Generac Power Systems GP1800 Repair Manual
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Generac Power Systems GP1800 Repair Manual

Gp series portable generators
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RepaiR
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gP series Portable generators
MODELS:
GP1800
GP3250
GP5000
GP5500
GP6500
GP7000
GP8000
P o r t a b l e g e n e r a t o r s

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Questions and answers

Donnie
April 1, 2025

My gas cutoff valve is leaking. Is there a gasket kit I can purchase or maybe but a new valve. What is the part number ?

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1 comments:
Mr. Anderson
May 14, 2025

The part number for the gas cutoff valve for the Generac GP1800 is 0H3384.

This answer is automatically generated

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Dan Turner
July 26, 2025

How do I fully access the breakers to replace them in a gp6500

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Summary of Contents for Generac Power Systems GP1800

  • Page 1 ® Diagnostic RepaiR Manual gP series Portable generators MODELS: GP1800 GP3250 GP5000 GP5500 GP6500 GP7000 GP8000 P o r t a b l e g e n e r a t o r s...
  • Page 2 Generac could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of the possible hazards and/or results of each method. We have not under- taken any such wide evaluation.

  • Page 3: Table Of Contents

    Specifications ............2 Test 4 – Field Flash Alternator (Configuration “A” Only) .......27 Part 1 – General Information ........9 Test 5 – Check Brushed Rotor Circuit ....28 Section 1.1 – Generator Fundamentals ....10 Test 6 – Check Capacitor .........29 Magnetism ............10 Test 7 –...

  • Page 4: Specifications

    SPECIFICATIONS – GP1800 Product Series GP1800 A/C Rated Output Watts: 1800 A/C Maximum Output Watts: 2050 A/C Voltage 120VAC A/C Frequency 60 Hz Rated 120 VAC Amperage Max 120 VAC Amperage Engine Displacement 163cc Engine Type Engine RPM 3600 Recommended Oil...
  • Page 5 SPECIFICATIONS – GP3250 Product Series GP3250 A/C Rated Output Watts: 3250 A/C Maximum Output Watts: 3750 A/C Voltage 120VAC A/C Frequency 60 Hz Rated 120 VAC Amperage 13.5 Max 120 VAC Amperage 15.6 Engine Displacement 206cc Engine Type Engine RPM 3600 Recommended Oil 5W30...
  • Page 6 SPECIFICATIONS – GP5000 Product Series GP5000 A/C Rated Output Watts: 5000 A/C Maximum Output Watts: 6250 A/C Voltage 120/240VAC A/C Frequency 60 Hz Rated 120/240 VAC Amperage 20.8 Max 120/240 VAC Amperage 26.0 Engine Displacement 389cc Engine Type Engine RPM 3600 Recommended Oil 5W30...
  • Page 7 SPECIFICATIONS – GP5500 Product Series GP5500 A/C Rated Output Watts: 5000 A/C Maximum Output Watts: 6875 A/C Voltage 120/240VAC A/C Frequency 60 Hz Rated 120/240 VAC Amperage 22.9 Max 120/240 VAC Amperage 28.6 Engine Displacement 389cc Engine Type Engine RPM 3600 Recommended Oil 5W30...
  • Page 8 SPECIFICATIONS – GP6500 Product Series GP6500 A/C Rated Output Watts: 6500 A/C Maximum Output Watts: 8000 A/C Voltage 120/240VAC A/C Frequency 60 Hz Rated 120/240 VAC Amperage 27.1 Max 120/240 VAC Amperage 33.3 Engine Displacement 389cc Engine Type Engine RPM 3600 Recommended Oil 5W30...
  • Page 9 SPECIFICATIONS – GP7000/GP7000E Product Series GP7000 A/C Rated Output Watts: 7000 A/C Maximum Output Watts: 8750 A/C Voltage 120/240VAC A/C Frequency 60 Hz Rated 120/240 VAC Amperage 29.2 Max 120/240 VAC Amperage 36.5 Engine Displacement 410cc Engine Type OHVI Engine RPM 3600 Recommended Oil 5W30...
  • Page 10 SPECIFICATIONS – GP8000/GP8000E Product Series GP8000/GP8000E A/C Rated Output Watts: 8000 A/C Maximum Output Watts: 10000 A/C Voltage 120/240VAC A/C Frequency 60 Hz Rated 120/240 VAC Amperage 33.3 Max 120/240 VAC Amperage 41.7 Engine Displacement 410cc Engine Type OHVI Engine RPM 3600 Recommended Oil 5W30...

