Generac GP3500iO - Portable Generator Manual

Loss of life. This product is not intended to be used in a critical life support application. Failure to adhere to this warning could result in death or serious injury.

Register your Generac product at:
WWW.GENERAC.COM
1-888-GENERAC
(1-888-436-3722)

Operating, servicing and maintaining this equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing your equipment. For more information go to www.P65Warnings.ca.gov.

Introduction

Thank you for purchasing a Generac Power Systems Inc. product. This unit has been designed to provide high-performance, efficient operation, and years of use when maintained properly.

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

If any section of the manual is not understood, contact your nearest Independent Authorized Service Dealer (IASD), or contact Generac Customer Service at 1-888-GENERAC (1888-436-3722), or www.generac.com with any questions or concerns.

The owner is responsible for proper maintenance and safe use of the equipment. Before operating, servicing or storing this generator:

• Study all warnings in this manual and on the product carefully.
• Become familiar with this manual and the unit before use.
• Refer to the Assembly section of the manual for instructions on final assembly procedures. Follow the instructions completely.

Save these instructions for future reference. ALWAYS supply this manual to any individual that will use this machine.

The information in this manual is accurate based on products produced at the time of publication. The manufacturer reserves the right to make technical updates, corrections, and product revisions at any time without notice.

Safety Rules

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit are, therefore, not all inclusive. If using a procedure, work method or operating technique that the manufacturer does not specifically recommend, verify that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the equipment unsafe.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

Indicates a hazardous situation 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 warnings cannot eliminate the hazards that they indicate. Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents.

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. 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.

Electrocution. Water contact with a power source, if not avoided, 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 operting 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.
• Point muffler exhaust away from people and occupied buildings.
• Minimum generator placement distance of five feet from windows, doors, or openings in walls with engine exhaust directed away from occupied buildings and if possible downwind.

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 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^.

• Wipe up any fuel or oil spills immediately. Verify that no combustible materials are left on or near the generator. Keep the area surrounding the generator clean and free from debris and keep a clearance of five (5) feet on all sides to allow for proper ventilation of the generator.
• 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.

Replacement owner's manuals are available at www.generac.com.

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.

Figure 2-3. 120 VAC, Duplex Receptacle

120 VAC, 30 Amp Receptacle
Use a NEMA L5-30R plug with this receptacle. Connect a suitable 3-wire cord set to the plug and to desired load. The cord set should be rated for 125 Volts AC at 30 Amps (or greater). See Figure 2-4.

Use this receptacle to operate 120 Volt AC, 60Hz, single phase loads requiring up to 3500 watts, 30 Amps starting power and 3000 watts of continuous power at 25 Amps. The outlet is protected by a 30 Amp push-to-reset circuit breaker.

Figure 2-4. 120 VAC, 30 Amp Receptacle
NEMA L5-30R

Off/On/Choke Switch

This controls the ON/OFF functions, choke and fuel valve operation. See Figure 2-5.

• The OFF position (1) stops the engine and shuts off fuel flow.
• The ON 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.
  NOTE: The CHOKE is not required to start a warm engine.

USB Outlets

The 5 VDC, 1/2.1 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 (nonmotor starting loads), especially when these loads are turning on and off (example: RV, air conditioner, hairdryer).

Generator Status Lights

See Figure 2-6.

• Overload LED (red): 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 (yellow): 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. 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 eachcorner from top to bottom.
2. Remove and verify carton contents prior toassembly. Carton contents should contain the following:

TABLE 3. Accessories

3. Call Generac Customer Service at 1-888GENERAC (1-888-436-3722) with the unit model and serial number for any missing carton contents.
4. Record model, serial number, and date ofpurchase 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. Clean area around oil fill and oil drain plug.
3. Remove oil fill cap and wipe dipstick clean. See Figure 2-7.
   
   Figure 2-7. Remove Dipstick
4. 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.

5. To check oil level, remove funnel andinsert dipstick into oil filler neck. See Figure 2-8.
   
   Figure 2-8. Safe Operating Range
6. Remove dipstick and verify oil level iswithin safe operating range.
   NOTE: Verify oil level often during filling process to ensure overfilling does not occur.
7. Install oil fill cap/dipstick and hand-tighten.

