Generac 5940-1 Owner's manual

Brand: Generac

Model: 5940-1

Category: Power generators

Type: Owner's manual

This manual is also suitable for

GENERAC _

Owner'sM

GPSeriesPortableGenerator

introduction.............................................................1

ReadthisManualThoroughly.................................1

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

StandardsIndex.............................................................3

Generalinformation................................................4

1.1 Unpacking......................................................................4

1.1.1 Accessory Box..................................................4

1.2 Assembly.......................................................................4

1.2.1 Assemblingthe AccessoryKit............................4

1.2.2 BatteryCableConnection(ElectricStart Only)....5

Operation................................................................5

2.1 Knowthe Generator.......................................................5

2.2 Hourmeter......................................................................7

2.3 CordSets andConnectionPlugs....................................7

2.3.1 120 VAC,20 Amp, DuplexReceptacle...............7

2.3.2 120/240VAC,30 Amp, Receptacle....................7

2.3.3 120 VAC,20 Amp, GFCIDuplexReceptacle.......7

2.3.4 120/240VAC,30 Amp Receptacle.....................8

2.4 Howto Usethe Generator..............................................8

2.4.1 Groundingthe GeneratorWhenUsed

asa Portable.....................................................8

2.4.2 Connectingthe Generatorto a Building's

ElectricalSystem...............................................9

2.5 Don'tOverloadthe Generator..........................................9

2.6 WattageReferenceGuide...............................................9

2.7 BeforeStartingtheGenerator.......................................10

2.7.1 Adding EngineOil............................................10

2.7.2 Adding Gasoline...............................................10

2.8 Starting Pull Start Engines............................................11

2.9 Starting ElectricStart Engines......................................11

2.9.1 ManualStart....................................................12

2.10 Stoppingthe Engine.....................................................12

2.11 LowOil LevelShutdownSystem..................................12

2.11.1 SensingLowOil Level......................................12

2.12 Chargingthe Battery(ElectricStart UnitsOnly).............12

Maintenance.........................................................13

3.1 PerformingScheduledMaintenance.............................13

3.2 MaintenanceSchedule.................................................13

3.3 ProductSpecifications..................................................13

3.3.1 GeneratorSpecifications..................................13

3.3.2 EngineSpecifications.......................................13

3.3.3 EmissionsInformation.....................................13

3.4 GeneralRecommendations...........................................13

3.4.1 GeneratorMaintenance....................................13

3.4.2 ToCleanthe Generator.....................................14

3.4.3 EngineMaintenance.........................................14

3.4.4 CheckingOil Level...........................................14

3.4.5 Changingthe Oil..............................................14

3.4.6 Replacingthe SparkPlug.................................14

3.4.7 BatteryReplacement(if applicable)..................14

3.5 ServiceAir Cleaner.......................................................15

3.5.1 CleanSparkArrestor Screen(CARDmodels)...15

3.6 ValveClearance............................................................15

3.7 General........................................................................15

3.8 Long TermStorage.......................................................16

3.9 OtherStorageTips.......................................................16

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

4.1 TroubleshootingGuide..................................................17

Warranty...............................................................18

MANUALDELPROPIETARIO.............................23

MANUELD'ENTRETIEN......................................47

iNTRODUCTiON

Thankyou for purchasingthis modelby GeneracPowerSystems,

Inc. This model is a compact, high performance, air-cooled,

engine driven generatordesigned to supply electrical power to

operateelectrical loads where no utility power is availableor in

placeof utility dueto a poweroutage.

BEADTHISMANUALTHOROUGHLY

If anyportion ofthis manualis notunderstood,contactthenearest

AuthorizedDealerfor starting, operatingandservicingprocedures.

The operator is responsible for proper and safe use of the

equipment.We strongly recommendthat the operator read this

manualandthoroughlyunderstandallinstructionsbeforeusingthe

equipment.Wealsostronglyrecommendinstructingotherusersto

properlystart andoperatethe unit.This preparesthemifthey need

to operatetheequipmentin an emergency.Savethese instructions

for future reference.If you loanthis unitto someone,ALWAYSloan

these instructionsto the individualaswelt.

Thegeneratorcan operatesafely,efficiently and reliablyonly if it

is properlylocated,operatedand maintained.Beforeoperatingor

servicingthe generator:

• Becomefamiliarwith and strictly adhereto alt local, stateand

nationalcodes and regulations.

• Study all safety warnings in this manual and on the product

carefully.

• Becomefamiliarwith this manualandthe unitbeforeuse.

Themanufacturercannot anticipateevery possible circumstance

that might involvea hazard.Thewarnings in this manual,and on

tags and decals affixedto the unit are,therefore,not all inclusive.

If usinga procedure,work method or operatingtechniquethat the

manufacturerdoes not specifically recommend,ensurethat it is

safe for others. Also make sure the procedure,work method or

operatingtechnique utilizeddoes not renderthe generatorunsafe.

THE INFORMATIONCONTAINEDHEREIN WAS BASED ON

MACHINESIN PRODUCTIONAT THE TIME OF PUBLICATION.

GENERACRESERVESTHERIGHTTOMODIFYTHISMANUALAT

ANYTIME.

SAFETYRULES

Throughoutthis publication,and on tags and decals affixedto the

generator,DANGER,WARNING,CAUTIONand NOTEblocks are

usedto alert personnelto special instructionsabout a particular

operation that may be hazardous if performed incorrectly or

carelessly.Observethem carefully.Theirdefinitionsareasfollows:

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.

_,CAUTION!

Indicates a hazardous situation or action which,

if not avoided, could result in minor or moderate

injury.

NOTE:

Notes containadditional informationimportantto a procedure

and will be found withinthe regulartextbody of thismanual.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliancewith the special

instructionswhileperforming theaction or serviceareessentialto

preventingaccidents.

Four commonly used safety symbols accompany the BANGER,

WARNINGand CAUTIONblocks. The type of information each

indicatesis asfollows:

,_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.

i/_This symbol points out potential fire hazard.

This symbol points out potential electrical

shock hazard.

GENERAL HAZARDS

• NEVERoperatein an enclosed area, in a vehicle, or indoors

EVENIFdoorsand windows areopen.

• For safety reasons, the manufacturer recommends that the

maintenanceof this equipmentis carried out by an Authorized

Dealer.Inspectthe generatorregularly,and contactthe nearest

AuthorizedDealerfor parts needingrepairor replacement.

• Operategeneratoronly onlevelsurfacesandwhereit will notbe

exposedto excessivemoisture,dirt, dust or corrosivevapors.

• Keephands,feet, clothing, etc., away from drive belts, fans,

and othermoving parts. Neverremoveany fan guardor shield

whilethe unit isoperating.

• Certain parts of the generator get extremely hot during

operation. Keep clear of the generator until it has cooled to

avoidsevereburns.

• Do NOToperategeneratorinthe rain.

• Do not alter the construction of the generator or change

controlswhich might createanunsafeoperatingcondition.

• Neverstart or stop the unit with electrical loads connected

to receptaclesAND with connecteddevicesturned ON. Start

the engine and let it stabilize before connecting electrical

loads. Disconnectall electricalloads beforeshutting downthe

generator.

