Generac GP2500i - Portable Generator Manual

Safety Rules

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The alerts in this manual, and on tags and decals affixed to the unit, are not all inclusive. If using a procedure, work method, or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others and does not render the equipment unsafe.
Throughout this publication, and on tags and decals affixed to the unit, DANGER, WARNING, CAUTION, and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Alert definitions are as follows:

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTE: Notes contain additional information important to a procedure and will be found within the regular text of this manual.
These safety alerts cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

Safety Symbols and Meanings

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.

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

• 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.

Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury.

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

Electrocution. Turn utility and emergency power supplies to OFF before connecting power source and load lines. Failure to do so will result in death or serious injury.

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer's instructions. Failure to do so could result in death or serious injury.

Equipment and property damage. Do not operate unit on uneven surfaces, or areas of excessive moisture, dirt, dust or corrosive vapors. Doing so could result in death, serious injury, property and equipment damage.

Moving Parts. Keep clothing, hair, and appendages away from moving parts. Failure to do so could result in death or serious injury.

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustables during use. Hot surfaces could result in severe burns or fire.

Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage.

Risk of injury. Do not operate or service this machine if not fully alert. Fatigue can impair the ability to service this equipment and could result in death or serious injury.

Injury and equipment damage. Do not use generator as a step. Doing so could result in falling, damaged parts, unsafe equipment operation, and could result in death or serious injury.

Equipment damage. Do not attempt to start or operate a unit in need of repair or scheduled maintenance. Doing so could result in serious injury, death, or equipment failure or damage.

• For safety reasons, it is recommended that the maintenance of this equipment be performed by an IASD. Inspect the generator regularly, and contact the nearest IASD for parts needing repair or replacement.

Exhaust and Location Hazards

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury.

Equipment and property damage. Do not alter construction of, installation, or block ventilation for generator. Failure to do so could result in unsafe operation or damage to the generator.

Asphyxiation. Always use a battery operated carbon monoxide alarm indoors and installed according to the manufacturer's instructions. Failure to do so could result in death or serious injury.

• If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air IMMEDIATELY. See a doctor, as you could have carbon monoxide poisoning.
• NEVER run a generator indoors or in a partly enclosed area such as garages.
• ONLY use outdoors and far away from windows, doors, vents, crawl spaces and in an area where adequate ventilation is available and will not accumulate deadly exhaust gas.
• Using a fan or opening a door will not provide sufficient ventilation.
• Point muffler exhaust away from people and occupied buildings.

Electrical Hazards

Electrocution. Contact with bare wires, terminals, and connections while generator is running will result in death or serious injury.

Electrocution. Water contact with a power source, if not avoided, will result in death or serious injury.

Electrocution. In the event of electrical accident, immediately shut power OFF. Use non-conductive implements to free victim from live conductor. Apply first aid and get medical help. Failure to do so will result in death or serious injury.

• The National Electric Code (NEC) 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.
• Use a ground fault circuit interrupter in any damp or highly conductive area (such as metal decking or steel work).
• Once generator has been started outside, connect electrical loads to extension cord(s) inside.

Fire Hazards

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

Explosion and Fire. Do not overfill fuel tank. Fill to 1/2 inch from top of tank to allow for fuel expansion. Overfilling may cause fuel to spill onto engine causing fire or explosion, which will result in death or serious injury.

Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage.

Fire risk. Fuel and vapors are extremely flammable. Do not operate indoors. Doing so could result in death, serious injury, or property or equipment damage.

Explosion and fire risk. Do not smoke near unit. Keep fire and spark away. Failure to do so could result in death, serious injury, or property or equipment damage.

Explosion and Fire. Do not smoke while refueling unit. Failure to do so could result in death, serious injury, or property or equipment damage.

• Allow at least 5 feet of clearance on all sides of the generator when operating to prevent overheating and fire.
• Do not operate the generator if connected electrical devices overheat, if 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.

General Information and Setup

TABLE 1. Generator Components

Know Your Generator

Consult Manual. Read and understand manual completely before using product. Failure to completely understand manual and product could result in death or serious injury.

