Generac Power Systems 1019-3 User manual

Owner's Manual
". | =*=
Generator
Wheel kit
Storage Cover
Battery
Battery Float Charger
Battery Charge Cables
Spare Spark Plug,Air Filter,and Oil Filter
Spark PlugWrench
(2) Locking 30 Amp Plugs
EngineOil
Owner's Manual
EngineManual
If any parts are missingor damaged,call 1-800-270-1408.
SafetyRules...................................... 2-4
Know Your Generator ............................... 5
Assembly........................................ 6-7
Operation ...................................... 8-13
Product Specifications .............................. 14
Maintenance...................................... 14
Storage.......................................... 15
Troubleshooting ................................... 15
Schematic........................................ 16
Wiring Diagram ................................... 17
Replacement Parts .............................. 18-22
Notes ........................................... 23
Warranty ................................... Last Page
Questions? Help is just a moment away!
Call:Generac Generator Helpline - 1-800-270-1408 M-F 8-5 CT
Web: www.generac-por tables.corn

EQUIPMENT
DESCRIPTION
_Read thls manual carefully and become
familiar with your generator. Know its
applications, its limitations and any hazards
involved,
The generators are an engine_riven, revolvTng field,
al:ernatTng current (AC) generator, It wzs designed _o
supply electrical power for operating compatible electrical
lighting, appliances, _ools and motor loads.The generator's
revolvTng field is drTvenat about 3,600 rpm by a single-
cylTnder engTne.
CAUTION! DO NOT exceed the generator's
wa_age/amperage c_pacfty. See ==Don't Overload
Genera_or" on page 13.
Every effor_ has been made _o ensure that fnforma_ion in
_his manual fs accurate and current, However, we reserve
the right to change, al_er or otherwfse improve the product
and thfs document at any tfme wfthout prfor no_ice.
The Emission Control System for this generator is
warranted for standards set by the Environmental
Pro_ecUon Agency. For warranty information refer to the
engine owner's manual.
!_ _h_ Sta_e of Californ! a aspzr_ zr_ster is _qu!_ d bylaw
(Sec:io_ 4_t2 of;he C_lifomi_ Public Resou_es Code).
Other S_es m_ _ave Sim!lar I_S. Fecle_l lawsZpply on
fede_l IzndSiIfYO_e_ip 1;hem_ffler _i_h Z spare arres_ r,
SAFETY RULES
_IL hls isthe safety alert symbol. It is used to
alert you to potential personal injury hazards.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
The safety alert symbol (_) is used with a signal word
(DANGER, CAUTION,WARNING), a pictorial and/or a
safety message _o aler_ you _o hzzards. DANGER indicates
a hzzard which, if not avoided, vAf!result in death or serious
injury.WARNING indicates a hazard which, if n_t avoided,
could result in death or serious iniury. CAUTION
indicates a hzzard which, if not avoided, might result in
minor or moderate injury. CAUTION, when used
without the aler_ symbol, indicates asituation that could
result in equipment damage. Follow sat'e_ messzges to
avoid or reduce the risk of iniury or de_th.
WARNING
The engine exhaust from (;his produc_ contains
chemicals known to the State of Callfornla to cause
cancer, birth defects, or o_her reproductive harm,
Hazard Symbols and Meanings
Electrocu_Jon Electrical Shock Electrical Shocl(
Toxic Fumes
Explosive Pressure
E_plesfen Fire
Chemical Burn Hot Surface