  • Page 11: Part 1 - General Information

    TABLE OF CONTENTS PART TITLE PAGE Generator Fundamentals PART 1 Measuring Electricity Brushless, Capacitor Excitation GENERAL System Brushed Excitation System INFORMATION Testing, Cleaning and Drying GP Series Portable Generators Part 1 – General Information ........9 Section 1.3 – Brushless, Capacitor Excitation System ......

  • Page 12: Section 1.1 - Generator Fundamentals

    SECTION 1.1 PART 1 GENERAL INFORMATION GENERATOR FUNDAMENTALS MAgNETISM NOTE: The “right hand rule” is based on the “cur- rent flow” theory which assumes that current flows from positive to negative. This is opposite Magnetism can be used to produce electricity and the “electron”...

  • Page 13: A Simple Ac Generator

    SECTION 1.1 PART 1 GENERAL INFORMATION GENERATOR FUNDAMENTALS A SIMPLE AC gENERATOR A MORE SOPHISTICATEd AC gENERATOR Figure 4 shows a very simple AC Generator. The gen- Figure 6 and 7 show two methods of creating alternat- erator consists of a rotating magnetic field called a ing current that are implemented on GP Series por- ROTOR and a stationary coil of wire called a STATOR.

  • Page 14: Generator Fundamentals

    SECTION 1.1 PART 1 GENERAL INFORMATION GENERATOR FUNDAMENTALS TO LOAD TO LOAD MLB = MAIN LINE MLB = MAIN LINE CIRCUIT BREAKER CIRCUIT BREAKER 240 VAC 240 VAC 120 VAC 120 VAC 120 VAC 120 VAC SENSING STATOR STATOR STATOR STATOR POWER POWER...

  • Page 15: Section 1.2 - Measuring Electricity

    SECTION 1.2 PART 1 GENERAL INFORMATION MEASURING ELECTRICITY METERS MEASURINg AC VOLTAgE Devices used to measure electrical properties are called An accurate AC voltmeter or a VOM may be used to meters. Meters are available that allow one to measure read the generator's AC output voltage.

  • Page 16: Measuring Current

    SECTION 1.2 PART 1 GENERAL INFORMATION MEASURING ELECTRICITY NOTE: If the physical size of the conductor or amme- Correct engine and Rotor speed is maintained by an engine speed governor. For models rated 60 Hertz, ter capacity does not permit all lines to be measured the governor is generally set to maintain a no-load fre- simultaneously, measure current flow in each indi- quency of about 62 Hertz with a corresponding output...

  • Page 17: Electrical Units

    SECTION 1.2 PART 1 GENERAL INFORMATION MEASURING ELECTRICITY Component testing may require a specific resis- OHM: tance value or a test for INFINITY or CONTINUITY. The OHM is the unit of RESISTANCE. In every circuit Infinity is an OPEN condition between two electrical there is a natural resistance or opposition to the flow points, which would read as no resistance on a VOM.

  • Page 18: Section 1.3 - Brushless, Capacitor Excitation System

    SECTION 1.3 PART 1 GENERAL INFORMATION BRUSHLESS, CAPACITOR EXCITATION SYSTEM INTROdUCTION a tapered crankshaft and is held in place with a single through bolt. A typical brushless type portable generator will need Note: Some Rotors have a magnet placed inside 4 major components to function—a prime mover, a to help excite the rotor after it has been left idle stator, a rotor, and a capacitor.

  • Page 19: Operation

    SECTION 1.3 PART 1 GENERAL INFORMATION BRUSHLESS, CAPACITOR EXCITATION SYSTEM OPERATION FIELD EXCITATION: An AC voltage is induced into the stator excitation (DPE) windings. The DPE winding circuit is completed STARTUP: to the capacitor where the charging and discharging When the engine is started, residual magnetism from causes a voltage to be induced back in to the rotor the rotor induces a voltage into (a) the stator AC which will regulate voltage.