Product Specifications

TABLE 2. Product Specifications

Connection Plugs

120 VAC, Duplex Receptacle

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

Off/Run/Choke Switch

This controls the ON/OFF functions, choke and fuel valve operation.

• The OFF position (1) stops the engine and shuts off fuel flow.
• The RUN position (2) is for normal operation and to gradually reduce the use of the choke.
• The CHOKE position (3) switches the fuel valve on to start the engine.

USB Outlet

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

Economy Switch

The economy switch has 2 modes of operation:

• On: The quietest mode and best when running appliances or equipment that are resistive loads (non-motor starting), (example: TV, video game, light, radio).
• Off: Best when running a both inductive (motor-starting loads) and resistive (non motor starting loads), especially when these loads are turning on and off (example: RV, air conditioner, hairdryer).

Generator Status Lights

• Overload LED (orange): Indicates system overload (2). During motor starting it is normal for the overload LED to illuminate for a few seconds. If LED stays illuminated and the ready LED turns off, the engine will continue to run without output power. Remove all applied loads and determine if attached devices exceed recommended output power. Check for faulty or shorted connections. To restore electrical output, turn dial OFF to reset. Start engine. If condition was corrected, the orange LED will not illuminate and electrical output will be restored. Loads can be applied once the green LED illuminates. If the orange LED returns, contact an IASD.
• Low Oil Level LED (red): Illuminates when oil level is below safe operating level. Engine shuts down (1).
• Power LED (green): Indicates output from generator (3) (unless there is a low oil or overload condition).

Circuit Protectors

The AC receptacles are protected by an AC circuit protector. The DC receptacles are protected by a DC circuit protector. If the generator is overloaded or an external short circuit occurs, the circuit protector will trip. If this occurs, disconnect all electrical loads to determine the cause of the problem before using the generator again. Reduce the load if the circuit protector is tripped.
NOTE: Continuous tripping of the circuit protector may cause damage to generator or equipment.
Push the button of the protector to reset the circuit protector.

Remove Contents from Carton

1. Open carton completely by cutting each corner from top to bottom.
2. Remove and verify carton contents prior to assembly. Carton contents should contain the following:
   TABLE 3. Accessories

   Item	Qty.
   Main Unit	1
   Owner's Manual	1
   Engine Oil	1
   Oil Funnel	1
   DC Charging Cable	1
   Tool Kit	1
   Service Warranty	1
   Emissions Warranty	1

3. Call Generac Customer Service at 1-888- GENERAC (1-888-436-3722) with the unit model and serial number for any missing carton contents.
4. Record model, serial number, and date of purchase on front cover of this manual.

Add Engine Oil

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

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

Fuel

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Add fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

Explosion and Fire. Do not overfill fuel tank. Fill to 1/2 inch from top of tank to allow for fuel expansion. Overfilling may cause fuel to spill onto engine causing fire or explosion, which will result in death or serious injury.

Fuel requirements are as follows:

• Clean, fresh, unleaded gasoline.
• Minimum rating of 87 octane/87 AKI (91 RON).
• Up to 10% ethanol (gasohol) is acceptable.
• DO NOT use E85.
• DO NOT use a gas oil mix.
• DO NOT modify engine to run on alternate fuels. Stabilize fuel prior to storage.

1. Verify unit is OFF and cooled entirely prior to fueling.
2. Place unit on level ground in a well ventilated area.
   
   
   Explosion and Fire. Verify fuel cap vent is set to ON for operation, and OFF for transportation and storage. Failure to do so could result in poor unit performance, death, or serious injury.
3. Clean area around fuel cap.
4. Turn cap slowly to remove.
5. Slowly add recommended fuel. Do not overfill.
   NOTE: Fill to red insert inside filler neck.
   
6. Install fuel cap.

NOTE: Allow spilled fuel to evaporate before starting unit.

IMPORTANT NOTE: It is important to prevent gum deposits from forming in fuel system parts such as the carburetor, fuel hose or tank during storage. Alcohol blended fuels (called gasohol, ethanol or methanol) can attract moisture, which leads to 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.