• Do notinsert objectsthrough unit's cooling slots.

• When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally

fatigued.

• Neverusethe generatoror anyof its parts as a step. Stepping

on the unit can stress and break parts, and may result in

dangerousoperating conditions from leakingexhaust gases,

fuel leakage,oil leakage,etc.

• Onelectricstart models,disconnectthe POSITIVE(+) battery

cable from the engine starter ORthe NEGATIVE(=) battery

cable from the battery terminal, whichever is easier, before

transportingthe generator.

EXHAUST& LOCATIONHAZARDS

• Never operate in an enclosed area or indoors!NEVERuse

in the home, in a vehicle,or in partlyenclosed areassuch

as garages,evenif doors and windowsare open! ONLYuse

outdoors and far from openwindows,doors, vents,andinan

areathatwill notaccumulatedeadly exhaust.

Using a generator indoors CAN KiLL YOU IN MINUTES,

Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell.

NEVER use inside a home

or garage, EVENIF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors_ and vents,

• The engine exhaustfumes contain carbon monoxide, which

you cannot see or smell. This poisonous gas, if breathedin

sufficientconcentrations,can causeunconsciousnessor 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 operationof the

generator.ThegeneratorMUSTbeoperatedoutdoors.

• Thisexhaustsystemmust be properlymaintained.Do nothing

that mightrendertheexhaustsystemunsafeorinnoncompliance

with any localcodes and/orstandards.

• Alwaysuseabatteryoperatedcarbonmonoxidealarmindoors,

installedaccordingto themanufacturersinstructions.

• If you start to feet sick, dizzy,or weak after the generatorhas

beenrunning,moveto fresh air IMMEDIATELYSeea doctor,as

you couldhavecarbonmonoxidepoisoning.

ELECTRICALHAZARDS

• The generator produces dangerouslyhigh voltage when in

operation.Avoidcontactwithbarewires,terminals,connections,

etc., while the unit is running,even on equipmentconnected

to the generator. Ensureall appropriate covers, guards and

barriersarein placebeforeoperatingthegenerator.

• Never handle any kind of electrical cord or device while

standinginwater,while barefootorwhile handsor feet arewet.

DANGEROUSELECTRICALSHOCKMAYRESULT.

• TheNationalElectricCode(NEC)requirestheframe andexternal

electrically conductive parts of the generator be properly

connectedto an approvedearthground.Local electricalcodes

may also require proper grounding of the generator.Consult

with a localelectricianfor groundingrequirementsin thearea.

• Use a ground fault circuit interrupter in any damp or highly

conductivearea(such as metaldecking or steelwork).

• Do not useworn, bare,frayedor otherwisedamagedelectrical

cord setswith the generator.

• Beforeperforminganymaintenanceonthegenerator,disconnect

the enginestarting battery (if equipped)to preventaccidental

start up. Disconnectthe cablefrom the batterypost indicated

by a NEGATIVE,NEGor (-) first. Reconnectthat cable last.

• In caseof accidentcausedby electricshock,immediatelyshut

down the source of electrical power. If this is not possible,

attempt to free the victim from the live conductor. AVOID

DIRECTCONTACTWITH THEVICTIM. Use a non-conducting

implement,such asa rope or board,to freethevictim from the

live conductor.If the victim is unconscious,applyfirst aid and

getimmediatemedical help.

FIREHAZARDS

• Gasolineishighly FLAMMABLEand itsvaporsare EXPLOSIVE.

Do not permitsmoking,open flames, sparksor heat in the

vicinitywhile handling gasoline.

• Neveraddfuel whileunit isrunningor hot. Allow engineto cool

completelybeforeaddingfuel.

• Never fill fuel tank indoors, Comply with all laws regulating

storageand handlingof gasoline.

• Do not overfill the fuel tank. Always allow roomfor fuel

expansion.If tank is over=filled,fuel can overflow onto a hot

engineandcauseFIREor an EXPLOSION.Neverstoregenerator

with fuel in tank where gasolinevapors might reachan open

flame, spark or pilot light (as on a furnace, water heateror

clothes dryer). FIREor EXPLOSIONmay result. Allow unit to

cool entirelybeforestorage.

• Wipe up any fuel or oil spills immediately.Ensure that no

combustiblematerialsareleft on or nearthegenerator.Keepthe

areasurroundingthe generatorcleanandfree from debrisand

keepa clearanceof five (5) feet on all side to allow for proper

ventilationofthe generator.

* Do notinsert objectsthrough unit's cooling slots.

* Do not operatethe generatorif connected electrical devices

overheat,if electricaloutputislost, if engineor generatorsparks

or ifflames or smokeare observedwhileunit is running.

* Keepafire extinguishernearthe generatoratall times.

STANDARDS/NDEZ

1. NationalFireProtectionAssociation(NFPA)70:TheNATIONAL

ELECTRICCODE(NEC)availablefrom www.nfpa.org

2. NationalFire ProtectionAssociation (NFPA)5000: BUILDING

CONSTRUCTIONAND SAFETYCODEavailablefrom www.

nfpa.org

3. InternationalBuildingCodeavailablefrom www.iccsafe.org

4. Agricultural Wiring Handbookavailablefrom www.rerc.org ,

Rural ElectricityResourceCouncil RO.Box 309 Wilmington,

OH45177-0309

5. ASAEEP-364.2Installationand Maintenanceof FarmStandby

Electric Power available from www.asabe.org, American

Society of Agricultural & Biological Engineers2950 Niles

Road,St. Joseph,MI 49085

This list is not all inclusive.Checkwith theAuthority HavingLocal

Jurisdiction (AHJ)for any localcodesor standardswhich may be

applicableto yourjurisdiction.

MODELNO:

SERIALNO:

Unit ID Location

DECAL

DATA

CALIFORNIAPROPOSITION65 WARNING

Engineexhaustand someof its constituentsareknown

to theStateof Californiato causecancer,birth defects

andotherreproductiveharm.

CALIFORNIAPROPOSITION65 WARNING

This productcontainsor emitschemicalsknown tothe

Stateof Californiato causecancer,birth defectsand

otherreproductiveharm.

1.1 UNPACKING

• Removeallpackagingmaterial.

• Removeseparateaccessorybox.

• Removethe generatorfrom carton.

1.1.1 ACCESSORYBOX

• 1-Owner's manual

• 1-Bottleof OilSAE30

• 3-ProductRegistrationCards (English,Spanish,French)

• 1-BatteryCharger(electricstart only)

• 1-HandleAssembly

• 1-FrameFoot(E)

• 2-Never-FlatWheels(H)

• 1-Hardwarebag(containingthefollowing):

- 2-LongCurvedHeadBolts(A)

- 2-AcornNuts(B)

- 4-Flangednuts(C)

- 2-RubberFeet(D)

- 2-ShortBolts(F)

- 2-AxlePins(G)

- 2-Washers(1)

- 2-CotterPins(J)

- 2-FlangeNuts(electricstartonly)

1.2 ASSEMBLY

The generator requires some assembly prior to using it. If

problems arise when assemblingthe generator,please call the

GeneratorHetplineat 1-888-436-3722.

