Generac Power Systems Portable Generator 004987 2 005396 0 User Manual

COMMERCIAL • INDUSTRIAL • RESIDENTIAL  
Owner’s  
Manual  
• Safety  
• Assembly  
• Operation  
• Maintenance  
• Troubleshooting  
• Electrical Data  
• Parts  
• Warranty  
FOR THE NEAREST  
AUTHORIZED SERVICE  
CENTER 1-800-333-1322  
MODELS:  
004987-2 (15,000 Watt)  
005396-0 (17,500 Watt)  
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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.  
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.  
Always disconnect spark plug wires and place  
the wires where they cannot contact the spark  
READ THIS MANUAL THOROUGHLY  
If any portion of this manual is not understood, contact the nearest  
Authorized Dealer for starting, operating and servicing procedures.  
plugs to prevent accidental starting when  
setting up, transporting, adjusting or making  
repairs to the generator.  
The generator produces dangerously high voltage that can cause  
extremely hazardous electrical shock. Avoid contact with bare  
wires, terminals, etc. Never permit any unqualified person to  
operate or service the generator.  
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:  
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 will result.  
DANGER  
The National Electric Code requires the frame and external  
electrically conductive parts of the generator be properly connected  
to an approved earth ground. Local electrical codes may also  
require proper grounding of the generator. Consult with a local  
electrician for grounding requirements in the area.  
After this heading, read instructions that, if  
not strictly complied with, will result in serious  
personal injury, including death and/or property  
damage.  
Use a ground fault circuit interrupter in any damp or highly  
conductive area (such as metal decking or steel work).  
After this heading, read instructions that, if not  
strictly complied with, may result in serious  
personal injury and/or property damage.  
Do not use worn, bare, frayed or otherwise damaged electrical  
cord sets with the generator.  
Operate generator only on level surfaces and where it will not be  
exposed to excessive moisture, dirt, dust or corrosive vapors.  
Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE.  
Do not permit smoking, open flames, sparks or heat in the vicinity  
while handling gasoline. Avoid spilling gasoline on a hot engine.  
Comply with all laws regulating storage and handling of gasoline.  
After this heading, read instructions that, if not  
strictly complied with, could result in damage to  
equipment and/or property.  
NOTE:  
Never add fuel while unit is running.  
Do not overfill the fuel tank. Always allow room  
After this heading, read explanatory statements that require  
special emphasis.  
for fuel expansion. If tank is over-filled, fuel can  
overflow onto a hot engine and cause FIRE or  
an EXPLOSION.  
These safety warnings cannot eliminate the hazards that they indicate.  
Common sense and strict compliance with the special instructions  
while performing the service are essential to preventing accidents.  
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.  
Four commonly used safety symbols accompany the DANGER,  
WARNING and CAUTION blocks. The type of information each  
indicates is as follows:  
Generator exhaust gases contain DEADLY carbon monoxide gas.  
This dangerous gas, if breathed in sufficient concentrations, can  
cause unconsciousness or even death. Operate this equipment  
only in the open air where adequate ventilation is available.  
This symbol points out important safety  
information that, if not followed, could endanger  
Allow at least two (2) feet of clearance on all sides of generator or  
damage could be done to the unit. Never operate the unit inside  
any room or enclosure where the free flow of cooling air into and  
out of the unit might be obstructed. Review the “Cold Weather  
Operation” section.  
personal safety and/or property of others.  
This symbol points out potential explosion  
hazard.  
This symbol points out potential fire hazard.  
DANGER  
This symbol points out potential electrical shock  
hazard.  
NEVER operate the generator indoors, in an  
attached garage or near an open window.  
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.  
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IMPORTANT SAFETY INSTRUCTIONS  
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's  
installation site. Safety should be stressed to all operators and potential operators of this equipment.  
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.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently,  
neglecting its maintenance or being careless  
can cause possible injury or death. Permit only  
responsible and capable persons to operate or  
maintain this equipment.  
Do not insert objects through unit's cooling slots.  