  • Page 20: Section 1.4 - Brushed Excitation System

    Section 1.4 PART 1 GENERAL INFORMATION BRUSHED EXCITATION SYSTEM INTROdUCTION to the negative (-) slip ring and brush on Wire 0. This current flow creates a magnetic field around the rotor having a flux concentration that is proportional to the A typical brushed type portable generator will need 4 amount of current flow.
  • Page 21 Section 1.4 PART 1 GENERAL INFORMATION BRUSHED EXCITATION SYSTEM windings and through the negative (-) slip ring and TO LOAD TO LOAD brush on Wire 0. The greater the current flow through the rotor wind- MLB = MAIN LINE MLB = MAIN LINE CIRCUIT BREAKER CIRCUIT BREAKER ings, the more concentrated the lines of flux around...

  • Page 22: Section 1.5 - Testing, Cleaning And Drying

    NOTES Page 20...

  • Page 23: Cleaning The Generator

    TABLE OF CONTENTS PART TITLE PAGE# Brushless Excitation Troubleshooting Flowcharts PART 2 Brushed Capacitor Troubleshooting Flowcharts AC GENERATORS AC Diagnostic Tests GP Series Portable Generators Part 2 – AC Generators ......... 21 Test 4 – Field Flash Alternator (Configuration “A” Only) .......27 Section 2.1 –...

  • Page 24: Section 2.1 - Brushless Capacitor Troubleshooting Flowcharts

    SECTION 2.1 PART 2 AC GENERATORS BRUSHLESS CAPACITOR TROUBLESHOOTING FLOWCHARTS The GP series portable generators currently use Identify the configuration of the alternator being ser- three different types of alternators. Two of the alterna- viced using Sections 1.3 and 1.4 of this manual and tors are brushless capacitor type with different style of proceed to the appropriate flowchart section.
  • Page 25 SECTION 2.1 PART 2 AC GENERATORS BRUSHLESS CAPACITOR TROUBLESHOOTING FLOWCHARTS Problem 2 – V oltage & Frequency Are Both High or Low GO TO FREQUENCY GOOD, LOW OR PROBLEM 1 RESIDUAL VOLTAGE TEST 40 – CHECK & ADJUST ENGINE GOVERNOR, 389cc ENGINE NO-LOAD FREQUENCY &...

  • Page 26: Section 2.2 - Brushed Excitation Troubleshooting Flowcharts

    SECTION 2.2 PART 2 AC GENERATORS BRUSHED EXCITATION TROUBLESHOOTING FLOWCHARTS The GP series portable generators currently use Identify the configuration of the alternator being ser- three different types of alternators. Two of the alterna- viced using Sections 1.3 and 1.4 of this manual and tors are brushless capacitor type with different style of proceed to the appropriate flowchart section.
  • Page 27 SECTION 2.4 PART 2 AC GENERATORS BRUSHED EXCITATION TROUBLESHOOTING FLOWCHARTS oltage & Frequency Are Both High or Low Problem 6 – V FREQUENCY GOOD, GO TO LOW OR RESIDUAL PROBLEM 5 VOLTAGE TEST 40 – CHECK & ADJUST ENGINE NO-LOAD FREQUENCY & GOVERNOR, 389cc ENGINE GO TO VOLTAGE GOOD BUT THEY...

  • Page 28: Section 2.3 - Ac Diagnostic Tests

    SECTION 2.3 PART 2 AC GENERATORS AC DIAGNOSTIC TESTS INTROdUCTION TEST 2 – CHECk CIRCUIT bREAkER The “Diagnostic Tests” in this chapter may be per- PROCEDURE: formed in conjunction with the “Flow Charts” of Section 2.1 and Section 2.2. Test numbers in this The generator has circuit breakers located on the chapter correspond to the numbered tests in the control panel.

  • Page 29: Test 4 - Field Flash Alternator

    SECTION 2.3 PART 2 AC GENERATORS AC DIAGNOSTIC TESTS TEST 4 – FIELd FLASH ALTERNATOR 2. Connect a VOM as shown in Figure 3 to each receptacle on the unit. (CONFIgURATION “A” ONLY) Note: Only one outlet on each receptacle needs to DISCUSSION: be tested.

  • Page 30: Test 5 - Check Brushed Rotor Circuit

    SECTION 2.3 PART 2 AC GENERATORS AC DIAGNOSTIC TESTS PLUG ENERGIZING CORD DEPRESS SWITCH FOR INTO AC OUTLET ONE SECOND CAPACITOR CAPICITOR REMAINS CONNECTED TO GENERATOR  Danger: The capacitor may need to be discharged before testing. A capacitor can be discharged by crossing the terminals with a metal insulated screw driver.

