5.2 GP2600 Air Cleaner .........................................16
3.6 Valve Clearance ............................................................16
3.6.1 GP5000/GP6000 Valve Clearance ....................16
3.6.2 GP2600 Valve Clearance .................................. 16
3.7 General ........................................................................17
3.8 Long Term Storage ....................................................... 17
3.9 Other Storage Tips .......................................................17
Troubleshooting .................................................... 18
4.1 Troubleshooting Guide .................................................. 18
Notes .................................................................... 19
...........................21
Table of Contents
INTRODUCTION
Thank you for purchasing this model by Generac Power Systems,
Inc. This model is a compact, high performance, air-cooled,
engine driven generator designed to supply electrical power to
operate electrical loads where no utility power is available or in
place of utility due to a power outage.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest
Authorized Dealer for starting, operating and servicing procedures.
The operator is responsible for proper and safe use of the
equipment. We strongly recommend that the operator read this
manual and thoroughly understand all instructions before using the
equipment. We also strongly recommend instructing other users to
properly start and operate the unit. This prepares them if they need
to operate the equipment in an emergency. Save these instructions
for future reference. If you loan this unit to someone, ALWAYS loan
these instructions to the individual as well.
The generator can operate safely, efficiently and reliably only if it
is properly located, operated and maintained. Before operating or
servicing the generator:
• Become familiar with and strictly adhere to all local, state and
national codes and regulations.
• Study all safety warnings in this manual and on the product
carefully.
• Become familiar with this manual and the unit before use.
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, ensure that it is
safe for others. Also make sure the procedure, work method or
operating technique utilized does not render the generator unsafe.
THE INFORMATION CONTAINED HEREIN WAS BASED ON
MACHINES IN PRODUCTION AT THE TIME OF PUBLICATION.
GENERAC RESERVES THE RIGHT TO MODIFY THIS MANUAL AT
ANY TIME.
SAFETY RULES
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:
INDICATES A HAZARDOUS SITUATION OR ACTION
WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH
OR SERIOUS INJURY.
Indicates a hazardous situation or action which, if
not avoided, could result in death or serious injury.
Indicates a hazardous situation or action 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 body 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.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
This symbol points out important safety
information that, if not followed, could
endanger personal safety and/or property of
others.
$
This symbol points out potential explosion
hazard.
!
This symbol points out potential fire hazard.
+
This symbol points out potential electrical
shock hazard.
GENERAL HAZARDS
• NEVER operate in an enclosed area, in a vehicle, or indoors
EVEN IF doors and windows are open.
• For safety reasons, the manufacturer recommends that the
maintenance of this equipment is carried out by an Authorized
Dealer. Inspect the generator regularly, and contact the nearest
Authorized Dealer for parts needing repair or replacement.
• Operate generator only on level surfaces and where it will not be
exposed to excessive moisture, dirt, dust or corrosive vapors.
• Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving parts. Never remove any fan guard or shield
while the unit is operating.
• Certain parts of the generator get extremely hot during
operation. Keep clear of the generator until it has cooled to
avoid severe burns.
• Do NOT operate generator in the rain.
• Do not alter the construction of the generator or change
controls which might create an unsafe operating condition.
• Never start or stop the unit with electrical loads connected
to receptacles AND with connected devices turned ON. Start
the engine and let it stabilize before connecting electrical
loads. Disconnect all electrical loads before shutting down the
generator.
• Do not insert objects through unit’s cooling slots.
• When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
1
Introduction
2
• 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
dangerous operating conditions from leaking exhaust gases,
fuel leakage, oil leakage, etc.
• On electric start models, disconnect the POSITIVE (+) battery
cable from the engine starter OR the NEGATIVE (-) battery
cable from the battery terminal, whichever is easier, before
transporting the generator.
EXHAUST & LOCATION HAZARDS
• Never operate in an enclosed area or indoors! NEVER use in
the home, in a vehicle, or in partly enclosed areas such as
garages, EVEN IF doors and windows are open! ONLY use
outdoors and far from open windows, doors, vents, and in an
area that will not accumulate deadly exhaust.
• The engine exhaust fumes contain carbon monoxide, which
you cannot see or smell. This poisonous gas, if breathed in
sufficient concentrations, can cause unconsciousness 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.
• This exhaust system must be properly maintained. Do nothing
that might render the exhaust system unsafe or in noncompliance
with any local codes and/or standards.
• Always use a battery operated carbon monoxide alarm indoors,
installed according 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 poisoning.
ELECTRICAL HAZARDS
• The generator produces dangerously high voltage when in
operation. Avoid contact with bare wires, terminals, connections,
etc., while the unit is running, even on equipment connected
to the generator. Ensure all appropriate covers, guards and
barriers are in place before operating the generator.
• Never handle any kind of electrical cord or device while
standing in water, while barefoot or while hands or feet are wet.
DANGEROUS ELECTRICAL SHOCK MAY RESULT.
• Local electrical codes may also require proper grounding of
the generator. Consult with a local electrician for grounding
requirements in the area.
• Do not use worn, bare, frayed or otherwise damaged electrical
cord sets with the generator.
• Before performing any maintenance on the generator, disconnect
the engine starting battery (if equipped) to prevent accidental
start up. Disconnect the cable from the battery post indicated
by a NEGATIVE, NEG or (–) first. Reconnect that cable last.