Neveroperategenerator: Indoorsorinanyenclosedcompartment;  
in rain; if connected electrical devices overheat; if electrical output  
is lost; if engine or generator sparks; if flames or smoke are  
observed while unit is running; if unit vibrates excessively.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
NOTE:  
This generator is equipped with a spark arrestor muffler. The  
spark arrestor must be maintained in effective working order by  
the owner/ operator. In the State of California, a spark arrestor is  
required by law (Section 4442 of the California Public Resources  
Code). Other states may have similar laws. Federal laws apply  
on federal lands.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
GENERAL HAZARDS  
  
Never operate in an enclosed area or indoors.  
Study these SAFETY RULES carefully before installing, operating or  
servicing this equipment. Become familiar with this Owner’s Manual  
and with the unit. The generator can operate safely, efficiently and  
reliably only if it is properly installed, operated and maintained. Many  
accidents are caused by failing to follow simple and fundamental rules  
or precautions.  
For safety reasons, the manufacturer recommends that the  
maintenance of this equipment is carried out by an Authorized  
Dealer.  
The engine exhaust fumes contain carbon monoxide, which  
can be DEADLY. This dangerous gas, if breathed in sufficient  
concentrations, can cause unconsciousness or even death. 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.  
• WARNING:  
The engine exhaust from this product contains  
chemicals known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
Keep hands, feet, clothing, etc., away from drive belts, fans, and  
other moving or hot parts. Never remove any drive belt or fan guard  
while the unit is operating.  
• WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
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.  
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 the manufacturer  
does not specifically recommend, satisfy yourself that it is safe for  
others. Make sure the procedure, work method or operating technique  
chosen does not render the generator unsafe.  
When working on this equipment, remain alert at all times. Never  
work on the equipment when physically or mentally fatigued.  
Inspect the generator regularly, and contact the nearest Authorized  
Dealer for parts needing repair or replacement.  
Before performing any maintenance on the generator, disconnect  
its battery cables to prevent accidental start up. Disconnect the  
cable from the battery post indicated by a NEGATIVE, NEG or (–)  
first. Reconnect that cable last.  
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.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
ELECTRICAL HAZARDS   
EXPLOSION HAZARDS   
Do not smoke around the generator. Wipe up any fuel or oil spills  
immediately. Ensure that no combustible materials are left on or  
near the generator, as FIRE or EXPLOSION may result. Keep the  
area surrounding the generator clean and free from debris.  
All generators covered by this manual produce dangerous electrical  
voltages and can cause fatal electrical shock. Utility power delivers  
extremely high and dangerous voltages as does the generator  
when it is in operation. Avoid contact with bare wires, terminals,  
connections, etc., while the unit is running. Ensure all appropriate  
covers, guards and barriers are in place before operating the  
generator. If work must be done around an operating unit, stand on  
an insulated, dry surface to reduce shock hazard.  
Gasoline is extremely EXPLOSIVE.  
STANDARDS INDEX  
Do not handle any kind of electrical device while standing in water,  
while barefoot, or while hands or feet are wet. DANGEROUS  
ELECTRICAL SHOCK MAY RESULT.  
In the absence of pertinent standards, codes, regulations and laws,  
the published information listed below may be used as a guideline  
for operation of this equipment. Always reference the latest revision  
available for the standards listed.  
The National Electrical Code (NEC) requires the frame and external  
electrically conductive parts of the generator to be connected to an  
approved earth ground. Local electrical codes also may require  
proper grounding of the generator electrical system.  
1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC  
CODE.  
2. Article X, NATIONAL BUILDING CODE, available from the  
American Insurance Association, 85 John Street, New York, N.Y.  
10038.  
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.  
3. AGRICULTURAL WIRING HANDBOOK, available from the Food  
and Energy Council, 909 University Avenue, Columbia, MO  
65201.  
4. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM  
STANDBY ELECTRICAL SYSTEMS, available from the American  
Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI  
49085.  
Never wear jewelry when working on this equipment. Jewelry can  
conduct electricity resulting in electric shock, or may get caught in  
moving components causing injury.  
5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS  
CODE.  
FIRE HAZARDS   
For fire safety, the generator must be operated and maintained  
properly. Operation must always comply with applicable codes,  
standards, laws and regulations. Adhere strictly to local,  
state and national electrical and building codes. Comply with  
regulations the Occupational Safety and Health Administration  
(OSHA) has established. Also, ensure that the generator is  
operated in accordance with the manufacturer’s instructions and  
recommendations. Do not alter the construction of the generator  
or change controls which might create an unsafe operating  
condition.  