DANGER
DANGER
,when using_eneratorforbackuppowen,_i_0t(!i_
, use a ground Circuit fault interrup_ (G FCI) in any damp or
highly conductive area_such _s rnc'ta! d0tl_ng or s_¢l wet I_
No- useg_n_r_r_th _let_ieal_o_swhicha_worn
NOT h_.ndle generac0r or _!ettriea! COrds Whi!_ standing
in water, While bar_o0t_ 0n while hands Or"fec-_
"DO N_ a!!0w unqualified Persons or chi!dren _O OPerate or
DANGER
,Wc_r protettiye goF_!esirubberapron_and rubber g!oves.
WHEN ADDING FUEL
,Turn g¢:n¢:rat.or OFF and let ic cool _t least _-min_os
n_rn0vIng gas taPi Lo_en caP slowfi co mJieve PreSSUrein _n Ic
,DO NOT overfitl_n_AI!ow apacefor
,Keep furl away fr°m aparksi open fl_mes,pi!oc I!ghtsi hear. and
,This generator is not for usein mobile equipment 0r m_.rin_
WHEN TRANSPORTING OR REPAIRI NG EQUIPMENT
, Transpo_repair with rue! tank EH_ or wi_h rue! shut_
, Disconnec_ apark plug wire:
WHEN STORING FUEL OR EQUIPMENT WITH FUEL
dryers or Other appliantes that h_ve pilot ligh_or Other
ignitionsouse _¢_uso thc_ican i_nitefuelvapo_
_WARNING
,This generator does not meet U.S.C_st Gua_ Regu]ad0n
33CFR=!83 _nd should not b_ used on marine _pplit_tions
,F_.ilur'__ USe=he,_.ppropri,_te OiSi GO_t Guard
genera_t, could _osult in bodily inju_ _nd/or prope_

CAUTION
,Al!ow eClurpm_ntto ¢ool befo_ _ouching
CAUTION
'Se_!'D0n!t Over!oad G_n_rac0r'' on page13.
, $_.rt generator and le_._ngine scabflfzebefor_ ¢0nne_ing
_l_ric_l I_dSi
! c0nn_=_I_C_I JOadS!nOFFpOS.sO,__he,__umONfo_
Opera'don.
, "-urn d_ccr!_l loads OFI: and d!sc0nn_¢cfrom generacor
CAUTION
'USegen_racOronly for incend_cluses.
'li_U h_-veqUe_'c(ons_-bOUCincendedU_eiaskd_io_ 0rC_-iI
,DO NOT expose g_ner_tor tOexCeS$(WmoiscU_i dust.dirt:_
' DO NOT inser__.n_Obj_ct_through €oolingsio_i
,i_¢0nnc_t.oddcv(cesoverhc_ti_um_h_m Off_nd disc0nnec_
,Shutc_ _n_ra_ot" if:
_l_ri_! 0utpu_ islost;
-un(€vibrat_s_Cossivoly.

KNOW YOUR G EN ERATOR
Read this owner's manual and safeb/rules before operating your genera_or,
Compare the illustratTons wi_h your genera_or, to familiarize yourself wT_ the Io_ions of various controls and
adjustments. S_¢ethis manual for future reference.
CTrcuit Breakers (AC) FuelTank
12Volt DC
Receptacle
Choke Lever
120/240VoltAC,
30 Amp Locldng
Receptacle
120VoltAC, 30Amp
Locl_TngReceptacle
120VoltAC, 20 Amp
Duplex Recep_cle
rl_Arres_er M_ffler
120/240VoltAC,
50 Amp Receptacle
GroundingF_stener
12Volt DC ReceptaCle LJse :his _ceP_€!e W!_h Ch0_ Leve r _ Used whe_ staring a c01d e_gi_e i
bat_e_ Charge cables_Charge a l2Vo!t b_ery, CirCUit Breake_ (AC)Each receptacle is provided
Am Ou exRete t=ucle_M be wth_ ush_orese_ clrcul_bre_k_r_oprotectd_
i20V°lt AC' 20 P P P i _Y ......... P: .... _ ...... ": 0ver d_d ........ ........... :
.......... gener_r" zga!_S:e!e_r!_ .... :.............
i20 volt ACi Single ph_e, 60 HZ eiectri_l lighti_gi Epplia_¢e, FUel Tank _CapaCity OfSeven (7)UiSi gaii0_S.
20VoitAC 30Am Lockin ........... ...................... :........... :
i, [p Ground n_ Fastener _If reci_fred p!ease consul_ a
usedtosuppyelectrica ower for the epera_Jon of ......... ,...... :" ,. I.... _ ..... :
20VotAC 30Amp, sngle phase bu.z elec_rica_I=g_ti g,....... _avi_ :UrSd ct0_ ........... :...................... :..............
............
! 20!240 Volt ACi 30 Amp I-ocldng Receptac!e _ ay at _brm_l (_igh)Speeds When the_ is _i0_d p_Se_ _nd
be used _ suppl_ e!ec_ic_l Power fop _he the engine at idle _I0W)Speeds whe_a 10ad i_ not
20 _ndt0r 240Vo_AC 30Amp S _gle:ph_e 60Hz Lrese_ ....................... :...........
eiec_H_i lighting;appliance, t001Z_d m_;0ri0adsi F
S0 Amp, snge phase,_O Hz e ec_r cal loads Run/S_op Switch -- _st be in "Run" posiUon to sta_
mengTneSette Stop tostoparunnmge_g e
Am Cleaner Uses a dry O/pe fTiter:element and lea , !
pre c e_er to EXhauSt muffler 10wets engine
into d_eenginei _oise _d is_Uipped Wi_h Z spzrP.Zrrester