1.2.1 ASSEMBLINGTHEACCESSORYKIT

Refer to the instructions below and Figures 1A, 1B, and 1C to

installthe handle,feet,and wheels.Note:the handlecomponents

are already pre-assembledfrom the factory. The wheels are

designedto greatly improve the portability of the generator.You

will needthefollowing tools to properlyinstallthe accessorykit:

• Ratchetanda 13mm [1/2"] socket

• 13mm [1/2"] boxwrench

• Needlenosepliers

Handle

1. Installthehandleassemblyto theframeby usingbolts (A) and

nuts (B).

Feet

2. Use nuts (C)to mount the rubberfeet (D)to thefoot bracket

(E).

3. Mountthefoot bracket(E)to theframewith two bolts (F)and

nuts (C).

Wheels

4. Slideaxlepin (G)through wheel(H), washer (I), andthrough

thebracketon theframe.

5. Secureaxlepin (G)to the frame with the cotterpin (J).

6. Usea pliersandbendonetab of cotterpin (J)outwardto lock

into place.

7. Repeatsteps5, 6, & 7 for otherwheel.

Figure 1A - Handle Assembly

Figure 1B - Foot Assembly

Figure lC - Wheel Assembly

BEND ONETAB

AFTERAXLE

PIN(G)IS

INSERTED _

THROUGH

THEFRAME

1.2.2 BATTERYCABLECONNECTION(ELECTRICSTART

ONLY)

The unit has been deliberately shipped with the battery cables

disconnected.Youwill needa lOmm wrenchto securethe battery

cables.

Toconnectthe battery(seeFigure17 for connectiondetails):

1. Cut off cable ties securing battery cables and remove red

coversfrom batteryterminals.

2. First,connectthe redcableto thepositive(+) batteryterminal

with the bolt, lock washer andnut supplied.

3. Connectthe black cable to the negative(-) batteryterminal

with the bolt, lock washer andnut supplied.

4. Make sureall connectionsare secure.Slidethe rubber boots

overtheterminalsand connectionhardware.

NOTE:

if the battery is unable to start the engine,chargeit with the

12V chargerincludedinthe accessory box (seethe "Charginga

Battery"sectionfor details).

2.1 KNOWTHEGENERATOR

Read the Owner'sManual and Safety Rules before operating

this generator.

Compare the generator to Figures 2 through 4 to become

familiarizedwith thelocationsofvariouscontrolsandadjustments.

Savethis manualfor future reference.

1. 120 Volt AC, 20 Amp, Duplex Receptacle - Supplies

electrical power for the operationof 120 Volt AC, 20 Amp,

single-phase,60 Hz electrical lighting, appliance, tool and

motor loads. CARBmodels areequippedwith GFCIoutlets.

2. 120/240 Volt AC, 30 Amp LockingReceptacle - Supplies

electricalpowerfor the operationof 120 and/or240 VoltAC,

30 Amp, single-phase,60 Hz, electrical lighting, appliance,

tool andmotor loads.

3. Circuit Breakers(AC)- Eachreceptacleis providedwith a

push-to-reset circuit breakerto protectthe generatoragainst

electricaloverload.

4. Oil Drain- Useto drainengineoil.

5. Air Filter- Filtersintakeairas it isdrawn intothe engine.

6. ChokeKnob- Usedwhen startinga cold engine.

7. FuelTank- SeegeneratorSpecificationsfor tank capacity.

8. GroundingLug- Groundthe generatorto an approvedearth

groundhere.See"Groundingthe Generator"for details.

g. Run/Stop Switch - Controls the operationof the generator

(pullstart models).

gA. Start Switch - Used to start engine from the starter motor

(electricstart modelsonly).

10. Muffler - Quietsthe engine.

11. Handle - Pivot and retract for storage. Press the spring-

loadedbuttonto move handles.

12. GasCap- Fuelfill location.

13. FuelGauge- Showsfuel levelin tank.

14. Oil Fill- Add oil here.

15. Recoil Starter - Useto start enginemanually.

15. FuelShut Off - Valvebetweenfueltank and carburetor.

17. BatteryCharger Input -This receptacleallowsthe capability

to rechargethe 12 volt DO storage battery provided with

the 12 Volt Adaptor Plug Chargerwhich is included in the

Accessory Box. Located behindthe battery chargerinput is

a 1.50 Amp in-line fuse which is insidethe control panelto

protectthe battery(electricstart models only).

18. Battery - Powersthe electric starter (electric start models

only).

lg. Hourmeter- Trackshoursof operation.

28. Spark Arrestor - Reducesfire hazardsby containing sparks

(CARBmodels only).

Figure2,4- Contro/Pane/(4g StateModels) Figure3 - GeneratorControls

Figure2B - Contro/Panel (CARBModels)

Figure4 - GeneratorControls

Figure 2C - Contro/Panel(CSAModels)

2.2 HOURIVIETER

TheHourmetertrackshoursofoperationforscheduledmaintenance

(Figure5):

Therewill be a "CHGOIL"messageevery100 hours.Themessage

will flash one hour before and one hour after each 100 hour

interval,providingatwo hourwindow to perform service.

This messagewill actuallybeginflashing at 99 hoursand disable

itselfat 101 hoursagain,providingatwo hourwindow to perform

the service.

Every200 hoursthe "SVC"icon on the lower left hand corner of

the display will flash. Themessagewill flash one hourbeforeand

onehourafter each200 hourintervalprovidingatwo hourwindow

to perform service.

Whenthe hour meter is inthe FlashAlert mode, the maintenance

message will always alternate with elapsedtime in hours and

tenths. The hours wilt flash four times, then alternatewith the

maintenancemessagefour timesuntil themeter resetsitself.

• 100 hours- CHGOIL-- Oil ChangeInterval(Every100 hrs)

• 200 hours- SVC-- ServiceAir Filter(Every200 hrs)

Note:

The hour glassgraphicwill flash on and off when the engine

is running.This signifiesthat the meter is tracking hours of

operation.

Figure 5 - Hourmeter

0000.0

HOURGLASS RESETBUTTON

GRAPHIC (IF EQUIPPED)

2.3 CORDSETSANDCONNECTIONPLUGS

2.3.1 120VAC,20 AMP,DUPLEXRECEPTACLE

This is a 120 Volt outlet protectedagainst overloadby a 20 Amp

push-to-resetcircuitbreaker(Figure6). Useeachsocketto power

120 VoltAC, singlephase,60 Hzelectricalloadsrequiringupto a

combined 2400 watts (2.4 kW) or 20 Amps of current. Useonly

high quality,well-insulated, 3-wire grounded cord sets ratedfor

125 Volts at 20 Amps (or greater).

Keep extensioncords as short as possible, preferablyless than

15 feet long, to preventvoltage drop and possibleoverheatingof

wires.

Figure 6 - 120 Volt AC, 20 Amp, Duplex Receptacle

2.3.2 120/240VAC,30 AMPRECEPTACLE

Use a NEMA L14-30 plug with this receptacle (rotate to lock!

unlock). Connecta suitable4-wire groundedcord set to the plug

andto thedesiredtoad.Thecordset shouldbe ratedfor 250 Volts

ACat 30 Amps (or greater)(Figure7).