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 priorto 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 notoverfill.
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. Alcoholblended 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 correct.
3. Verify unit is secure on level ground, withproper 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.

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.

Risk of Fire. Hot surfaces could ignite combustibles, resulting in fire. Fire 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. See Figure 3-1.

• Neutral Floating
  
  Figure 3-1.Grounding the Generator

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.

Know Generator Limits

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

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

1. Figure the watts needed to start the largestmotor.
2. Add to that figure the running watts of allother connected loads.

NOTE: If engine fires, but does not continue to run, rotate the Off/On/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 electricalloads 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/On/Choke dial to OFF (3).
4. Turn fuel cap OFF.

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/On/Choke dial from STOP to ON. This will open the fuel valve and permit starting.
2. Firmly grasp recoil handle and pull slowlyuntil increased resistance is felt. Pull rapidly up and away.

Low Oil Level Shutdown System

The engine is equipped with a low oil level sensor that shuts down the engine automatically when the oil level drops below a specified level to prevent engine damage. See Figure 3-3 (B). The engine will not run until the oil has been filled to the proper level.

If the engine shuts down and there is sufficient fuel, check engine oil level.

Parallel Operation

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 isin the same position on both generators.
2. Make appropriate parallel connections tothe 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: Only use Generac approved parallel kit.

Maintenance and Troubleshooting

Maintenance

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

NOTE: Call 1-888-GENERAC (1-888-4363722) 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. Clean area around oil fill, and oil drainplug.
3. Remove oil fill cap and wipe dipstick clean. See Figure 4-1.
   
   Figure 4-1. Engine Oil Fill
4. To check oil level, insert dipstick into oilfiller neck without screwing it in. See Figure 4-2.
   
   Figure 4-2. Safe Operating Range
5. Remove dipstick and verify oil level iswithin safe operating range.
6. Add recommended engine oil as necessary.

NOTE: Verify oil level often during filling process to ensure overfilling does not occur.

7. Replace oil fill cap 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. Disconnect the spark plug wire from thespark plug and place the wire where it cannot contact spark plug.
3. Clean area around oil fill and oil drain plug.
4. Remove oil fill cap and wipe dipstick clean.
5. Tip unit and drain oil completely into a suitable container.
6. Once oil is sufficiently drained from unit, tipunit back to a level position.
7. Insert funnel into oil fill opening. See Figure 4-3. Add recommended engine oil as necessary.
   
   Figure 4-3. Oil Fill Opening With Funnel
8. To check oil level, remove funnel andinsert dipstick into oil filler neck without screwing it in. See Figure 4-2.
9. Remove dipstick and verify oil level iswithin safe operating range.
   NOTE: Verify oil level often during filling process to ensure overfilling does not occur.
10. Replace oil fill cap and hand-tighten.
11. Wipe up any spilled oil.
12. 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. Unscrew bolt (A) and remove air filtercover. See Figure 4-4.
   
   Figure 4-4. Air Filter Assembly
2. Wash filter (B) in soapy water. Squeezedry in clean cloth (DO NOT TWIST).
3. Clean air filter cover before installation.
4. 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 wire feelergauge and reset spark plug gap to 0.6 0.7mm (0.024 - 0.028 in). See Figure 4-5.
   
   Figure 4-5. Spark Plug

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 tightenan additional 3/8 to 1/2 turn using spark plug wrench.

Inspect Muffler and Spark Arrestor

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 arrestor, 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 arrestor 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 arrestor, if equipped, inspect for damage or carbon blockage. Replace parts as required.

Inspect Spark Arrestor 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 50 hours of operation or every season, whichever comes first.

To service spark arrestor:

1. See Figure 4-6. Remove the clamp to remove retainer.
   
   Figure 4-6. Spark Arrestor Screen
2. Slide spark arrestor screens out from themuffler 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, andsecure with clamp.

Valve Clearance

Important: Please contact an Independent Authorized Service Dealer for service assistance. Proper valve clearance is essential for prolonging the life of the engine.

Check valve clearance after the first fifty-hours of operation. Adjust as necessary.

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

Storage

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 engineoil 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. (000181)

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