ASSEMBLY
Your generator requires some assembly and is ready for
use at_er it has been properly serviced with the
recommended oil and fuel.
If you have any problems with the assembly of your
generator, please call the generator helpllne at
1-800-270-1408.
IMPORTANT:Any a_empt to run the unit before it hzs
been serviced with the recommended oil will result in an
engine failure.
Remove Generator From Carton
I, Set _rton on a rigid flat surface with "This Side Up"
arrows pointing upward.
2. Carefully open top flaps of shipping car_on. Review
"Cold Weather Operation" on pzge 10.
3. Cut down corners at one end of _rton from top to
bo_om and laythat side of _rton down tla=
4. Remove all pacl(Tngmaterial, car_on fillers, etc.
S. Remove the generator from the shipping carton.
Install Wheel Kit
The wheel Idt is designed to greatly improve the por_bili_
of your generator.
NOTE:Wheel kit is not intended for over-the-road use.
You will need a socket wrench with I/2" or 13ram socl(ets
and a needle-nose plier to instil this kit,
Refer to Figure I and install the wheel kit as follows:
I. Place the bo_om of the generator cradle on aflat,
even surface.Temporarily place unit on bloc_ to e_se
assembly.
2. Slide zxle through both axle mounting brackets on
cradle frame, as shown in Figure I.
3. Slide a wheel over the axle.
NOTE: Be sure to install both wheels with the air
pressure valve on the outboard side.
4. Place the e-ring onto the groove in the axle.You may
add the flat washer if desired.
NOTE: Use retaining pins instead of e-clip, if appli_ble.
5. Place one end of the needle nose pliers on the bot_m
of the axle and the other end of the pliers on top of
the e-ring. Seat the e-ring by pressing the pliers closed.
6. Repeat step 3through 5 to secure second wheel.
II vv

7. Removetie _emporary blocks.
8. At_ch the vibration mourns to the support leg with
30ram capscrews, washers and lock nuts,
9, With the wheels on, you can now Hft up the handle
end and a_ch tie suppor_ leg wTth 20ram cap screws
and lock nuts.
IO, Check tiatallfastenersarerightznd thetiresare Tnfla_d
_o tile value marked on tile tTre or wTthin IS and 40 psT.
Check Battery /Attach Negative
Battery Wire
The sealed battery on the generator is fully charged and
pre-Tns_lled except for the negative (blacl_) battery cable,
To install;
I. Cut off _ie wrap securing loose end of negative (black)
c_ble.
2, Remove nut and washer on negative bakery terminal,
3, Slide negative battery cable over screw on negative
_erminal (Figure 2),
Negative
battery \_
c_ble Screw Positive battery cable
_t. Re_ch wzsher and nut and tighten,
5. Verify tiat connections to bakery and generator are
_Jghtand secure,
BEFORE STARTING THE
ENGINE
Add Engine Oil and Fuel
•Place generator on a level surface.
• Refer to engfne owner's manual and follow ofl and fuel
recommendations and instructions,
CAUTION
NOTE: Checl_ oil often during engine break-in, Refer to
engine owner's manual for recommendations,
NOTE: The generator zssembly rotates on a prelubricated
and sealed ball bearing that recIuires no additional
lubrication for the life of tie bearing,