• In case of accident caused by electric shock, immediately shut
down the source of electrical power. If this is not possible,
attempt to free the victim from the live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a non-conducting
implement, such as a rope or board, to free the victim from the
live conductor. If the victim is unconscious, apply first aid and
get immediate medical help.
FIRE HAZARDS
• Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE.
Do not permit smoking, open flames, sparks or heat in the
vicinity while handling gasoline.
• Never add fuel while unit is running or hot. Allow engine to cool
completely before adding fuel.
• Never fill fuel tank indoors. Comply with all laws regulating
storage and handling of gasoline.
• Do not overfill the fuel tank. Always allow room for fuel
expansion. If tank is over-filled, fuel can overflow onto a hot
engine and cause FIRE or an EXPLOSION. Never store generator
with fuel in tank where gasoline vapors might reach an open
flame, spark or pilot light (as on a furnace, water heater or
clothes dryer). FIRE or EXPLOSION may result. Allow unit to
cool entirely before storage.
• Wipe up any fuel or oil spills immediately. Ensure 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 side to allow for proper
ventilation of the generator.
• Do not insert objects through unit’s cooling slots.
• 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.
Safety Rules
REGISTRATION
Register your product online at www.generac.com to receive
important product information or updates.
MODEL NO:
SERIAL NO:
Unit ID Location
MODEL
DATA
DECAL
3
Safety Rules
4
1.1 UNPACKING
• Remove all packaging material.
• Remove separate accessory box.
• Remove the generator from carton.
1.1.1 ACCESSORY BOX (COMMON)
GP2600
• 1-Owner’s Manual/Warranty
• 1-Frame Foot (E)
• 2-Wheels (H)
• 1-Axle (K)
• 1-Handle with Grip (L)
• 1-Plastic Spacer (M)
• 1-Handle Bracket (N)
• 1-Hardware bag (containing the following):
– 2-M8 Flange Nuts (C)
– 2-Rubber Feet (D)
– 2-M8 x 16 Bolts (F)
– 2-Cotter Pins (J)
– 2-M8 x 40 Bolts (P)
– 1-M6 x 40 Bolt (T)
– 1-M6 Lock Nut (U)
GP5000/GP6000
• 1-Owner’s Manual/Warranty
• 2-Frame Foot (E)
• 2-Wheels (H)
• 1-Handle Assembly (Q)
• 2-Long Curved Head Bolts (A)
• 2-Flange Nuts (electric start only)
• 1-Battery Charger (electric start only)
• 1- Adapter Cable (see the "Adapter Cable, 50 Hz" section)
• 1-Hardware bag (containing the following):
– 4-M8 Flange Nuts (C)
– 2-M6 Flange Nuts (S)
– 2-Rubber Feet (D)
– 4-M8 Bolts (F)
– 2-M6 bolts (R)
– 2-Cotter Pins (J)
– 2-Acorn Nuts (B)
– 2-Axle Pins (G)
– 2-Washers (I)
1.2 ASSEMBLY
The generator requires some assembly prior to using it. If
problems arise when assembling the generator, please call an
authorized dealer at www.generac.com/Dealer Locator.
1.2.1 ASSEMBLING THE ACCESSORY KIT
Refer to the instructions below and Figures 1A through 1E to install
the handle, feet, and wheels. Note: the handle components are
already pre-assembled from the factory. The wheels are designed
to greatly improve the portability of the generator. You will need the
following tools to properly install the accessory kit:
• Ratchet and a 13mm socket (GP5000/GP6000)
• Ratchet and 10mm and 12mm Socket (GP2600)
• 13mm box wrench (GP5000/GP6000)
• 10mm and 12mm box wrench (GP6000)
• Needle nose pliers
Handle (GP5000/GP6000) (Figure 1A)
1. Install the handle assembly to the frame by using bolts (A) and
nuts (B).
Handle (GP2600)
2. Refer to Figure 1B to install the handle assembly as shown.
– Install the handle bracket (N) to the frame using two Bolts (P) (if
not already assembled).
– Slide the plastic spacer (M) onto the handle assembly (L) then
align with the holes in the handle bracket (N) (if not already
assembled).
– Secure the handle assembly (L) to the handle bracket (N) using the
Bolt (T) and one hex flange nut (U).
Feet (Figure 1B & 1C)
3. Use nuts (C) to mount the rubber feet (D) to the foot bracket
(E) (if not already assembled).
4. Mount the foot bracket (E) to the frame with two bolts (F)
(Figure 1B) and 4 M8 flange nuts (Figure 1C).
Wheels (GP5000/GP6000) (Figure 1D)
5. Slide axle pin (G) through wheel (H), washer (I), and through
the bracket on the frame.
6. Secure axle pin (G) to the frame with the cotter pin (J).
7. Use a pliers and bend one tab of cotter pin (J) outward to lock
into place.
8. Repeat steps 5, 6, & 7 for other wheel.
Wheels (GP2600)
9. Refer to Figure 1E to install the wheels as shown.
– Slide the axle (K) through the frame brackets.
– Slide on the wheels (H) then install the cotter pins (J).