Figure 7 - 120/240 VAC, 30 Amp Receptacle

12OV/24OV

3CA

Use this receptacleto operate120 Volt AC, 60 Hz, singlephase

loadsrequiringup to 3600 watts (3.6kW) of powerat30 Amps or

240 VoltAC,60 Hz,singlephaseloadsrequiringup to 7200 watts

(7.2 kW) of powerat 30 Amps. Theoutlet is protectedby two 30

Amp push-to-resetcircuit breakers.

2.3.3 120VAC,20AMP,GFC/OUPLEXRECEPTACLE

This is a 120 Volt outlet protectedagainst overloadby a 20 Amp

push-to=resetcircuitbreaker(Figure8). Useeachsocketto power

120 VoltAC, singlephase,60 Hzelectricalloadsrequiringup to a

combined 2400 watts (2.4 kW) or 20 Amps of current.Use only

high quality,well-insulated, 3-wire grounded cord sets ratedfor

125 Volts at 20 Amps (or greater).

Keepextensioncords as short as possibleto preventvoltagedrop

and possibleoverheatingof wires.

Figure 8 - 120 Vo/t AC, 20 Amp, GFC/ Duplex Receptac/e

2.3.4 120/240VAC,30 AMPRECEPTACLE

Use a NEMA L14-30 plug with this receptacle (rotate to lock!

unlock). Connecta suitable4-wire groundedcord set to the plug

andto thedesiredtoad.Thecordset shouldbe ratedfor 250 Volts

ACat30 Amps (or greater)(Figure9).

Figure 9 - 120/240 VAC, 30 Amp Receptac/e

_t he 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.

_t 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.

_t 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.

_t Always use a battery operated carbon

monoxide alarm indoors, installed according to

the manufacturers instructions.

12OV/24OV

3CA

Using a generator indoors CAN KiLL YOU iN MINUTES.

Generator exhaust contains carbon monoxide. This is

a poison you cannot see or smell.

NEVER use inside a home

or garage, EVEN iF doors

and windows are open.

Only use OUTSIDE and

far away from windows,

doors, and vents.

Use this receptacleto operate120 Volt AC, 60 Hz, singlephase

loads requiringup to 3600 watts (3.6 kW) of powerat 30 Amps

or 240 Volt AC, 60 Hz,single phase loads requiringup to 7200

watts (7.2 kW) of power at 30 Amps. The outlet is protectedby

two 25 Amp (5.0/5.5kW) or two 30 Amp (6.5kW) push-to-reset

circuit breakers.

2.4 H0WTOUSETHEGENERATOR

Seethe "ToStart the Engine"sectionfor howto safelystart and

stop the generatorand how to connect and disconnect loads. If

there are any problems operatingthe generator,pleasecall the

generatorhelplineat 1-888-436-3722.

_t ever 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.

2.4.1 GROUNDINGTHEGENERATORWHENUSEDASA

PORTABLE

This generator has an equipment ground that connects the

generatorframe componentsto the ground terminals on the AC

output receptacles (see NEC 250.34 (A) for explanation).This

allows the generatorto be used as a portablewithout grounding

theframe ofthe generatoras specifiedin NEC250.34.

SpecialRequirements

There may be Federalor State OccupationalSafety and Health

Administration(OSHA)regulations,localcodes,or ordinancesthat

applyto the intendeduse ofthe generator.

Pleaseconsult a qualified electrician, electricalinspector, or the

local agencyhavingjurisdiction:

* In some areas, generators are requiredto be registeredwith

local utilitycompanies.

* If the generatoris used at a construction site, there may be

additionalregulationswhich must be observed.

2.4.2 CONNECT/NGTHEGENERATORTOABU/LD/NG'$

ELECTR/CALSYSTEM

Connectionsfor standby power to a building's electricalsystem

must be made by a qualifiedelectricianand in strict compliance

with all national and local electrical codes and laws. The

connectionmust isolatethe generatorpowerfrom utility poweror

otheralternativepowersources.

NOTE:

Because the generatorequipment ground is bonded to the AC

neutral wires in the generator(see Figure8), either a 3-pole

transferswitch or a 2 pole transferswitch with a switching

neutral kit is requiredto connectthis generatorto a building

load. in this application the generator becomes a separately

derived system(see NEC250.20 (D)), and mustbe grounded

in accordance with the national or local electrical code

requirements.

GroundingtheGeneratorina BuildingStandbyApplication

_ he National Electrical Code requires that the

frame and external electrically conductive parts

of this generator be properly connected to an

approved earth ground.

Local electrical codes may also require proper grounding of the

unit (Figure 10). For that purpose, connecting a No. 10 AWG

(AmericanWire Gauge)strandedcopperwireto the groundinglug

and to an earth=drivencopperor brass groundingrod (electrode)

provides adequateprotection against electricalshock. However,

local codes mayvary widely.Consultwith a localelectrician for

grounding requirementsinthe area.

Proper groundingof the generator will help preventelectrical

shockintheeventof a groundfault condition inthe generatoror in

connectedelectricaldevices.Propergroundingalsohelpsdissipate

static electricity,which often buildsup in ungroundeddevices.

Figure 10- Grounding theGenerator

2.5 DON'TOVEBLOADTHEGENEBATOB

Overloadinga generatorin excess of its ratedwattage capacity

can result in damageto the generatorand to connectedelectrical

devices.Observethefollowing to preventoverloadingthe unit:

* Addupthetotal wattageofall electricaldevicesto beconnected

at one time. This total should NOT be greater than the

generator'swattagecapacity.

* Theratedwattageof lights can betaken from light bulbs. The

ratedwattageof tools, appliancesand motors can usually be

found on a data labelor decalaffixedto the device.

* If the appliance,toot or motor does not give wattage,multiply

voltstimes ampereratingto determinewatts (volts x amps =

watts).

* Someelectric motors, such as induction types, require about

threetimes morewatts of powerfor startingthan for running.

This surge of power lasts only a few seconds when starting

suchmotors. Makesureto allowfor high startingwattagewhen

selectingelectricaldevicesto connectto the generator:

1. Figurethe watts neededto start the largestmotor.

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

loads.

TheWattageReferenceGuideis providedto assist in determining

how many itemsthegeneratorcanoperateat onetime.

NOTE:

All figures are approximate.See data label on appliancefor

wattage requirements.