Keep a fire extinguisher near the generator at all times.Extinguishers  
rated “ABC” by the National Fire Protection Association are  
appropriate for use on the standby electric system. Keep the  
extinguisher properly charged and be familiar with its use. If there  
are any questions pertaining to fire extinguishers, consult the local  
fire department.  
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Section 1 – General Information  
1.1 UNPACKING  
1.2 ASSEMBLY  
The generator requires some assembly prior to using it. If problems  
arise when assembling the generator, please call the Generator  
Helpline at 1-800-333-1322.  
Set the palleted carton on a rigid flat surface.  
Remove staples along bottom of carton that fasten carton to pallet.  
Open carton from top.  
Remove all packaging material.  
Remove separate accessory box.  
Lift carton off the generator.  
1.2.1 ASSEMBLING THE WHEEL KIT  
The wheel kit is designed to greatly improve the portability of the  
generator. A socket wrench with a 9/16” socket, a 1/2” socket, a  
1/2” wrench and a pair of pliers are the tools that will be needed for  
assembly of the wheel kit.  
Remove generator from shipping pallet by removing bolts through  
the shipping brackets (Figure 1).  
Figure 1 - Bracket Removal  
NOTE:  
The wheel kit is not intended for over-the-road use.  
Refer to Figure 2 and install the wheel kit as follows:  
Place the generator on a hard flat surface.  
Stand at the engine end of the unit and gently tilt the generator  
forward, high enough to place wooden blocks beneath the cradle.  
This will allow space to install the wheel assemblies.  
Shipping  
Bracket (x4)  
Attach an axle bracket assembly with attached sleeve to either side  
of the frame. Ensure the sleeve faces outward.  
Slide the axle through the sleeves on the axle brackets.  
Slide one wheel with flat washer to the outside and a spacer to the  
inside onto each end of the axle. Make sure the air inflation valve  
on the wheel is facing outward.  
Insert retaining pins and using pliers, bend out the ends to prevent  
the pins from falling out of the axle. Remove the wooden blocks.  
1.2.2 ASSEMBLING THE HANDLE  
Attach the handle by aligning one side of the handle on the cradle,  
then spread the handle around the cradle and let it spring into  
place. Secure the handle to the frame using the 5/16’ hex head  
bolts provided. Check each fastener to ensure that it is secure.  
1.1.1 ACCESSORY BOX  
Check all contents. If any parts are missing or damaged locate an  
authorized dealer at 1-800-333-1322.  
Using the handle, lift the unit high enough to place wooden blocks  
under the unit. Attach the front support foot to the underside of the  
cradle using the 3/8” carriage bolts provided.  
Contents include:  
Wheel Axle  
Bolt-on tubular handle  
2 – Pneumatic Wheels  
2 – Axle Bracket Assemblies  
Bolt-on Foot  
Remove the shipping brackets from the cradle, if it has not already  
been done.  
2 – Washers  
2 – Wheel Spacers  
2 – Cotter Pins  
2 – Spark Plugs  
Air Filter  
Spark Plug Wrench  
Oil Filter  
Pre-cleaner  
Battery Charge Cable  
6 – Carriage Bolts, Washers, Nuts  
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Section 1 - General Information  
Figure 2 - Handle Assembly  
Figure 3 - Battery Connections  
1.2.3 BATTERY CONNECTION  
The battery shipped with the generator has been provided fully  
charged. Caution must be taken when connecting the battery.  
Positive  
Cable  
Negative  
Cable  
NOTE:  
A battery may lose some of it’s charge when not in use for  
prolonged periods of time.  
Cut the tie wrap cable holding the RED and BLACK battery cables  
to the stator.  
Connect the RED battery cable to the battery Positive terminal (+).  
After making sure that the connection is tight, slip the rubber boot  
over the terminal connection.  
Connect the BLACK battery cable to the battery Negative terminal  
(–). Make sure the connection is tight.  
Double check all connections to ensure they are in the correct  
location and secure. See Figure 3.  
5  
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