Figure 1A – Handle Assembly (GP5000/GP6000)
General Information
5
Figure 1B – Handle Assembly/Foot Assembly (GP2600)
C
F
D
E
U
L
M
T
N
P
Figure 1C – Foot Assembly (GP5000/GP6000)
E
F
D
R
S
Figure 1D – Wheel Assembly (GP5000/GP6000)
BEND ONE TAB
OUTWARD
AFTER AXLE
PIN (G) IS
INSERTED
THROUGH
THE FRAME
Figure 1E – Wheel Assembly (GP2600)
General Information
6
1.2.2 BATTERY CABLE CONNECTION (ELECTRIC START
ONLY)
The unit has been deliberately shipped with the battery cables
disconnected. You will need a 10mm wrench to secure the battery
cables.
To connect the battery (see Figure 15 for connection details):
1. Cut off cable ties securing battery cables and remove red
covers from battery terminals.
2. First, connect the red cable to the positive (+) battery terminal
with the bolt, lock washer and nut supplied.
3. Connect the black cable to the negative (-) battery terminal
with the bolt, lock washer and nut supplied.
4. Make sure all connections are secure. Slide the rubber boots
over the terminals and connection hardware.
NOTE:
If the battery is unable to start the engine, charge it with the
12V charger included in the accessory box (see the "Charging a
Battery" section for details).
2.1 KNOW THE GENERATOR
Read the Owner’s Manual and Safety Rules before operating
this generator.
Compare the generator to Figures 2 through 4 to become
familiarized with the locations of various controls and adjustments.
Save this manual for future reference.
1. 230 Volt AC, 16 Amp, CEE 7/4, Type F Receptacle – Supplies
electrical power for the operation of 230 Volt AC, 16 Amp,
single-phase, 50 Hz electrical lighting, appliance, tool and
motor loads.
2. 230 Volt AC, 30 Amp Locking Receptacle – Supplies
electrical power for the operation of 230 Volt AC, 30 Amp,
single-phase, 50 Hz, electrical lighting, appliances, tools and
motor loads. To be used with supplied adapter cord.
3. Circuit Breakers (AC) – Each receptacle is provided with a
push-to-reset circuit breaker to protect the generator against
electrical overload.
4. Oil Drain – Use to drain engine oil.
5. Air Filter – Filters intake air as it is drawn into the engine.
6. Choke Knob – Used when starting a cold engine.
7. Fuel Tank – See generator Specifications for tank capacity.
8. Grounding Lug – Ground the generator to an approved earth
ground here. See "Grounding the Generator" for details.
9. Run/Stop Switch – Controls the operation of the generator
(pull start models).
9A. Start Switch – Used to start engine from the starter motor
(electric start models only).
10. Muffler – Quiets the engine.
11. Handle – Pivot and retract for storage. Press the spring-
loaded button to move handles (GP5000/GP6000 only).
12. Gas Cap – Fuel fill location.
13. Fuel Gauge – Shows fuel level in tank.
14. Oil Fill – Add oil here.
15. Recoil Starter – Use to start engine manually.
16. Fuel Shut Off – Valve between fuel tank and carburetor.
17. Battery Charger Input – This receptacle allows the capability
to recharge the 12 volt DC storage battery provided with
the 12 Volt Adaptor Plug Charger which is included in the
Accessory Box. Located behind the battery charger input is
a 1.50 Amp in-line fuse which is inside the control panel to
protect the battery (electric start models only).
18. Battery – Powers the electric starter (electric start models
only).
19. Hourmeter – Tracks hours of operation (GP5000/GP6000
only).
20. Spark Arrestor – Reduces fire hazards by containing sparks
(GP2600 only).
Figure 2A - Control Panel (GP5000)
Figure 2B - Control Panel (GP6000)
Operation
7
Figure 2C - Control Panel (GP2600)
Figure 3A - Generator Controls (GP5000/GP6000)
8
7
12
6
5
11
15
16
Figure 3B - Generator Controls (GP2600)
15
13
14
4
7
12
16
5
6
Figure 3C - Generator Controls (GP5000/GP6000)
Operation
8
Figure 3D - Muffler (GP2600)
10
11
20
2.2 HOURMETER (GP5000/GP6000 ONLY)
The Hourmeter tracks hours of operation for scheduled maintenance
(Figure 4):
There will be a "CHG OIL" message 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.
This message will actually begin flashing at 99 hours and disable
itself at 101 hours again, providing a two hour window to perform
the service.
Every 200 hours the "SVC" icon on the lower left hand corner of
the display will flash. The message will flash one hour before and
one hour after each 200 hour interval providing a two hour window
to perform service.
When the hour meter is in the Flash Alert mode, the maintenance
message will always 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 resets itself.
• 100 hours - CHG OIL — Oil Change Interval (Every 100 hrs)
• 200 hours - SVC — Service Air Filter (Every 200 hrs)
NOTE:
The hour glass graphic will flash on and off when the engine
is running. This signifies that the meter is tracking hours of
operation.
Figure 4 – Hourmeter
HOUR GLASS
GRAPHIC
RESET BUTTON
(IF EQUIPPED)
0000.0
2.3 CORD SETS AND CONNECTION PLUGS
2.3.1 230 VAC, 16 AMP, CEE 7/4, TYPE F RECEPTACLE
This is a 230 Volt outlet (Figure 5) protected against overload by
a 16 Amp push-to-reset circuit breaker. Use each socket to power
230 Volt AC, single phase, 50 Hz electrical loads requiring up to a
combined 3,680 watts (3.6 kW) or 16 Amps of current. Use only
high quality, well-insulated, 3-wire grounded cord sets rated for
230 Volts at 16 Amps (or greater).
Keep extension cords as short as possible, preferably less than
5 meters long, to prevent voltage drop and possible overheating
of wires.