  • Page 31: Test 6 - Check Capacitor

    SECTION 2.3 PART 2 AC GENERATORS AC DIAGNOSTIC TESTS TEST 6 – CHECk CAPACITOR SET TO READ CAPACITANCE DISCUSSION: µf The brushless rotor system relies on the charging and 59.0 discharging of a capacitor to induce voltage into the rotor and also to regulate voltage once 240 VAC is achieved.

  • Page 32: Test 7 - Test Brushless Dpe Winding

    SECTION 2.3 PART 2 AC GENERATORS AC DIAGNOSTIC TESTS TEST 7 – TEST bRUSHLESS dPE WINdINg TEST 8 – TEST bRUSHLESS STATOR WINdINgS DISCUSSION: DISCUSSION: A DPE or Displaced Phase Excitation winding is used The brushless stator has three internal windings, to charge a capacitor, which discharges and charges, two main power windings and a DPE winding.

  • Page 33: Test 9 - Test Brushed Stator Windings

    SECTION 2.3 PART 2 AC GENERATORS AC DIAGNOSTIC TESTS TEST 9 – TEST bRUSHEd STATOR WINdINgS RESULTS: 1. If the unit is overloaded, reduce the load. DISCUSSION: 2. If load is within limits, but frequency and voltage still drop Most brushed stators have three main windings that excessively, refer back to Flow Chart.
  • Page 34 SECTION 2.3 PART 2 AC GENERATORS AC DIAGNOSTIC TESTS 6. Ensure all material is clear of the alternator before pro- ceeding. 7. Set START-STOP-RUN switch to START 8. Refer to Figure 10 for location of adjustment screw. 9. Adjusting screw clockwise will increase voltage, adjust- ing counterclockwise will lower the voltage.

  • Page 35: Part 3 - Engine Troubleshooting

    TABLE OF CONTENTS PART TITLE PAGE# 389/206/163cc Troubleshooting PART 3 Flow Charts 410cc Troubleshooting Flow ENGINE Charts Diagnostic Tests TROUBLESHOOTING GP Series Portable Generators Part 3 – Engine Troubleshooting ......33 Test 30 – Choke Test ........47 Test 33 – Check Valve Adjustment ....47 Section 3.1 –...

  • Page 36: Section 3.1 - 389/206/163Cc Troubleshooting

    SECTION 3.1 PART 3 ENGINE TROUBLESHOOTING 389/206/163cc TROUBLESHOOTING FLOW CHARTS There are 4 different types of engines on the GP Series The Specifications section at the front of this manual generators: 410cc, 389cc, 206cc, 163cc. Section 3 is provides details about engine displacement for the vari- divided into difference subsections that provide engine ous GP Series generators.
  • Page 37 SECTION 3.1 PART 3 ENGINE TROUBLESHOOTING 389/206/163cc TROUBLESHOOTING FLOW CHARTS Problem 12 – Engine Turns Over But Will Not Start CHECK TEST 26 – CHECK FUEL TEST 39 – REMOVE FUEL GOOD CHECK SHUTOFF WIRE 18 / GOOD SUPPLY SPARK SHUTDOWN LEAD VALVE SPARK...

  • Page 38: Section 3.1 - 389/206/163Cc Troubleshooting

    SECTION 3.1 PART 3 ENGINE TROUBLESHOOTING 389/206/163cc TROUBLESHOOTING FLOW CHARTS Problem 13 – Engine “Hunts” / Erratic Idle *Acceptable running limits for the engine are between 59-61 Hertz. TEST 26 – TEST 33 – TEST 30 – STILL CHECK CHECK VALVE GOOD CHOKE TEST SURGING...