2.6 WATTAGEBEFEBENCEGUIDE

Device ................................... RunningWatts

*Air Conditioner(12,000 Btu).......................... 1700

*Air Conditioner(24,000 Btu).......................... 3800

*Air Conditioner(40,000 Btu).......................... 6000

BatteryCharger(20 Amp).............................. 500

BeltSander(3") .................................... 1000

ChainSaw ........................................ 1200

CircularSaw(6-1/2") ........................... 800to 1000

*Clothes Dryer (Electric) ............................. 5750

*Clothes Dryer (Gas) ................................. 700

*Clothes Washer ................................... 1150

CoffeeMaker ...................................... 1750

*Compressor (1 HP)................................. 2000

*Compressor (3/4 HP)............................... 1800

*Compressor (1/2 HP)............................... 1400

CurlingIron......................................... 700

*Dehumidifier....................................... 650

DiscSander(9").................................... 1200

EdgeTrimmer....................................... 500

Electric Blanket...................................... 400

Electric NailGun.................................... 1200

Electric Range(per element)........................... 1500

ElectricSkillet...................................... 1250

*Freezer............................................ 700

*FurnaceFan(3/5 HP) ................................ 875

*GarageDoor Opener............................ 500 to 750

HairDryer......................................... 1200

HandDrill .................................... 250to 1100

HedgeTrimmer...................................... 450

ImpactWrench...................................... 500

Iron.............................................. 1200

*JetPump......................................... 800

LawnMower....................................... 1200

LightBulb.......................................... 100

MicrowaveOven............................... 700to1000

*MilkCooler....................................... 1100

OilBurneronFurnace................................. 300

OilFiredSpaceHeater(140,000Btu)..................... 400

OilFiredSpaceHeater(85,000Btu)...................... 225

OilFiredSpaceHeater(30,000Btu)...................... 150

*PaintSprayer,Airless(1/3HP)......................... 600

PaintSprayer,Airless(handheld)......................... 150

Radio......................................... 50to200

*Refrigerator........................................ 700

SlowCooker........................................ 200

*SubmersiblePump(1-1/2HP)........................ 2800

*SubmersiblePump(1HP)........................... 2000

*SubmersiblePump(1/2HP).......................... 1500

*SumpPump................................. 800to1050

*TableSaw(10")............................. 1750to2000

Television..................................... 200to500

Toaster..................................... 1000to1650

WeedTrimmer...................................... 500

*Allow3timesthelistedwattsforstartingthesedevices.

2.7 BEFORESTARTIN6THEGENERATOR

Priorto operatingthe generator,engineoil and gasolinewill need

to be added,asfollows:

2.7.1 AL}gitVGEtVGIflEO/L

All oil should meet minimum American PetroleumInstitute (API)

Service Class SJ, SL or better.Use no special additives. Select

the oil's viscosity grade according to the expected operating

temperature(also seechart).

* Above40° F,useSAE30

* Below40° Fand downto 10° F,use10W-30

* Below10° F,usesynthetic5W-30

mEm

°F -20 -10 0 10 20 32 40 60 80 100

oc-3'o -_o -lo o lo 2'0 3'o 4b

Temperature Range of Expected Use

1. Placegeneratoron a levelsurface (notto exceed15° in any

direction).

2. Cleanareaaroundoil fill andremoveoil fill cap.

3. Slowly fill enginewith oil until the dipstick readsfull. Stop

filling occasionallyto checkoil level.

4. Installdipstick andfingertighten securely.

5. Checkengineoil levelbeforestarting eachtime thereafter.

2.7.2 ADD/NGGASOLINE

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. UseregularUNLEADEDgasolinewith thegeneratorengine.Do

not usepremiumgasoline.Do notmix oil with gasoline.

2. Cleanareaaroundfuelfill cap, removecap.

3. Slowly add unleaded regular gasoline to fuel tank. Fill to

bottom of screenfilter. Be carefulnottooverfill (Figure11).

4. Installfuelcap andwipe up any spilledgasoline.

IMPORTANT:Itis importantto preventgum depositsfrom forming

in fuel system parts such as the carburetor,fuel hose or tank

during storage. Alcohol-blendedfuels (called gasohol, ethanol

or methanol)can attract moisture, which leadsto separationand

formationof acids duringstorage.Acidicgascandamagethefuel

system of an enginewhile in storage.Toavoid engineproblems,

the fuel system should be emptiedbefore storage of 30 days or

longer.Seethe "Storage"section. Neveruseengineor carburetor

cleanerproductsinthefueltank aspermanentdamagemay occur.

Figure 11 - Fuel Tank

FueJTank

Fuel/ Do NOTFillAboveLip

_CAUTION!

Any attempt to crank or start the engine

before it has been properly serviced with the

recommended oil may result in an engine

failure.

2.8 STARTINGPULLSTARTENGINES

Never start or stop engine with electrical

devices plugged into the receptacles AND

devices turned on.

1. Unplugall electrical loadsfrom the unit's receptaclesbefore

startingthe engine.

2. Make surethe unitis in a levelposition (notto exceed15° in

anydirection).

3. OPENthe FuelShut-offValve(Figure12).

4. TurnengineRUN/STOPswitch to ONposition (Figure13).

5. Slide engine choke to the LEFT to FULL CHOKEposition

(Figure14).

Figure 12- FuelShut-off Valve

Figure 13 - Engine ON/OFF Switch

ENGINE ON/OFF SWITCH

(PULL START ENGINES ONLY)

lllh

FUEL SHUTOFF

Figure 14 - Choke Position

CHOKELEVER

LEFT= CHOKE(START)

RIGHT= RUN

Tostart engine,firmly graspthe recoilhandleandpull slowly

until increasedresistanceisfelt. Pullrapidlyup and away.

Whenenginestarts,move chokeknobto 1/2-CHOKEposition

until engine runs smoothly and then fully into RUNposition.

If enginefalters,move chokeback outto 1/2-CHOKEposition

untilengine runssmoothly andthento RUNposition.

NOTE:

if enginefires, but does not continueto run,move chokelever

to FULLCHOKEand repeatstarting instructions.

IMPORTANT:Donotoverloadthe generator.Also, do not overload

individual panel receptacles.These outlets are protectedagainst

overload with push-to-reset-type circuit breakers. If amperage

rating of any circuit breakeris exceeded,that breakeropensand

electricaloutputtothat receptacleislost. Read"Don't Overloadthe

Generator"carefully.

2.9 STARTINGELECTRICSTARTENGINES

Never start or stop engine with electrical

devices plugged into the receptacles AND

devices turned on.

1. Unplugall electricalloads from the unit's receptaclesbefore

startingthe engine.

2. Makesurethe unit is in a levelposition (notto exceed15° in

anydirection).

3. Openthefuel shut-off valve (Figures12).

4. Move engineCHOKEknoboutward to FULLCHOKEposition

(Figure14).

5. Tostart engine,press and hold the Start/Run/Stopswitch in

the"Start" position.Theenginewill crankandattemptto start.

Whentheenginestarts, releasethe switchto the run position.

Whenthe engine starts, move choke knob to "1/2 Choke"

position untilthe enginerunssmoothly andthenfully into the

"Run" position.If enginefalters,move chokeknobbackoutto

"1/2 Choke"position untiltheengineruns smoothly andthen

to "Run" position.

2.9.1 MANUALSTART

Thisgeneratoris alsoequippedwith a manualrecoilstarterwhich

may be usedif the batteryis discharged.

NOTE:

The switch must be in the RUN position. Use one of the

generator's receptacle outletsalong with the includedbattery

chargerto chargethe battery while the generator is running.

Tostart manually,firmly grasptherecoil handleand pull slowly

until increasedresistanceis felt. Pull rapidly up and away to

start engine.Thenfollow thesame choke sequence.

NOTE:

If enginefires, but does not continueto run, move chokelever

to FULLCHOKEand repeatstarting instructions.

IMPORTANT:Donotoverloadthe generator.Also, do not overload

individual panel receptacles.These outlets are protectedagainst

overload with push-to-reset-type circuit breakers. If amperage

ratingof any circuit breakeris exceeded,that breakeropens and

electricaloutputto that receptacleislost. Read"Don't Overloadthe

Generator"carefully.