Figure 5 - 230 Volt AC, 16 Amp, CEE 7/4, Type F
Receptacle
Operation
9
2.3.2 230 VAC, 30 AMP RECEPTACLE (GP5000/GP6000
ONLY)
Use this receptacle (rotate to lock/unlock) to operate 230 Volt AC,
50 Hz, single phase loads requiring up to 5000 watts (5.0 kW)
or 6000 watts (6.0 kW), depending on the model. The outlet is
protected by one 30/25 Amp circuit breaker.
Figure 6 - 230 VAC, 30 Amp Receptacle
2.3.3 ADAPTPER CABLE, 50 HZ (GP5000/GP6000 ONLY)
Included with this generator is an adapter cable that plugs into the
30 Amp Twistlock receptacle on the generator control panel on one
end, and provides a 32 Amp IP44 CEE 2P+E socket on the other
end (Figure 7).
Figure 7 – Adapter Cable
2.4 HOW TO USE THE GENERATOR
To obtain contact information for the nearest authorized dealer, go
to www.generac.com/Dealer Locator.
Never operate in an enclosed area or indoors!
NEVER use in the home, in a vehicle, or in
partly enclosed areas such as garages, EVEN
IF doors and windows are open! ONLY use
outdoors and far from open windows, doors,
vents, and in an area that will not accumulate
deadly exhaust.
The engine exhaust fumes contain carbon
monoxide, which can you cannot see or smell.
This poisonous gas, if breathed in sufficient
concentrations, can cause unconsciousness 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.
This exhaust system must be properly
maintained. Do nothing that might render the
exhaust system unsafe or in noncompliance
with any local codes and/or standards.
The manufacturer recommends installing
a battery operated carbon monoxide alarm
indoors, according to the manufacturers
instructions.
2.4.1 SYSTEM GROUND
The generator has a system ground that connects the generator
frame components to the ground terminals on the AC output
receptacles.
Special Requirements
There may be federal, state, safety or health administration
regulations, local codes, or ordinances that apply to the intended
use of the generator.
Please 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 which must be observed.
Operation
10
2.4.2 CONNECTING TO A BUILDING’S ELECTRICAL
SYSTEM
Connections for standby power to a building’s electrical system
must be made by a qualified electrician. The connection must
isolate the generator power from utility power or other alternative
power sources and must comply with all applicable laws and
electrical codes.
Grounding The Generator
Local electrical codes may require proper grounding of the unit
(Figure 8). For that purpose, connecting a 2.59mm stranded
copper wire to the grounding lug and to an earth-driven copper
or brass grounding rod (electrode) provides adequate protection
against electrical shock. However, local codes may vary widely.
Consult with a local electrician for grounding requirements in
the area.
Figure 8 - Grounding the Generator
Proper grounding of the generator will help prevent electrical
shock in the event of a ground fault condition in the generator or in
connected electrical devices. Proper grounding also helps dissipate
static electricity, which often builds up in ungrounded devices.
2.5 DON’T OVERLOAD THE GENERATOR
Overloading a generator in excess of its rated wattage capacity
can result in damage to the generator and to connected electrical
devices. Observe the following to prevent overloading the unit:
• Add up the total wattage of all electrical devices to be connected
at one time. This total should NOT be greater than the
generator's wattage capacity.
• The rated wattage of lights can be taken from light bulbs. The
rated wattage of tools, appliances and motors can usually be
found on a data 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.
2.6 BEFORE STARTING THE GENERATOR
Prior to operating the generator, engine oil and gasoline will need
to be added, as follows:
2.6.1 ADDING ENGINE OIL
Use no special additives. Select the oil's viscosity grade according
to the expected operating temperature (also see chart).
• Above 4° C, use SAE 30
• Below 4° C and down to -12° C, use 10W-30
• Below -12° C, use synthetic 5W-30
SAE 30
10W-30
Synthetic 5W-30
Any attempt to crank or start the engine
before it has been properly serviced with the
recommended oil may result in an engine
failure.
1. Place generator on a level surface (not to exceed 15° in any
direction).
2. Clean area around oil fill and remove oil fill cap.
3. Slowly fill engine with oil until the dipstick reads full. Stop
filling occasionally to check oil level.
4. Install dipstick and finger tighten securely.
5. Check engine oil level before starting each time thereafter.
Operation
11
2.6.2 ADDING GASOLINE
$
NEVER fill fuel tank indoors. Avoid spilling
gasoline on hot engine. Allow engine to cool
entirely before adding fuel. NEVER fill fuel tank
when engine is running or hot. DO NOT light
a cigarette or smoke when filling the fuel tank.
Gasoline is highly flammable and its vapors are
EXPLOSIVE.
$
Do not overfill the fuel tank. Always leave room
for fuel expansion. If the fuel tank is overfilled,
fuel can over flow onto a hot engine and cause
fire or an explosion. Wipe up any spilled fuel
immediately.
1. Use regular UNLEADED gasoline with the generator engine. Do
not use premium gasoline. Do not mix oil with gasoline.
2. Clean area around fuel fill cap, remove cap.
3. Slowly add unleaded regular gasoline to fuel tank. Be careful
not to overfill (Figure 9).