Operation

Operation and Use Questions

Call Generac Customer Service at 1-888GENERAC (1-888-436-3722) with questions or concerns about equipment operation and maintenance.

Before Starting Engine

1. Verify engine oil level is correct.
2. Verify fuel level is sufficient.
3. Verify unit is secure on level ground, with proper clearance and is in a well ventilated area.

Prepare Generator for Use

Asphyxiation. Running engines produce carbon monoxide, a colorless, odorless, poisonous gas. Carbon monoxide, if not avoided, will result in death or serious injury.

Asphyxiation. The exhaust system must be properly maintained. Do not alter or modify the exhaust system as to render it unsafe or make it noncompliant with local codes and/or standards. Failure to do so will result in death or serious injury.

Risk of fire. Do not use generator without spark arrestor installed. Failure to do so could result in death or serious injury.

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.

Grounding the Generator When In Use

The generator is equipped with an equipment ground connecting the generator frame and the ground terminals on the AC output receptacles (see NEC 250.34 (A). This allows the generator to be used as a portable without grounding the frame of the generator as specified in NEC 250.34.

• Neutral Floating

The generator (stator winding) is isolated from the frame and from the AC receptacle ground pin. Electrical devices that require a grounded receptacle pin connection will not function if the receptacle ground pin is not functional.

Special Requirements

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

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

Connecting to a Building Electrical System

Use a manual transfer switch when connecting directly to a building electrical system. Installation and connections must be performed by a qualified electrician and in strict compliance with all national and local electrical codes and laws.
Always operate the generator with the Eco Mode Switch OFF (if equipped).

Know Generator Limits

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

• Add the total wattage of all electrical devices to be connected at one time. This total should NOT be greater than the generator's wattage capacity.
• The rated wattage of lights can be taken from light bulbs. The rated wattage of tools, appliances, and motors can be found on a data label or decal affixed to the device.
• If the appliance, tool, or motor does not give wattage, multiply volts times ampere rating to determine watts (volts x amps = watts).
• Some electric motors, such as induction types, require approximately three times more watts of power for starting than for running. This surge of power lasts only a few seconds when starting such motors. Make sure to allow for high starting wattage when selecting electrical devices to connect to the generator:

1. Calculate the watts needed to start the largest motor.
2. Add to that figure the running watts of all other connected loads.

The Wattage Reference Guide is provided to assist in determining how many items the generator can operate at one time.
NOTE: All figures are approximate. See data label on appliance for wattage requirements.

Wattage Reference Guide

Transporting/Tipping of the Unit

Do not store or transport the unit at an angle greater than 15 degrees.
Secure unit during transport to avoid spilling fuel and oil.

Starting Cold Engines

Recoil Hazard. Recoil could retract unexpectedly. Kickback could result in death or serious injury.

Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.

1. Rotate the Off/Run/Choke dial to CHOKE (1).
2. Switch Economy switch to OFF.
3. Firmly grasp recoil handle and pull slowly until increased resistance is felt. Pull rapidly up and away.
4. See Figure 3-2. When engine starts, rotate Off/Run/Choke dial to RUN (2). Choke operation is reduced as Off/Run/Choke dial is rotated towards RUN.

NOTE: If engine fires, but does not continue to run, rotate the Off/Run/Choke dial to OFF and repeat starting instructions.

IMPORTANT NOTE: Do not overload generator or individual panel receptacles. See Figure 3-3. If an overload occurs, the overload LED (A) will illuminate and AC output ceases. To correct, see Generator Status Lights. Read Know Generator Limits carefully.

Generator Shut Down

Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.

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

Starting Hot Engines

Equipment and property damage. Disconnect electrical loads prior to starting or stopping unit. Failure to do so could result in equipment and property damage.

1. See Figure 3-2. Turn Off/Run/Choke dial from STOP to RUN. This will open the fuel valve and permit starting.
2. Firmly grasp recoil handle and pull slowly until increased resistance is felt. Pull rapidly up and away.