2.10STOPPINGTHEENGINE

1. Shut off all loads, then unplug the electrical loads from

generatorpanel receptacles.Never start or stop the engine

with electricaldevicespluggedin andturnedon.

2. Let enginerun at no-load for severalminutesto stabilizethe

internaltemperaturesof engineandgenerator.

3. Move Run/Stopswitch to OFFposition.

4. Closefuelvalve.

2.11LOW01LLEVELSHUTDOWNSYSTEM

Theengineis equippedwith a low oil levelsensorthat shutsdown

the engineautomaticallywhenthe oil leveldropsbelowa specified

level. If the engine shuts down by itself and the fuel tank has

enoughgasoline,check engineoil level.

2.11.1 SENSINGLOWOILLEVEL

If the system senses a low oil levelduring operation,the engine

shuts down. Theenginewill not rununtil the oil has beenrefilled

to the proper level.

2.12 CHARGINGTHEBATTERY(ELECTRICSTART

UNITSONLY)

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.

_tDo not permit smoking, flame, sparks

open

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.

NOTE:

The battery shipped withthe generator hasbeen fully charged.

A battery may lose some of its chargewhen not in use for

prolongedperiodsof time. If the battery is unable to crankthe

engine,plugin the12V chargerincludedin the accessory box.

RUNNINGTHEGENERATORDOESNOTCHARGETHEBATTERY.

Usebatterychargerplugto keepthebatterychargedandreadyfor

use. Batterychargingshouldbe done in a dry location.

1. Plugchargerinto "BatteryChargerInput"jack, locatedon the

control panel.Plugwall receptacleend of the batterycharger

into a 120 VoltACwall outlet.

2. Unplugbatterychargerfrom wall outletand control paneljack

whengeneratoris goingto be in use.

NOTE:

Do not use the battery chargerfor more than 48 hoursat one

charge.

Figure 15 - Battery Charger Jack

BATTERY

CHARGER

INPUT

3.1 PERFORMINGSCHEDULEDMAINTENANCE

It is importantto perform serviceas specifiedin the Maintenance

Schedulefor proper generatoroperation,and to ensurethat the

generatorcomplieswith the applicableemissionstandardsfor the

durationof its useful life.Serviceandrepairsmay be performedby

any capablepersonor repairshop. Additionally,emissionscritical

maintenancemust be performed as scheduled in order for the

Emissions Warrantyto be valid. Emissions critical maintenance

consists of servicing the air filter and spark plugs in accordance

with the MaintenanceSchedule.

3.2 MAINTENANCESCHEDULE

Follow the calendar intervals. More frequent service is required

whenoperatingin adverseconditionsnotedbelow.

CheckOil Level

ChangeOil

CheckValveClearance

ServiceAir Filter

ReplaceSparkPlug

At EachUse

*Every 100 hoursor EverySeason

***Every Season

** Every200 hoursor EverySeason

EverySeason

:i: Changeoil after first 30 hours of operationthenevery season.

* Changeoiland oilfilter everymonth whenoperatingunderheavy load or in high

temperatures.

** Clean more often under dirty or dusty operating conditions. Replaceair filter

parts if they cannot beadequatelycleaned.

*** Check valve clearance and adjust if necessary after first 50 hours of

operationand every 100 hoursthereafter.

3.3 PRODUCTSPECIFICATIONS

3.3.1 GENERATORSPEC/F/CATiONS

RatedPower............................................................... 5.0/5.5/6.5 kW**

SurgePower............................................................... 6.25/6.88/8.0 kW

RatedACVoltage...................................................................... 120/240

RatedAC Load

Current@ 240V (5.0/5.5/6.5 kW)..................20.8/22.9/27.1 Amps**

Current@ 120V (5.0/5.5/6.5 kW)..................41.6/45.8/54.2 Amps**

RatedFrequency.................................................... 60 Hz@ 3600 RPM

Phase................................................................................ SinglePhase

** Maximumwattageandcurrentaresubjectto,andlimitedby,suchfactors

asfuelBtucontent,ambienttemperature,altitude,enginecondition,etc..

Maximumpowerdecreasesabout3.5%foreach1,000feetabovesealevel;

andwillalsodecreaseabout1%for each6° C(10° F)above16° C(60° F)

ambienttemperature.

3.3.2 ENGINESPECIFICATIONS

Displacement.............................................................................. 389 cc

SparkPlugType................................ NHSPLDF7TCor ChampionN9YC

SparkPlug PartNo........................................................... 0G84420101

SparkPlug Gap.............................0.028-0.031 inch or (0.70-0.80 mm)

GasolineCapacity......................................................... 7.2 U.S.gallons

OilType.................. SeeChartin "Before Startingthe Generator"Section

OilCapacity.................................................................... 1 L (1.06 Qts.)

RunTimeat 50% Load (5.0/5.5/6.5 kW)..................................10 Hours

3.3.3 EM/SS/ONS/NFORIVIAT/ON

TheEnvironmentalProtectionAgency(and CaliforniaAir Resource

Board for generators certified to CA standards) require(s)that

this generator comply with exhaust and evaporative emission

standards.Locate the emissions compliancedecalon the engine

to determinewhat standardsthe generatormeets. This generator

is certified to operateon gasoline.The emission control system

includesthefollowing components(if equipped):

Air Induction System • Ignition System

- IntakePipe/ Manifold -- SparkPlug

- Air Cleaner -- IgnitionModule

Fuel System • Exhaust System

- Carburetor -- ExhaustManifold

- FuelTank/Cap -- Muffler

- FuelLines -- PulsedAir Valve

- EvaporativeVentLines -- Catalyst

- CarbonCanister

3.4 GENERALRECOMMENDATIONS

Thewarrantyof thegeneratordoes notcover itemsthat havebeen

subjectedto operator abuseor negligence.To receivefull value

from the warranty, the operator must maintain the generatoras

instructed inthis manual.

Some adjustmentswilt need to be made periodically to properly

maintainthegenerator.

All adjustmentsin the Maintenancesectionof this manualshould

be madeat leastonceeachseason.Followthe requirementsinthe

"MaintenanceSchedule".

NOTE:

Once a year replacethe spark plug and replacethe air filter.

A new spark plug and clean air filter assure properfuel-air

mixture andhelpthe engine runbetter andlast longer.

3.4.1 GENERATORMAINTENANCE

Generatormaintenanceconsistsof keepingthe unitcleanand dry.

Operateand storethe unit in a cleandry environmentwhereit will

not be exposedto excessivedust,dirt, moistureor any corrosive

vapors.Coolingair slotsin thegeneratormustnot becomeclogged

with snow, leaves,or anyotherforeign material.

Checkthe cleanlinessof the generatorfrequentlyand cleanwhen

dust, dirt, oil, moistureor otherforeign substancesarevisible on

its exteriorsurface.

,ACAUTION!

,_ Never insert any object or tool through the air

cooling slots, even if the engine is not running.