4. Install fuel cap and wipe up any spilled gasoline.
IMPORTANT: It is important to prevent gum deposits from forming
in fuel system parts such as the carburetor, fuel hose or tank during
storage. Fuel can attract moisture, which leads to separation and
formation of acids during storage. Acidic gas can damage the fuel
system of an engine while in storage. To avoid engine problems,
the fuel system should be emptied before storage of 30 days or
longer. See the "Storage" section. Never use engine or carburetor
cleaner products in the fuel tank as permanent damage may occur.
Figure 9 - Fuel Tank
DO NOT Fill Above Lip
Fuel
Fuel Tank
2.7 STARTING PULL START ENGINES
+
Never start or stop engine with electrical
devices plugged into the receptacles AND
devices turned on.
1. Unplug all electrical loads from the unit's receptacles before
starting the engine.
2. Make sure the unit is in a level position (not to exceed 15° in
any direction).
3. OPEN the Fuel Shut-off Valve (Figure 10).
4. Turn engine RUN/STOP switch to ON position (Figures 2C or
11).
5. Slide engine choke to the LEFT to FULL CHOKE position
(Figure 12).
Figure 10 - Fuel Shut-off Valve
6. To start engine, firmly grasp the recoil handle and pull slowly
until increased resistance is felt. Pull rapidly up and away.
7. When engine starts, move choke knob to 1/2-CHOKE position
until engine runs smoothly and then fully into RUN position.
If engine falters, move choke back out to 1/2-CHOKE position
until engine runs smoothly and then to RUN position.
NOTE:
If engine fires, but does not continue to run, move choke lever
to FULL CHOKE and repeat starting instructions.
IMPORTANT: Do not overload the generator. Also, do not overload
individual panel receptacles. These outlets are protected against
overload with push-to-reset-type circuit breakers. If amperage
rating of any circuit breaker is exceeded, that breaker opens and
electrical output to that receptacle is lost. Read “Don’t Overload the
Generator” carefully.
Figure 11 - Engine ON/OFF Switch
ENGINE ON/OFF SWITCH
(GP5000 ENGINES ONLY)
Operation
12
Figure 12 - Choke Position
CHOKE LEVER
LEFT = CHOKE (START)
RIGHT = RUN
2.8 STARTING ELECTRIC START ENGINES
+
Never start or stop engine with electrical
devices plugged into the receptacles AND
devices turned on.
1. Unplug all electrical loads from the unit's receptacles before
starting the engine.
2. Make sure the unit is in a level position (not to exceed 15° in
any direction).
3. Open the fuel shut-off valve (Figures 10).
4. Move engine CHOKE lever to FULL CHOKE position (Figure
12).
5. To start engine, press and hold the Start/Run/Stop switch
(control panel) in the “Start” position. The engine will crank
and attempt to start. When the engine starts, release the
switch to the run position.
6. When the engine starts, move choke knob to “1/2 Choke”
position until the engine runs smoothly and then fully in to the
“Run” position. If engine falters, move choke knob back out to
“1/2 Choke” position until the engine runs smoothly and then
to “Run” position.
2.8.1 MANUAL START
This generator is also equipped with a manual recoil starter which
may be used if the battery is discharged.
NOTE:
The switch must be in the RUN position. Use one of the
generator’s receptacle outlets along with the included battery
charger to charge the battery while the generator is running.
• To start manually, firmly grasp the recoil handle and pull slowly
until increased resistance is felt. Pull rapidly up and away to
start engine. Then follow the same choke sequence.
NOTE:
If engine fires, but does not continue to run, move choke lever
to FULL CHOKE and repeat starting instructions.
IMPORTANT: Do not overload the generator. Also, do not overload
individual panel receptacles. These outlets are protected against
overload with push-to-reset-type circuit breakers. If amperage
rating of any circuit breaker is exceeded, that breaker opens and
electrical output to that receptacle is lost. Read “Don’t Overload the
Generator” carefully.
2.9 STOPPING THE ENGINE
1. Shut off all loads, then unplug the electrical loads from
generator panel receptacles. Never start or stop the engine
with electrical devices plugged in and turned on.
2. Let engine run at no-load for several minutes to stabilize the
internal temperatures of engine and generator.
3. Move Run/Stop switch to OFF position.
4. Close fuel valve.
2.10 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. If the engine shuts down by itself and the fuel tank has
enough gasoline, check engine oil level.
2.10.1 SENSING LOW OIL LEVEL
If the system senses a low oil level during operation, the engine
shuts down. The engine will not run until the oil has been refilled
to the proper level.
2.11 CHARGING THE BATTERY (ELECTRIC START
UNITS ONLY)
$
Storage batteries give off explosive hydrogen
gas while recharging. An explosive mixture will
remain around the battery for a long time after
it has been charged. The slightest spark can
ignite the hydrogen and cause an explosion.
Such an explosion can shatter the battery and
cause blindness or other serious injury.
Do not permit smoking, open flame, sparks
or any other source of heat around a battery.
Wear protective goggles, rubber apron and
rubber gloves when working around a battery.
Battery electrolyte fluid is an extremely
corrosive sulfuric acid solution that can cause
severe burns. If spill occurs flush area with
clear water immediately.
Maintenance
13
Maintenance
NOTE:
The battery shipped with the generator has been fully charged.
A battery may lose some of its charge when not in use for
prolonged periods of time. If the battery is unable to crank the
engine, plug in the 12V charger included in the accessory box.
RUNNING THE GENERATOR DOES NOT CHARGE THE BATTERY.