  • Page 39: Section 3.2 - 410Cc Troubleshooting Flowcharts

    SECTION 3.2 PART 3 ENGINE TROUBLESHOOTING 410cc TROUBLESHOOTING FLOW CHARTS Problem 20 – Engine Will Not Crank TEST 22 – CHECK TEST 23 – CHECK TEST 21 – CHECK NO VOLTAGE VOLTAGE AT START-RUN-STOP BATTERY GOOD MEASURED STARTER SWITCH & CABLES CONTACTOR 12 VDC MEASURED...
  • Page 40 SECTION 3.2 PART 3 DC CONTROL 410cc TROUBLESHOOTING FLOW CHARTS Problem 22 – Engine Cranks But Will Not Start CHECK CHECK FUEL TEST 26 – PULL CHOKE FUEL SHUTOFF FULL OUT GOOD GOOD CHECK FULL OUT SUPPLY VALVE SPARK PULL OUT REPLENISH FUEL TURN...
  • Page 41 SECTION 3.2 PART 3 DC CONTROL 410cc TROUBLESHOOTING FLOW CHARTS Problem 23 – Engine Starts Hard and Runs Rough TEST 27 – TEST 26 – CHECK CHOKE CHECK FUEL CHECK CHECK GOOD GOOD POSITION AND GOOD GOOD SUPPLY SPARK PLUG SPARK OPERATION LOW FUEL...
  • Page 42 SECTION 3.2 PART 3 ENGINE TROUBLESHOOTING 410cc TROUBLESHOOTING FLOW CHARTS Problem 25 – Battery Will Not Charge TEST 20 – REPLACE CHECK CONNECTIONS CHECK 1.5 GOOD GOOD BATTERY ON BATTERY CHARGE AMP FUSE CHARGER SOCKET REPLACE REPLACE FUSE Problem 26 – Engine “Hunts” / Erratic Idle *Acceptable running limits for the engine are between 59-62 Hertz.
  • Page 43 NOTES Page 41...

  • Page 44: Flowcharts

    SECTION 3.3 PART 3 DC CONTROL DIAGNOSTIC TESTS TEST 20 – CHECk 1.5 AMP FUSE TEST 22 – CHECk VOLTAgE AT STARTER CONTACTOR (SC) PROCEDURE: 1. Set voltmeter to measure DC voltage. 2. Disconnect Wire 16 from the Starter Contactor located on the Starter motor.

  • Page 45: Test 24 - Test Off-On Switch

    SECTION 3.3 PART 3 DC CONTROL DIAGNOSTIC TESTS 3. Connect one meter lead to Terminal 2 and connect the PROCEDURE: other meter lead to Terminal 1. Actuate switch to the 1. Disconnect Point A from the switch harness (see Figure 3). START position.

  • Page 46: Diagnostic Tests

    STARTER Figure 6. Clamp-On Ammeter TACHOMETER: Figure 4. Starter Motor (SM) A tachometer is available from your Generac Power Systems source of supply. Order as P/N 042223. The CHECKING THE PINION: tachometer measures from 800 to 50,000 RPM (see Figure 7).

  • Page 47: Test 25 - Check Ignition Spark

    TESTING STARTER MOTOR: to test the engine ignition system. One can also be 1. A fully charged 12 volt battery is required. purchased from Generac Power Systems (Part No. 0C5969). 2. Connect jumper cables and clamp-on ammeter as 1. Disconnect the spark plug lead from a spark plug.

  • Page 48: Test 26 - Check Spark Plugs

    SECTION 3.3 PART 3 DC CONTROL DIAGNOSTIC TESTS SPARK TESTER SPARK TESTER CLAMP GROUNDED TO SPARK PLUG CYLINDER HEAD BOOT Figure 12. Setting Spark Plug Gap NORMAL MISFIRES Figure 10. Testing Ignition System SPARK TESTER CLAMP CONNECTED TO SPARK TESTER SPARK PLUG SPARK PLUG BOOT...

  • Page 49: Test 30 - Choke Test

    SECTION 3.3 PART 3 DC CONTROL DIAGNOSTIC TESTS TEST 33 – CHECk VALVE AdjUSTMENT • Water in fuel. • Intake valve stuck open. • Needle/float stuck open. ADJUSTING VALVE CLEARANCE: If the spark plug is dry look for the following: Improperly adjusted valves can cause various engine related problems including, but not limited to, hard starting, •...

  • Page 50: Test 36 - Check Engine / Cylinder Leak Down Test / Compression Test

    SECTION 3.3 PART 3 DC CONTROL DIAGNOSTIC TESTS 4. Lock the flywheel at top dead center. 5. Attach cylinder leak down tester adapter to spark plug hole. CROW'S FOOT 6. Connect an air source of at least 90 psi to the leak down tester.

  • Page 51: Test 39 - Remove Wire 18 / Shutdown Lead

    SECTION 3.3 PART 3 DC CONTROL DIAGNOSTIC TESTS 2. Remove the flywheel cover so that the magneto is exposed. ENGINE WIRE HARNESS 3. Disconnect Wire 18 from the magneto. SPARK PLUG 4. Repeat Test 25, “Check Ignition Spark.” WIRE 18 TO START-RUN-STOP SWITCH (SHUTDOWN LEAD) RESULTS:...