NOTE:

DONOTusea garden hoseto cleangenerator. Water canenter

the enginefuel systemand causeproblems.In addition,ifwater

enters thegenerator throughcoolingair slots,some waterwill

be retainedin voidsand crevicesof therotorand stator winding

insulation.Water and dirt buildup on the generator internal

windingswill eventually decrease the insulationresistanceof

these windings.

3.4.2 TOCLEANTHEGENERATOR

• Usea dampcloth to wipe exteriorsurfaces clean.

• A soft, bristlebrush may be usedto loosencaked on dirt, oil,

etc.

• A vacuumcleanermay be usedto pick up loosedirt anddebris.

• 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 ENG/NEMA/NTENANCE

//_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 CNECK/NGO/LLEVEL

Seethe "BeforeStartingthe Generator"sectionfor informationon

checkingthe oil level.Theoil levelshouldbe checkedbeforeeach

use, or at least every eight hours of operation. Keepthe oil level

maintained.

3.4.5 CNANG/NGTHEO/L

Changethe oil after the first 30 hours of operation. Changethe

oil every 100 hours or every season thereafter. If running this

unit underdirty or dusty conditions, or in extremelyhot weather,

changethe oil moreoften.

,A CAUTION!

,l_ 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.

Usethefollowinginstructionstochangetheoil aftertheengine

coolsdown:

1. Cleanareaaroundoil drain plug.

2. Removeoil drain plugfrom engineandoil fill plugto drainoil

completely intoa suitablecontainer.

3. When oil has completely drained, install oil drain plug and

tighten securely.

4. Filloil sumpwith recommendedoil. (See"BeforeStartingthe

Generator"for oil recommendations).

5. Wipeup any spilledoil.

6. Disposeof usedoil ata propercollectioncenter.

3.4.6 REPLACINGTHESPARKPLUG

SeeEngineSpecificationsfor recommendedspark plug.Replace

theplugonceeachyear.This will helptheenginestarteasierand

run better.

1. Stopthe engineand pull the spark plug wire off of the spark

plug.

2. Cleanthe areaaroundthe spark plug and remove itfrom the

cylinder head.

3. Setthe spark plug'sgap to 0.70-0.80 mm (0.028-0.031 in.).

Installthe correctly gappedspark plug intothe cylinder head

(Figure16).

Figure 16 - Spark Plug Gap

3.4.7 BATTERYREPLACEMENT{IFAPPLICABLE)_

NOTE:

Thebattery shippedwith thegenerator hasbeen fully charged.

A battery may lose some of its chargewhen not in use for

prolongedperiodsof time. If the battery is unable to crank

the engine,plugin the 12V chargerincludedin the accessory

box (see the Charging a Battery section). RUNNINGTHE

GENERATORDOES NOT CHARGETHE BATTERY.The part

numberfor this batteryis 0G9449.

,_ CAUTION!

,l_The NEGATIVE battery terminal should:

1. Always be DISCONNECTEDFIRST.

2. Alwaysbe CONNECTEDLAST.

Figure17- Battery Connections

3.5 SERVICEAiRCLEANER

The engine will not run properly and may be damagedif using

a dirty air cleaner.Clean or replacethe air cleaner paper filter

once a year.Cleanor replacemore often if operatingunder dusty

conditions(Figure18). Theair filter part numberis 0G84420151.

Tocleanor replacepaperair filter:

1. Removeair cleanercover andremove paperfilter.

2. Cleanpaperfilter bytappingit gently on a solid surface. If the

filter is too dirty, replaceit with a newone. Disposeofthe old

filter properly.

3. Cleanair cleanercover,then insert new paper filter into the

baseof theair cleaner.Re-installair cleanercover.

Figure 18- Air Filter

8.5.1CLEANSPARKARRESTORSCREEN(CARB

MOOELS

The engineexhaustmuffler has a spark arrestor screen. Inspect

and cleanthe screenat leastonce eachyear (Figure19). If unit is

usedregularly,inspectand cleanmoreoften.

i,_lf 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.

Cleanandinspectthe sparkarrestorwhenthe engineisat ambient

temperatureasfollows:

1. Remove the spark arrestor screen from the muffler by

looseningthe clamp andremovingthe screw.

2. Inspect screen and replace if torn, perforated or otherwise

damaged. DONOTUSEa defective screen. If screen is not

damaged,cleanit with commercialsolvent.

3. Replacethe spark arrestor and secure with the clamp and

screw.

Figure 19 - Spark Arrestor Screen

ARRESTDR

SPARK

ARRESTOR

SCREEN2

NOTE:

Toorder a newair filteror sparkarrestor screen,pleasecontact

the nearestauthorizedservice centerat 1-800-333-1322.

3.6 VALVECLEARANCE

* Intake-- 0.15 _ O.02mm(cold), (0.006" _ 0.0008" inches)

* Exhaust-- 0.20 _ O.02mm(cold) (0.008" _ 0.0008" inches)

After the first 50 hoursof operation, checkthe valve clearance

in the engineand adjustif necessary.

Important: If feelinguncomfortable aboutdoing this procedureor

the propertools are not available,pleasetakethe generatorto the

nearestservicecenterto havethevalveclearanceadjusted.Thisis

a very important stepto ensurelongestlifefor the engine.

3.7 GENERAL

Thegeneratorshouldbestartedatleastonceeverythirty days and

be allowedto run at least30 minutes. If this cannot be done and

the unitmust be stored for morethan 30 days, usethe following

informationasa guideto prepareit 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.

,_AIIow unit to cool entirely before storage.

3.8 LONGTERMSTORAGE

It is importantto preventgum depositsfrom forming in essential

fuel systemparts such asthe carburetor,fuel hoseor tank during

storage. Also, experience indicates that alcohol-blendedfuels

(calledgasohol,ethanolor methanol)can attract moisture,which

leadsto separationand formation of acids during storage.Acidic

gas candamagethefuel systemof an enginewhile in storage.

To avoid engine problems, the fuel system should be emptied

beforestorageof 30 days or longer,asfollows:

1. Addaqualitygasolinestabilizertothefuelperthemanufacturers

specifications,and run theunitfor 10-15 minutes.

2. After enginecools down, remove all gasolinefrom the fuel

tank. Usea commercially available,non-conductivevacuum

siphon.

Drain fuel into approved container outdoors,

away from open flame, Be sure engine is cool,

Do not smoke.

3. Start andrun engineuntilenginestops from lack offuel.

4. After engine cools down, drain oil from engine. Refill with

recommendedgrade.

5. Removespark plug and pour about 1/2 ounce (15 mt) of

engine oil into the cylinder.Cover spark plug hole with rag.

Pull the recoil starter a coupletimes to lubricatethe piston

ringsand cylinder bore.A fogging agentcan also be used in

the placeof oil.

• , CAUTION!

Avoid spray from spark plug hole when

cranking engine.

6. Installandtightenspark plug.Donotconnectsparkplugwire.

7. Cleanthe generatorouter surfaces. Check that cooling air

slots and openingson generatorare openand unobstructed.

8. Storethe unitin a clean,dry place.

3.9 OTHERSTORAGETiPS

* Donot store gasolinefrom oneseasonto another.

* Replacethe gasolinecan if it starts to rust. Rustand/or dirt in

the gasolinewill cause problems with the carburetorand fuel

system.