Use battery charger plug to keep the battery charged and ready for
use. Battery charging should be done in a dry location.
1. Plug charger into “Battery Charger Input” jack, located on
the control panel (Figure 13). Plug wall receptacle end of the
battery charger into a 230 Volt AC wall outlet.
2. Unplug battery charger from wall outlet and control panel jack
when generator is going to be in use.
NOTE:
Do not use the battery charger for more than 48 hours at one
charge.
Figure 13 - Battery Charger Jack
BATTERY
CHARGER
INPUT
3.1 PERFORMING SCHEDULED MAINTENANCE
It is important to perform service as specified in the Maintenance
Schedule for proper generator operation, and to ensure that the
generator complies with the applicable emission standards for the
duration of its useful life. Service and repairs may be performed by
any capable person or repair shop. Additionally, emissions critical
maintenance must be performed as scheduled in order for the
Emissions Warranty to be valid. Emissions critical maintenance
consists of servicing the air filter and spark plugs in accordance
with the Maintenance Schedule.
3.2 MAINTENANCE SCHEDULE
3.2.1 GP5000/GP6000 MAINTENANCE SCHEDULE
Follow the calendar intervals. More frequent service is required
when operating in adverse conditions noted below.
Check Oil Level At Each Use
Change Oil ‡ *Every 100 hours or Every Season
Check Valve Clearance ***Every Season
Service Air Filter ** Every 200 hours or Every Season
Replace Spark Plug Every Season
‡ Change oil after first 30 hours of operation then every season.
* Change oil and oil filter 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 first 50 hours of
operation and every 100 hours thereafter.
3.2.2 GP2600 MAINTENANCE SCHEDULE
Follow the calendar intervals. More frequent service is required
when operating in adverse conditions noted below.
Check Oil Level At Each Use
Change Oil ¥ *Every 50 Hours
Check Valve Clearance ***Every Season
Service Air Filter **Every 25 Hours
Replace Spark Plug ****Every 100 Hours
¥ Change oil after first 20 hours of operation.
* 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 first 50 hours of
operation and every 100 hours thereafter.
**** Clean and re-gap spark plug every 50 hours.
3.3 PRODUCT SPECIFICATIONS
3.3.1 GP5000/GP6000 GENERATOR SPECIFICATIONS
Rated Power .....................................................................5.0/6.0 kW**
Surge Power .........................................................................7.5/9.0 kW
Rated AC Voltage .............................................................................230
Rated AC Load
Current @ 230V (5.0/6.0 kW) ................................21.7/26.0 Amps**
Rated Frequency .................................................... 50 Hz @ 3000 RPM
Phase ................................................................................ Single Phase
Weight (GP5000/GP6000) ......82.5 kg (181.5 lbs.)/88.9 kg (195.5 lbs.)
** Operating temperature range: -18° C (0° F) to 40° C (104° F) When operated
above 25° C (77° F), there may be a decrease in engine 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.
Notes
14
3.3.2 GP2600 GENERATOR SPECIFICATIONS
Rated. Power ..........................................................................2.6 kW**
Surge Power ...............................................................................3900W
Rated AC Voltage .............................................................................230
Rated Current ....................................................................11.3 Amps**
Rated Frequency .................................................... 50 Hz @ 3000 RPM
Phase ................................................................................ Single Phase
Weight (GP2600) ..........................................................50 kg (110 lbs.)
** Operating temperature range: -18° C (0° F) to 40° C (104° F) When operated
above 25° C (77° F), there may be a decrease in engine power.
** Maximum wattage is 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.
3.3.3 GP5000/GP6000 ENGINE SPECIFICATIONS
Displacement ..................................... 389 cc (5.0 kW)/420 cc (6.0 kW)
Spark Plug Type ................................ NHSP LDF7TC or Champion N9YC
Spark Plug Part No. .......................................................... 0G84420101
Spark Plug Gap ............................................................... 0.70-0.80 mm
Gasoline Capacity (5.0/6.0 kW) .........................................25.6 L/28.4 L
Oil Type.................. See Chart in "Before Starting the Generator" Section
Oil Capacity ......................................................................................1 L
Run Time at 50% Load (5.0/6.0 kW) .............................10.8/10.5 Hours
3.3.4 GP2600 ENGINE SPECIFICATIONS
Displacement .............................................................................. 208 cc
Spark Plug Type ......................F6TC, NGK BP61S or Champion RN11YC
Spark Plug Gap ........................................................................0.76 mm
Gasoline Capacity ........................................................................12.7 L
Oil Type.................. See Chart in "Before Starting the Generator" Section
Oil Capacity ...................................................................................0.6 L
Run Time ..................................................Up to 12.5 Hours at 1/2 Load
3.4 GENERAL RECOMMENDATIONS
The warranty of the generator does not cover items that have been
subjected to operator abuse or negligence. To receive full value
from the warranty, the operator must maintain the generator as
instructed in this manual.
Some adjustments will need to be made periodically to properly
maintain the generator.
All adjustments in the Maintenance section of this manual should
be made at least once each season. Follow the requirements in the
"Maintenance Schedule".
NOTE:
Once a year replace the spark plug and replace the air filter.
A new spark plug and clean air filter assure proper fuel-air
mixture and help the engine run better and last longer.
3.4.1 GENERATOR MAINTENANCE
Generator maintenance consists of keeping the unit clean and dry.