  • Page 52: Test 41 - Check / Adjust Governor

    SECTION 3.3 PART 3 DC CONTROL DIAGNOSTIC TESTS TEST 41 – CHECk / AdjUST gOVERNOR 3. Tighten the governor lever clamp bolt to 110 inch- pounds. (410cc ENgINE) RUNNING ADJUSTMENT: DISCUSSION: After completing the initial adjustment, final adjust- The generator AC frequency output is directly pro- ment is accomplished with the engine running under portional to the speed of the rotor.

  • Page 53: Test 45 - Check Oil Level Switch

    SECTION 3.3 PART 3 DC CONTROL DIAGNOSTIC TESTS 3. Set VOM to measure resistance. 4. Connect one meter test lead to the previously discon- GOVERNOR nect wire coming from the oil level switch. Connect the SHAFT other meter test lead to frame ground. INFINITY should be measured.

  • Page 54: Test 49 - Test Recoil Function

    (2) If oil pressure is below about 10 psi, shut engine down immediately. A problem exists in the engine lubrication system. Refer to PROCEDURE: Service Manual, Generac P/N 0F6923 for 1. Attempt to pull start the engine and make the following engine service recommendations. observations while doing so.
  • Page 55 TABLE OF CONTENTS PART TITLE 4.1. Major Disassembly PART 4 DISASSEMBLY GP Series Portable Generators Page 53...

  • Page 56: Section 4.1 - Major Disassembly

    SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY MAjOR dISASSEMbLY DISCUSSION. Each generator will have its own unique method of disassembly. Provided is a simplified version of disassembly that does not go into step by step instructions. The figure below represents the basic disassembly and sequence of steps needed to remove the fuel tank, stator, rotor, and the engine.

  • Page 57: Part 4 - Disassembly

    SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY Page 55...

  • Page 58: Major Disassembly

    SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY Exploded View – GP1800 – Drawing No. 0H0609-A Page 56...
  • Page 59 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION ENGINE, 196CC RECOIL ASSEMBLY CARBURETOR AIR CLEANER COVER AIR FILTER CARBURETOR GASKET SPARK PLUG BOOT OIL LEVEL SENSOR FRAME, 1800W FUEL SHUTOFF VALVE VIBRATION MOUNT, #1 VIBRATION MOUNT, #2 BRUSH ASSEMBLY SPARK ARRESTOR MUFFLER ASSEMBLY...
  • Page 60 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY Exploded View – GP3250 – Drawing No. 0H0522-C PORTABLE KIT Page 58...
  • Page 61 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION ENGINE, 208CC BOLT, FLANGE M6-1.0 X 40 RECOIL ASSEMBLY BOLT, FLANGE M6-1.0 X 16 CARBURETOR RUBBER GRIP, HANDLE 3250W AIR CLEANER COVER HANDLE, PORTABLE 3250W AIR FILTER ASSY, HANDLE BRACKET 3250W CARBURETOR GASKET ASSEMBLY, ALTERNATOR BRUSH...
  • Page 62 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY Exploded View – GP5000 – Drawing No. 0G9384A-C Page 60...
  • Page 63 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION FRAME PARTS EXHAUST PARTS ASSY CRADLE BASE BRACKET, MUFFLER SHIELD, BOTTOM CRADLE END ASSY MUFFLER, 389cc PANEL RAIL BRACKET, MUFFLER SHIELD TOP BACK RAIL GASKET, EXHUAST. 389cc CURVED HEAD BOLT 5/16-18 x 1.625"...
  • Page 64 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY Exploded View – GP5500 – Drawing No. 0H1253-A Page 62...
  • Page 65 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION ASSY CRADLE BASE SCREW HHTT M6-1.0 X 25 CRADLE END FUEL TANK ASSY 6.6 GAL PORTABLE ASSEMBLY, FRAME 1 PIECE SCREW HHTT M8-1.25 X 20 PANEL RAIL FUEL CAP, VENTED BACK RAIL SHIELD, HEAT, SKU...
  • Page 66 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY Exploded View – GP6500 – Drawing No. 0G9384B-C 36 37 Page 64...
  • Page 67 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION FRAME PARTS SCREW HHTT M8-1.25 x 20 ASSY CRADLE BASE EXHAUST PARTS CRADLE END BRACKET, MUFFLER SHIELD, BOTTOM PANEL RAIL ASSY MUFFLER, 389cc BACK RAIL BRACKET, MUFFLER SHIELD TOP CURVED HEAD BOLT 5/16-18 x 1.625"...
  • Page 68 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY Exploded View – GP7000 – Drawing No. 0G9384D-B Page 66...
  • Page 69 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION CRADLE END LUG SLDLSS #2-#8 X 17/64 CU BACK RAIL WASHER LOCK SPECIAL 1/4" CURVED HEAD BOLT 5/16-18 x 1.625" SCREW PPPH #8-16 x 1/2" BZC LONG CAP NUT LOCKING 5/16-18 THREAD, ASSY GND WIRE ALT TO BASE 5/16"...
  • Page 70 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY Exploded View – GP8000 – Drawing No. 0G9384F-B Page 68...
  • Page 71 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY ITEM QTY. DESCRIPTION ITEM QTY. DESCRIPTION TIRE 9.5" DIA RUN FLAT PLASTIC CRADLE END HUB/RUBBER TREAD BACK RAIL SCREW, HHC 1/2"-13 x 4-1/2" LONG CURVED HEAD BOLT 5/16-18 x 1.625" NUT, HEX LOCK 1-2"-13 NYLON LONG INSERT CAP NUT LOCKING 5/16-18 THREAD)
  • Page 72 SECTION 4.1 PART 4 DISASSEMBLY MAJOR DISASSEMBLY Page 70...