USING THE GENERATOR
System Ground
The generator has a system ground :hat connects the
generator frame components _o the ground terminals on
the AC output recep_cles.The system ground is connected
_o the AC neutral wire (see "EquTpment DescrTpdon",
earlier in thTs manual).
Special Requirements
There may be Federal or $_te OccupatTonal Safety and
Health AdmTnTstratTon(OSHA) regulations, local codes, or
ordinances that apply _o the in_ended use of the generator.
Please consult aqualifTedelectrician, electrical inspector, or
the local zgency having jurisdiction.
• In some areas, generators are required to be registered
with local utili_/companies.
•It'the generator is used at a construction site, there may
be additional regulations which must be observed.
Connecting to a Building's Electrical
System
Connections for s_ndby power to a building's electrical
system must be made by aqualified electrician.The
connection must isolate the generator power from u_ility
power, and must comply with all applicable laws and
electrical codes. DANGER
,wh_, usi,g_o,o_tor_orbackupp0*o_,,_i_
,Use aground_UI_Circuit interrUp_ (G FCI) in anydamp or'
highly ¢0nducciye arca_suchRsmG_a!d_€l_ngor' s_¢l wor`I_
N_ h_ndl_gcn_r_cOr`Or'_!ec_rica!cordsWhi!_s_nding
W_rer,Whi]_b_oo_ Orwhileh_.nd_.Or _ec_
N_ a!!owunqualified_mons or chi]d_nro op_ or
How to Use the Battery Charger
Use bakery float charger iack to I_s_ep:he sr_r_ing battery
charged and ready for use. B_t_ery charging should be done
in adry Ioc_ion, such as inside a g_rage.
•Plug the charger into the unit's"Battery Float Charger"
jack, which is located on the s_rter switch (Figure 3).
Plug ba:tery charger into a 120VoltAC wall recep_cle.
\\
• Unplug :he charger from :he unit and the wall ouder when
generator is being s_r_ed and while it is in operation.
•Keep this charger plugged in when generator is not in
use to prolong battery life.The charger has a built in float
ecIualizer and will not overcharge the b_tery, even when
plugged in for an ex_ended period of time.
IN PORTANT: See "B_ery Maintenance" on pzge 14 for
additional information.
OPERATING THE
G EN ERATO R
IN PORTANT: Always unplug the battery float charger
before star_ing :he generator.
CAUTION
S_ [DOnt_erlo_.d GCner_t:or_on pa_¢ 3;
"S_ _ne_t:or _.nd!et__ngin_ s_bi!!ze_before €onn_ct:ing
electrical Ic_dSi
, C0nn_c__l_¢tr!cal !0ads !n OFF p0sitJon,rhen turn ON for`
,Turn oJf:ccr(_.lloadsOFF andd(sconn_¢cfrom generator