Operate and store the unit in a clean dry environment where it will
not be exposed to excessive dust, dirt, moisture or any corrosive
vapors. Cooling air slots in the generator must not become
clogged with snow, leaves, or any other foreign material.
Check the cleanliness of the generator frequently and clean when
dust, dirt, oil, moisture or other foreign substances are visible on
its exterior surface.
Never insert any object or tool through the air
cooling slots, even if the engine is not running.
NOTE:
DO NOT use a garden hose to clean generator. Water can enter
the engine fuel system and cause problems. In addition, if water
enters the generator through cooling air slots, some water will
be retained in voids and crevices of the rotor and stator winding
insulation. Water and dirt buildup on the generator internal
windings will eventually decrease the insulation resistance of
these windings.
3.4.2 TO CLEAN THE GENERATOR
• Use a damp cloth to wipe exterior surfaces clean.
• A soft, bristle brush may be used to loosen caked on dirt, oil,
etc.
• A vacuum cleaner may be used to pick up loose dirt and debris.
• Low pressure air (not to exceed 25 psi) may be used to
blow away dirt. Inspect cooling air slots and openings
on the generator. These openings must be kept clean and
unobstructed.
3.4.3 ENGINE MAINTENANCE
+
When working on the generator, always
disconnect negative cable from battery. Also
disconnect spark plug wire from spark plug and
keep wire away from spark plug.
3.4.4 CHECKING OIL LEVEL
See the “Before Starting the Generator” section for information on
checking the oil level. The oil level should be checked before each
use, or at least every eight hours of operation. Keep the oil level
maintained.
Maintenance
15
3.4.5 CHANGING THE OIL
Change the oil after the first 20 to 30 hours of operation. Change
the oil every 50 to 100 hours or every season thereafter. If running
this unit under dirty or dusty conditions, or in extremely hot
weather, change the oil more often.
Hot oil may cause burns. Allow engine to
cool before draining oil. Avoid prolonged
or repeated skin exposure with used oil.
Thoroughly wash exposed areas with soap.
Use the following instructions to change the oil after the engine
cools down:
1. Clean area around oil drain plug.
2. Remove oil drain plug from engine and oil fill plug to drain oil
completely into a suitable container.
3. When oil has completely drained, install oil drain plug and
tighten securely.
4. Fill oil sump with recommended oil. (See “Before Starting the
Generator” for oil recommendations).
5. Wipe up any spilled oil.
6. Dispose of used oil at a proper collection center.
3.4.6 REPLACING THE SPARK PLUG
See Engine Specifications for recommended spark plug. Replace
the plug once each year. This will help the engine start easier and
run better.
1. Stop the engine and pull the spark plug wire off of the spark
plug.
2. Clean the area around the spark plug and remove it from the
cylinder head.
3. Set the spark plug's gap to 0.70-0.80 mm. Install the correctly
gapped spark plug into the cylinder head (Figure 14).
Figure 14 - Spark Plug Gap
3.4.7 BATTERY REPLACEMENT (IF APPLICABLE)
NOTE:
The battery shipped with the generator has been fully charged.
A battery may lose some of its charge when not in use for
prolonged periods of time. If the battery is unable to crank the
engine, plug in the 12V charger included in the accessory box
(see the Charging a Battery section). RUNNING THE GENERATOR
DOES NOT CHARGE THE BATTERY. The part number for this
battery is 0G9449.
The NEGATIVE battery terminal should:
1. Always be DISCONNECTED FIRST.
2. Always be CONNECTED LAST.
Figure 15 - Battery Connections
RED (+)
BLACK (-)
3.4.8 SPARK ARRESTOR
The engine exhaust muffler has a spark arrestor screen. Inspect
and clean the screen at least once each year (Figure 16). If unit is
used regularly, inspect and clean more often.
NOTICE:
If using the generator on any forest-covered, brush-covered
or grass-covered unimproved land, it must equipped with a
spark arrestor. The spark arrestor must be maintained in good
condition by the owner/operator.
Clean and inspect the spark arrestor as follows:
1. Remove clamp and spark arrestor from muffler.
2. Inspect screen and replace if torn, perforated or otherwise
damaged. DO NOT USE a defective screen. If screen is not
damaged, clean it with commercial solvent.
3. Replace the spark arrestor and clamp.
Maintenance
16
Figure 16 - Spark Arrestor
3.5 SERVICE AIR CLEANER
3.5.1 GP5000/GP6000 AIR CLEANER
The engine will not run properly and may be damaged if using a
dirty air filter. Clean the air filter every 50 hours or once a year
(Figure 16). Clean or replace more often if operating under dusty
conditions. The air filter part number is 0G84420151.
1. Remove air filter cover.
2. Wash in soapy water. Squeeze filter dry in clean cloth (DO
NOT TWIST).
3. Clean air filter cover before re-installing it.
NOTE:
To order a new air filter, please contact the nearest authorized
service center at 1-888-436-3722.
Figure 17 - Air Filter (GP5000/GP6000)
Screw
3.5.2 GP2600 AIR CLEANER
The engine will not run properly and may be damaged if using a
dirty air filter. Clean the air filter every 25 hours (Figure 18). Clean
or replace more often if operating under dusty conditions.
1. Remove air filter cover.
2. Wash in soapy water. Squeeze filter dry in clean cloth (DO
NOT TWIST).