Low Oil Level Shutdown System

The engine is equipped with a low oil level sensor to shut down the engine automatically when the oil level drops below a specified level. The engine will not run until the oil has been filled to the proper level.

IMPORTANT NOTE: Verify proper engine oil and fuel levels before use.

Charging a 12 VDC Battery

Explosion. Batteries emit explosive gases while charging. Keep fire and spark away. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.

Risk of burns. Batteries contain sulfuric acid and can cause severe chemical burns. Wear protective gear when working with batteries. Failure to do so could result in death or serious injury.
NOTE: A battery may lose some of its charge when not in use for prolonged periods of time.
The DC charging output is not regulated. The circuit protector does not prevent over charging a battery. Battery charging should be done in a dry location.

1. Start generator and turn Economy switch OFF.
2. Plug Battery Charging Cable into BatteryCharger Output jack, located on the control panel.
   
3. Connect positive (+) battery clamp (redwire) to battery FIRST.
4. Connect negative (-) battery clamp (blackwire) to battery SECOND.

NOTE: This receptacle can not recharge 6volt batteries and can not be used to crank an engine having a discharged battery.

Environmental Hazard. Always recycle batteries at an official recycling center in accordance with all local laws and regulations. Failure to do so could result in environmental damage, death, or serious injury.

Parallel Operation

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

1. Make sure the Engine Economy Switch is in the same position on both generators.
2. Make appropriate parallel connections to the outlets on each Generac inverter as outlined in the owner's manual supplied with the kit.
   NOTE: Do not disconnect any parallel kit connections once the units are running.
3. Start both units per starting instructions. Once the green output indicator illuminates, devices can be connected and turned on using the parallel kit outlet.
4. Follow Generator Shut Down instructions.

NOTE: For inverters, load applied to the parallel kit is not to exceed 4180 watts due to a 5% power loss when paralleling. See manual.
NOTE: Only use Generac approved parallel kit.

Maintenance

Regular maintenance will improve performance and extend engine/equipment life. Generac Power Systems, Inc. recommends that all maintenance work be performed by an Independent Authorized Service Dealer (IASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner's choosing. To obtain emissions control warranty service free of charge, the work must be performed by an IASD. See the emissions warranty.
NOTE: Call 1-888-GENERAC (1-888-4363722) with questions about component replacement.

Maintenance Schedule

Follow maintenance schedule intervals, whichever occurs first according to use.
NOTE: Adverse conditions will require more frequent service.
NOTE: All required service and adjustments should be each season as detailed in the following chart.

Preventive Maintenance

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

Personal injury. Do not insert any object through the air cooling slots. Generator can start at any time and could result in death, serious injury, and unit damage.

• Use a damp cloth to wipe exterior surfaces clean.
• Use a soft bristle brush to loosen caked on dirt, oil, etc.
• Use a vacuum to pick up loose dirt and debris.
• Low pressure air (not to exceed 25 psi) may be used to blow away dirt. Inspect cooling air slots and openings on generator. These openings must be kept clean and unobstructed.

NOTE: DO NOT use a garden hose to clean generator. Water can enter engine fuel system and cause problems. If water enters generator through cooling air slots, some water will be retained in voids and crevices of rotor and stator winding insulation. Water and dirt buildup on generator internal windings will decrease insulation resistance of windings.

Engine Maintenance

Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.

Engine Oil Recommendations

To maintain the product warranty, the engine oil should be serviced in accordance with the recommendations of this manual. For your convenience, maintenance kits designed and intended for use on this product are available from the manufacturer that include engine oil, oil filter, air filter, spark plug(s), a shop towel and funnel. These kits can be obtained from an Independent Authorized Service Dealer (IASD).

Inspect Engine Oil Level

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

1. Place generator on a level surface.
2. Remove screws and side cover.
   
3. Clean area around oil fill cap.
4. Remove oil fill cap and wipe dipstick clean.
   
5. To check oil level, insert dipstick into oil filler neck without screwing it in.
   
6. Remove dipstick and verify oil level iswithin safe operating range.
7. Add recommended engine oil as necessary.
   NOTE: Verify oil level often during filling process to ensure overfilling does not occur.
8. Install oil fill cap/dipstick and hand-tighten.
   NOTE: Some units have more than one oil fill location. It is only necessary to use one oil fill point.