* If possible,storethe unitindoorsandcover itto giveprotection

from dust and dirt. BESURETOEMPTYTHEFUELTANK,

, If it is not practical to emptythe fuel tank and the unit is to

be stored for some time, use a commercially availablefuel

stabilizer added to the gasoline to increase the life of the

gasoline.Runtheunitfor 10-15 minutes,turn off thefuel valve

andallow to run untilenginestopsfrom lack of fuel.

, Coverthe unit with a suitable protective cover that does not

retainmoisture.

_t NEVER cover the generator while engine and

exhaust areas are warm,

4.1 TROUBLESHOOTINGGUIDE

Engineisrunning,but noACoutput

is available.

1. Circuit breakeris open.

2. Poorconnectionor defectivecord set.

3. Connecteddevice is bad.

4. Faultin generator.

1. Resetcircuit breaker.

2. Checkand repair.

3. Connectanotherdevicethat is in good condition.

4. ContactAuthorizedServiceFacility.

Engine runs well hut bogsdown 1. Short circuit in a connectedload. 1. Disconnectshorted electricalload.

whenloads areconnected. 2. Generatoris overloaded. 2. See"Don't Overloadthe Generator".

3. Enginespeedis too slow. 3. ContactAuthorizedServiceFacility.

4. Shorted generatorcircuit. 4. ContactAuthorizedServiceFacility.

Enginewiil notstart; orstartsand

runsrough.

FuelShut-off is OFF. 1.

Dirtyair filter. 2.

Out of gasoline. 3.

Stale gasoline. 4.

Spark plugwire not connectedto sparkplug. 5.

Badsparkplug. 6.

TurnFuelShut-offto ON.

Cleanor replaceair filter.

Fillfuel tank.

Drainfuel tank and fill with fresh fuel.

Connectwireto sparkplug.

Replacesparkplug.

7. Waterin gasoline.

8. Over-choking.

9. Lowoil level.

10. Excessiverich fuel mixture.

11. Intakevalvestuck open or closed.

12. Enginehas lost compression.

7. Drainfuel tank; fill with fresh fuel.

8. Put choke knobto No Chokeposition.

9. Fillcrankcaseto proper level.

10. ContactAuthorizedServiceFacility.

11. ContactAuthorizedServiceFacility.

12. ContactAuthorizedServiceFacility.

i i

Engineshuts down during 1. Out of gasoline. 1. Fillfuel tank.

operation. 2. Lowoil level. 2. Fillcrankcaseto proper level.

3. Faultinengine. 3. ContactAuthorizedServiceFacility.

Engine lacks power. 1. Loadis toohigh. 1. Reduceload (see"Don'tOverloadthe Generator").

2. Dirtyair filter. 2. Cleanor replaceair filter.

3. Engineneedsto beserviced. 3. ContactAuthorizedServiceFacility.

Engine "hunts" orfalters. 1. Chokeis openedtoosoon. 1. Movechoketo halfway position untilengineruns

smoothly.

2. Carburetoris runningtoo rich or too lean. 2. ContactAuthorizedServiceFacility.

1"7

U,S, EPA EMiSSiON CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLiGATiONS

TheUnited StatesEnvironmentalProtectionAgency (EPA)andGeneracPowerSystems,Inc. (Generac)arepleasedto explainthe EmissionControl

SystemWarranty(ECSWarranty)on yournew 2011 andlaterequipment.New equipmentthat use smallspark-ignitedenginesmust bedesigned,built,

andequippedto meetstringentanti-smog standardsfor the federalgovernment.Generacwill warrantthe emission control systemon your equipment

for the period of time listed belowprovidedtherehas beenno abuse, neglect,unapprovedmodificationor impropermaintenanceofyour equipment.

Theemission control system on this equipmentincludesall componentswhose failurewould increasethe emissionsof anyregulatedpollutant.These

componentsarelisted in the Emissions Information sectionofthis manual.

MANUFACTURER'S WARRANTY COVERAGE:

This ECSWarranty is validfor two years,orfor the sameperiod as specifiedin the GeneracLimitedWarranty,whicheveris longer.Forequipmentwith

hourmeters,the warranty period is anumber of hours equalto halfthe UsefulLifeto whichthe equipmentis certified, or the warrantyperiod specified

abovein years,whicheveris less.TheUsefulLife can befound on the EmissionControlLabelon the engine.If, during suchwarranty period,any

emission-relatedpart on yourequipment isfound to be defectivein materials or workmanship, repairsor replacementwill be performedby a Generac

AuthorizedWarrantyServiceDealer.

OWNER'S WARRANTY RESPONSiBiLiTiES:

Asthe equipmentowner,you areresponsiblefor the completion of all requiredmaintenanceaslisted in your factory suppliedOwner'sManual.For

warranty purposes,Generacrecommendsthat you retainall receiptscovering maintenanceon your generator,but Generaccannotdeny warranty

solelydueto the lack of receipts.

Youshould beawarethat Generacmay deny anyand/or all warrantycoverageor responsibilityif your equipment,or a part!componentthereof,has

failed due to abuse,neglect, impropermaintenance,or unapprovedmodifications.

Youare responsiblefor contactingaGeoeracAuthorizedWarrantyDealeras soonas a problemoccurs.Thewarranty repairsshouldhe

completed in a reasonable amount oftime, not to exceed 30 days.

Warrantyservice can bearrangedby contactingeitheryour sellingdealeror aGeneracAuthorizedWarrantyServiceDealer.Tolocate the Generac

AuthorizedWarrantyServiceDealernearestyou, call ourtoll free numberbelow, or email[email protected].

1-800-333-1322

IMPORTANTNOTE:This warranty statementexplainsyour rights and obligationsunderthe EmissionControlSystemWarranty,which is providedto

you by Generacpursuantto federallaw. Seealsothe "GeneracLimitedWarrantiesfor GeneracPowerSystems,Inc.," which is enclosedherewith on a

separatesheet,also providedto you by Generac.Notethat this warranty shallnot applyto any incidental,consequentialor indirect damagescaused

bydefects in materialsor workmanship or any delayin repairor replacementof the defectivepart(s). This warranty is in place of all other warranties,

expressedor implied.Specifically,Generacmakesno otherwarrantiesasto the merchantabilityor fitness for aparticular purpose.Any implied

warrantieswhich areallowed by law, shallbe limited in durationto the terms of the expresswarranty providedherein.Somestates do not allow

limitationson how long an impliedwarrantylasts, sothe abovelimitation may not applyto you.

TheECSWarrantyappliesonly to the emissioncontrol system of your newequipment.Boththe ECSWarrantyandthe GeneracWarrantydescribe

importantrights and obligationswith respectto your new engine.

Warrantyservice can beperformed onlyby a GeneracAuthorizedWarrantyServiceFacility.When requestingwarranty service,evidencemust be

presentedshowingthe dateofthe saleto the originalpurchaser/owner.

Ifyou haveany questionsregardingyour warranty rightsandresponsibilities,you shouldcontact Generacatthe following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, Wi 53190

PartI of 2

PartNo. 0J3335 Rev.C 11/11

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Generac 5940-1 Owner's manual

Brand: Generac

Model: 5940-1

Category: Power generators

Type: Owner's manual

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