Starting the Engine
Disconnect all electrical loads from the generator, Use the
following s_r_ instruction steps by numerical order:
I, Make sure unit is on a level sur_ce,
IMPORTANT= Failure to star_ and operate unit on alevel
sur_ce will c_use the unit not _o start or shut down during
operation.
2. Turn the fuel valve to the "On" position (Figure 4).The
fuel valve handle should be vertical (pointing toward
_he ground) for fuel to flow.
3. Mal__esure the Idle Control switch is in "Off" position
(Figure 5).
_m BI
IDLE
4. Start the engine according to instructions given in 1:he
engine owner's manual.
NOTE: If engine starts after 3 pulls but f_ils to run, or if
unit shu_sdown during opera_ion, mal_ sure unit is on a
level su_ace and check for proper oil level in crankcase.
This unit mm/be equipped wi_h alow oil protection device.
See engine manual.
Connecting Electrical Loads
•Let engine s_bilize and warm up for a few minu_es after
starting,
• Plug in and turn on the desired 120 and/or 240VoltAC,
single phase, 60 Hz electrical loads.
• DO NOT connect 240Volt loads to the 120Volt
recep_cles.
• DO NOT connect 3-phase loads to the generator.
• DO NOT connect 50 Hz loads _o _he generator.
•DO NOT OVERLOADTHE GENERATOR, See
"Don't Overload Generator" on page 13.
Stopping the Engine
I. Unplug all electrical loads from generator panel
recep_cles. NEVER star_ or stop engine with electrical
devices plugged in and turned on.
2. Put idle control switch in "OFF' position.
3. Let engine run at no-load for 30 seconds _o stabilize
in_ernal _empera_uras of engine and generator.
4. Turn engine off"according to instructions given in
engine owner's manual.
S. Move fuel valve to "OFF' position.
Operating Automatic Idle Control
This switch is designed to greedy improve fuel economy.
When this _wltch is turned ON, the engine will only
run at i_snormal high governed engine speed when an
electrical load is connected,When an electrical load is
removed, the engine will run at a reduced speed. With the
switch off, the engine will run at _he normal high engine
speed. Always have the switch off when starting and
stopping the engine.
Charging a Battery
Your generator has _he capability of recharging a discharged
12Volt automotive or utiliL-ystyle storage battery. DO
NOT use the unit _o charge am/6Volt batteries. DO NOT
use the unit _o crank an engine having a discharged battery.
DANGER
To recharge 12Volt bat_rles, proceed as follows:
I. Check fluid level in all bat%erycells. If necessary, add
ONLY distilled water to cover separators in battery
cells. DO NOT use tap wa_r.

2. It"bakery TsequTppedwTth yen= caps, make sure =hey
are Jnsr_lledand are tTght.
3. It"necessary, clean battery termTnals.
4. Connec= battery charge cable connec=or plug to panel
recep_cle identified by the words "I2-VO/TS D.C."
S. Connect bat_ry charge cable clamp with red handle
_o the positive (+) battery terminal (Figure 6),
6. Connect battery charge cable clamp with black handle
_o the negative (-) b_ery termTnal (Figure 6).
7. Start engine, let engine run while bz_tery recharges.
8. When battery has charged, shut down engine
NOTE: Use an amomod_ hydrometer _o _st battery s_a_e
of charge and condition. Follow the hydrometer
m_nofaztzrer's instrucUons care4ully.Gener_l_ a b_'_ery is
considered _o be at 100% state of charge when specific gr_Ly
of_ fluid (_ measured by hydrometer) is 1_260or higher.
COLD WEATH ER
OPERATION
Under cer!_inweather conditions(t_mperatures below
40OF[4=C] and a high dew point),your generatormay
experienceicing of the c_rburetor and/or the crankcase
breather system.
Build astructure that will enclose three sidesand the top
of the genera_0r.
I. Make sure entire muffler-side of generator is exposed.
Note that your generator may appear different from
that shown fn Figure 7.
2. Ensure a minimum of _wo feet clearance between open
side of box and nearest obiec=
3. Face exposed end away from wind and elements.
4. Enclosure should hold enough heat created by
generator to prevent problems.
DANGER
.Keep at:!eas t 2 "_ec_of clearance on al!sides Ofg_n_rator for
_d_qUateventilati0n.
, DO NOT Oper_egen_r_or insidoaw buildingOrendc_i
!ncluding_ gene_r comparm_ c_z_rr._or_J v_icl_ _RV).
, P,_m0vegener_t0r_romShelterwhen _emperatureiSabove
_0 [ c] ..................................................................