Change Engine Oil

Accidental start-up. Disconnect spark plug wires when working on unit. Failure to do so could result in death or serious injury.
When using generator under extreme, dirty, dusty conditions, or in extremely hot weather, change oil more frequently.
NOTE: Don't pollute. Conserve resources. Return used oil to collection centers.
Change oil while engine is still warm from running, as follows:

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

Air Filter

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

1. Remove screws and side cover. See Figure 4-3.
2. Unscrew bolt (A) and remove air filtercover.
   
3. Wash filter (B) in soapy water. Squeezedry in clean cloth (DO NOT TWIST).
4. Clean air filter cover before installation.
5. Replace side cover and screws.

NOTE: To order a new air filter, contact the nearest authorized service center at 1-888436-3722.

Service Spark Plug

To service spark plug:

1. Remove spark plug cover. See Figure 2-1.
2. Clean area around spark plug.
3. Remove and inspect spark plug.
4. Inspect electrode gap with feeler gaugeand reset spark plug gap to 0.6 - 0.7mm (0.024 - 0.028 in).
   
   NOTE: Replace spark plug if electrodes are pitted, burned or porcelain is cracked. Use ONLY recommended replacement plug. See Product Specifications.
5. Install spark plug finger tight, and tighten an additional 3/8 to 1/2 turn using spark plug wrench.

Inspect Muffler and Spark Arrester

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

Inspect Spark Arrester Screen

Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.

Clean Spark Arrestor Screen
The engine exhaust muffler has a spark arrestor screen. Inspect and clean the screen every 100 hours of operation or every season, whichever comes first.
To service spark arrestor:

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

Valve Clearance

Please contact an Independent Authorized Service Dealer for service assistance. Proper valve clearance is essential for prolonging the life of the engine.
Check valve clearance after the first fifty-hours of operation. Adjust as necessary.

• Intake — 0.10 ± 0.02mm (cold), (0.004" ± 0.001" inches)
• Exhaust — 0.15 ± 0.02mm (cold) (0.006" ± 0.001" inches)

Storage

General

Explosion and Fire. Fuel and vapors are extremely flammable and explosive. Store fuel in a well ventilated area. Keep fire and spark away. Failure to do so will result in death or serious injury.

Risk of Fire. Verify machine has properly cooled before installing cover and storing machine. Hot surfaces could result in fire.
It is recommended to start and run the generator for 30 minutes, every 30 days. If this is not possible, refer to the following list to prepare unit for storage.

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

Prepare Fuel System/Engine for Storage

Fuel stored over 30 days can go bad and damage fuel system components. Keep fuel fresh, use fuel stabilizer.
If fuel stabilizer is added to fuel system, prepare and run engine for long term storage. Run engine for 10-15 minutes to circulate stabilizer throughout fuel system. Adequately prepared fuel can be stored up to 24 months.
NOTE: If fuel has not been treated with fuel stabilizer, it must be drained into an approved container. Run engine until it stops from lack of fuel. Use of fuel stabilizer in fuel storage container is recommended to keep fuel fresh.

1. Change engine oil.
2. Remove spark plug.
3. Pour tablespoon (5-10cc) of clean engine oil or spray a suitable fogging agent into cylinder.
   
   
   Vision Loss. Eye protection is required to avoid spray from spark plug hole when cranking engine. Failure to do so could result in vision loss.
4. Pull starter recoil several times to distribute oil in cylinder.
5. Install spark plug.
6. Pull recoil slowly until resistance is felt. This will close valves so moisture cannot enter engine cylinder. Gently release recoil.

Change Oil

Change engine oil before storage. See Change Engine Oil.

Troubleshooting

Generac Power Systems, Inc.
S45 W29290 Hwy. 59
Waukesha, WI 53189
1-888-GENERAC (1-888-436-3722)
www.generac.com