  • Page 73: Part 5 - Electrical Data

    TABLE OF CONTENTS DWG# TITLE PAGE Electrical Schematic, GP1850 0H0612-A PART 5 0H0523-A Electrical Schematic, GP3250 Electrical Schematic, 0G9769-C ELECTRICAL GP5000/5500/6500 0G9769-C Wiring Diagram, DATA GP5000/5500/6500 Electrical Schematic, 0G9849-A GP7000E/8000E 0G9849-A Wiring Diagram, GP7000E/8000E Electrical Formulas GP Series Portable Generators Page 71...

  • Page 74: Electrical Schematic, Gp1850

    ELECTRICAL SCHEMATIC, GP1850 PART 5 ELECTRICAL DATA Brushed Alternator Drawing No. 0H0612-A SENSING Page 72...

  • Page 75: Electrical Schematic, Gp3250

    PART 5 ELECTRICAL SCHEMATIC, GP3250 ELECTRICAL DATA Brushed Alternator Drawing No. 0H0523-A SENSING Page 73...

  • Page 76: Electrical Schematic, Gp5000/5500/Gp6500

    ELECTRICAL SCHEMATIC, GP5000/5500/6500 PART 5 ELECTRICAL DATA Brushed Alternator Drawing No. 0G9769-C Page 74...

  • Page 77: Wiring Diagram, Gp5000/5500/Gp6500

    PART 5 WIRING DIAGRAM, GP5000/5500/6500 ELECTRICAL DATA Brushed Alternator Drawing No. 0G9769-C Page 75...

  • Page 78: Electrical Schematic, Gp7000E/Gp8000E

    ELECTRICAL SCHEMATIC, GP7000E/8000E PART 5 ELECTRICAL DATA Brushless Alternator Drawing No. 0G9849-A Page 76...

  • Page 79: Wiring Diagram, Gp7000E/Gp8000E

    PART 5 WIRING DIAGRAM, GP7000E/8000E ELECTRICAL DATA Brushless Alternator Drawing No. 0G9849-A Page 77...

  • Page 80: Electrical Formulas

    ELECTRICAL FORMULAS TO FIND KNOWN VALUES 1-PHASE E x I KILOWATTS (kW) Volts, Current, Power Factor 1000 E x I Volts, Current 1000 kW x 1000 AMPERES kW, Volts, Power Factor WATTS Volts, Amps, Power Factor Volts x Amps 2 x 60 x Frequency NO.
  • Page 81 NOTES...
  • Page 82 NOTES Page 80...
  • Page 84 Generac Power Systems, Inc. S45 W29290 Hwy. 59 • Waukesha, WI 53189 Part No. 0H0285 rev. A / Printed in USA 02.09 1-888-GENERAC • generac.com © 2009 Generac Power Systems, Inc. All rights reserved. (1-888-436-3722)

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