3. Clean air filter cover before re-installing it.
Figure 18 - Air Filter
AIR FILTER
COVER
AIR
FILTER
UNLOCK
COVER
MOVE TO
THE RIGHT
3.6 VALVE CLEARANCE
3.6.1 GP5000/GP6000 VALVE CLEARANCE
• Intake — 0.15 ± 0.02mm (cold)
• Exhaust — 0.20 ± 0.02mm (cold)
After the first 50 hours of operation, check the valve clearance
in the engine and adjust if necessary.
Important: If feeling uncomfortable about doing this procedure or
the proper tools are not available, please take the generator to the
nearest service center to have the valve clearance adjusted. This is
a very important step to ensure longest life for the engine.
3.6.2 GP2600 VALVE CLEARANCE
• Intake — 0.10 ± 0.02mm (cold)
• Exhaust — 0.15 ± 0.02mm (cold)
After the first 50 hours of operation, check the valve clearance
in the engine and adjust if necessary.
Important: If feeling uncomfortable about doing this procedure or
the proper tools are not available, please take the generator to the
nearest service center to have the valve clearance adjusted. This is
a very important step to ensure longest life for the engine.
Maintenance
17
3.7 GENERAL
The generator should be started at least once every 30 days and
be allowed to run at least 30 minutes. If this cannot be done and
the unit must be stored for more than 30 days, use the following
information as a guide to prepare it for storage.
$
NEVER store engine with fuel in tank indoors
or in enclosed, poorly ventilated areas where
fumes may reach an open flame, spark or pilot
light as on a furnace, water heater, clothes dryer
or other gas appliance.
Allow unit to cool entirely before storage.
3.8 LONG TERM STORAGE
It is important to prevent gum deposits from forming in essential
fuel system parts such as the carburetor, fuel hose or tank during
storage. Also, experience indicates that fuel can attract moisture,
which leads to separation and formation of acids during storage.
Acidic gas can damage the fuel system of an engine while in
storage.
To avoid engine problems, the fuel system should be emptied
before storage of 30 days or longer, as follows:
1. Add a quality gasoline stabilizer to the fuel per the manufacturer's
specifications, and run the unit for 10-15 minutes.
2. After engine cools down, remove all gasoline from the fuel
tank. Use a commercially available, non-conductive vacuum
siphon.
$
Drain fuel into approved container outdoors,
away from open flame. Be sure engine is cool.
Do not smoke.
3. Start and run engine until engine stops from lack of fuel.
4. After engine cools down, drain oil from engine. Refill with
recommended grade.
5. Remove spark plug and pour about 1/2 ounce (15 ml) of
engine oil into the cylinder. Cover spark plug hole with rag.
Pull the recoil starter a couple times to lubricate the piston
rings and cylinder bore. A fogging agent can also be used in
the place of oil.
Avoid spray from spark plug hole when
cranking engine.
6. Install and tighten spark plug. Do not connect spark plug wire.
7. Clean the generator outer surfaces. Check that cooling air
slots and openings on generator are open and unobstructed.
8. Store the unit in a clean, dry place.
3.9 OTHER STORAGE TIPS
• Do not store gasoline from one season to another.
• Replace the gasoline can if it starts to rust. Rust and/or dirt in
the gasoline will cause problems with the carburetor and fuel
system.
• If possible, store the unit indoors and cover it to give protection
from dust and dirt. BE SURE TO EMPTY THE FUEL TANK.
• If it is not practical to empty the fuel tank and the unit is to
be stored for some time, use a commercially available fuel
stabilizer added to the gasoline to increase the life of the
gasoline. Run the unit for 10-15 minutes, turn off the fuel valve
and allow to run until engine stops from lack of fuel.
• Cover the unit with a suitable protective cover that does not
retain moisture.
NEVER cover the generator while engine and
exhaust areas are warm.
Maintenance
18
Troubleshooting
4.1 TROUBLESHOOTING GUIDE
PROBLEM CAUSE CORRECTION
Engine is running, but no AC output
is available.
1. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Fault in generator.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in good condition.
4. Contact Authorized Service Facility.
Engine runs well but bogs down
when loads are connected.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator” .
3. Contact Authorized Service Facility.
4. Contact Authorized Service Facility.
Engine will not start; or starts and
runs rough.
1. Fuel Shut-off is OFF.
2. Dirty air filter.
3. Out of gasoline.
4. Stale gasoline.
5. Spark plug wire not connected to spark plug.
6. Bad spark plug.
7. Water in gasoline.
8. Over-choking.
9. Low oil level.
10. Excessive rich fuel mixture.
11. Intake valve stuck open or closed.
12. Engine has lost compression.
1. Turn Fuel Shut-off to ON.
2. Clean or replace air filter.
3. Fill fuel tank.
4. Drain fuel tank and fill with fresh fuel.
5. Connect wire to spark plug.
6. Replace spark plug.
7. Drain fuel tank; fill with fresh fuel.
8. Put choke knob to No Choke position.
9. Fill crankcase to proper level.
10. Contact Authorized Service Facility.
11. Contact Authorized Service Facility.
12. Contact Authorized Service Facility.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Authorized Service Facility.
Engine lacks power. 1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. Reduce load (see “Don’t Overload the Generator”).
2. Clean or replace air filter.
3. Contact Authorized Service Facility.
Engine “hunts” or falters. 1. Choke is opened too soon.
2. Carburetor is running too rich or too lean.
1. Move choke to halfway position until engine runs
smoothly.
2. Contact Authorized Service Facility.
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