GT POWER GT5500D User manual

GT5500D

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GT5500D
Contents
Introduction.............................................3
Environmental Protection..........................3
Scope of Product.......................................3
Specifications......................................3
SafetyInformation......................................4
Unpacking the Generator...........................6
Warning Labels.........................................7
Symbols and Meanings.............................8
Parts Diagram.........................................10
Parts Explained.......................................11
Assembling the Generator.......................12
Preparation before Operating..................12
Starting the Generator.............................14
Shutting Down the Generator...................15
Transporting.........................................16
Maintenance.........................................16
Storage.............................................19
Environmental Requirements.................19
Troubleshooting....................................20
ElectricalDiagrams..................................21
Calculating Your Power Needs ...............23
Warranty................................................25

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GT5500D
Introduction
Your new GT POWER Generator will more
than satisfy your expectations. It has been
manufactured under stringent quality stand-
ards to meet superior performance criteria.
You will nd your new tool easy and safe to
operate, and, with proper care, it will give
you many years of dependable service.
CAUTION: Carefully read through
this entire Instruction Manual before
using your new GT POWER Genera-
tor. Take special care to heed the
Cautions and Warnings.
Your generator has many features that will
make your job faster and easier. Safety,
performance, and dependability have been
given top priority in the development of this
tool, making it easy to maintain and operate.
Environmental
Protection
Recycle unwanted materials instead of
disposing of them as waste. All tools, hoses
and packaging should be sorted, taken to
the local recycling centre and disposed of in
an environmentally safe way.
Scope Of Product
This product is suited for home and camping,
back-up power, rural and commercial
applications.
Specifications
AC Output: 230V AC ~ 50Hz
Rated Power: 5000W
Peak Power: 5500W
Phase: Single
Power Factor: COS O = 1
Displacement: 462cc
Engine: LC462D
Rated Speed: 3000 RPM
Fuel Tank Capacity: 14.5L
Fuel Type: Diesel Fuel
Engine Oil Type: 10W30 Diesel Oil
Operation Noise Level: 89dBA
Net Weight: 112kg
L x W x H: 685 x 520 x 595

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GT5500D
Safety Information
Read this manual carefully and become
familiar with your generator. Know its
applications, its limitations and any
hazards involved.
Throughout this brochure, on tags and
decals afxed to the generator, DANGER,
WARNING, CAUTION and NOTICE marks
are used to alert personnel with special
instructions about a particular operation that
may be hazardous if performed incorrectly,
or carelessly. Observe them carefully. Their
denitions are as follows:
DANGER: indicates a hazard which,
if not avoided, will result in death or
serious injury.
WARNING: indicates a hazard which,
if not avoided, could result in death or
serious injury.
CAUTION: indicates a hazard which,
if not avoided, could result in minor or
moderate injury.
NOTE: covers some practices which
may not be related to personal injury.
A running engine gives off carbon monox-
ide, an odourless, colourless, poison gas.
Breathing carbon monoxide could result
in death,serious injury, headache, fatigue,
dizziness,vomiting, confusion, seizures,
nausea or fainting.
• Operate this product ONLY outdoors.
• Install a battery operated carbon monoxide
alarm near the bedrooms.
• Keep exhaust gas away from entering a
conned area through windows, doors,
ventilation intakes, or other openings.
• NEVER operate this product inside any
building, carport, porch, mobile equipment,
marine applications, or enclosure, even if
windows and doors are open.
WARNING: Starter cord kickback
(rapid retraction) will pull hand and
arm toward engine faster than you
can let go which could cause broken
bones, fractures, bruises, or sprains
resulting in serious injury.
• When starting engine, pull cord slowly
until resistance is felt and then pull rapidly
to avoid kickback.
• NEVER start or stop engine with electrical
devices plugged in and turned on.
WARNING: Fuel and its vapours are
extremely ammable and explosive
which could cause burns, re or
explosion resulting in death, serious
injury and/or property damage.
When Adding or Draining Fuel
• Turn generator engine OFF and let it cool
at least 2 minutes before removing fuel
cap. Loosen cap slowly to relieve pressure
in tank.
• Fill or drain fuel tank outdoors.
• DO NOT overll tank, Allow space for fuel
expansion.
• If fuel spills, wait until it evaporates before
starting engine.
• Keep fuel away from sparks, open ames,
pilot light, heat, and other ignition sources.
• Check fuel lines, tank, cap and ttings
frequently for cracks or leaks. Replace if
necessary.
• DO NOT light a cigarette or smoke.

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GT5500D
When Starting Equipment
• Ensure mufer, fuel cap and air cleaner
are in place.
When Operating Equipment
• DO NOT operate this product inside any
building, carport, porch, mobile equipment,
marine applications or enclosure.
• DO NOT tip engine or equipment at angle
which causes fuel to spill.
• DO NOT stop engine by moving choke
control to “OFF” position.
When Transporting or Repairing
Equipment
• Transport/move/repair with fuel tank
EMPTY or with fuel valve OFF.
• DO NOT tip engine or equipment at angle
which cause fuel to spill.
When Storing Fuel or
Equipment with Fuel in Tank
• Store away from furnaces, stoves,
water heaters, clothes dryers, or other
appliances that have light or other ignition
source because they could ignite fuel
vapours.
WARNING: Generator voltage
could cause electrical shock or burn
resulting in death or serious injury.
• Use approved transfer equipment to
prevent back feed by isolating generator
from electric utility workers.
• When using generator for backup power,
notify utility company.
• Use a ground fault circuit interrupter in any
damp or highly conductive area, such as
metal decking or steel work.
• DO NOT touch bare wires or receptacles.
• DO NOT use generator with electrical
cords which are worn, frayed, bare or
otherwise damaged.
• DO NOT operate generator in the rain or
wet weather.
• DO NOT handle generator or electrical
cords while standing in water, while bare-
foot, or while hands or feet are wet.
• DO NOT allow unqualied persons or
children to operate or service generator.
WARNING: Exhaust heat/gases could
ignite combustibles, structures or dam-
age fuel tank causing a re, resulting
in death, serious injury and/or property
damage. Contact with mufer area
could cause burns resulting in serious
injury.
• DO NOT touch hot parts and AVOID hot
exhaust gases.
• Allow equipment to cool before touching.
• Keep at least 5 feet (1.5m) of clearance
on all sides of generator including overhead.
CAUTION: Excessively high operating
speeds could result in minor injury and/
or generator damage. Excessively low
speeds impose a heavy load.
• DO NOT tamper with governor spring,
links or other parts to increase engine
speeds. Generator supplies correct rated
frequency and voltage when running at
governed speed.
WARNING: Unintentional sparking
could cause re or electric shock
resulting in death or serious injury.

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GT5500D
Other Safety Precautions
WARNING: Starter and other rotating
parts could entangle hands, hair,
clothing, or accessories resulting in
serious injury.
• DO NOT connect to a home power
system. See “Connecting to a Home
Power Supply” on the following page
• NEVER operate generator without
protective housing or covers.
• DO NOT wear loose clothing, jewellery or
anything that could be caught in the
starter or other rotating parts.
• Tie up long hair and remove jewellery.
• DO NOT modify generator in any way.
NOTE: Exceeding generators
wattage/amperage capacity could
damage generator and/or electrical
devices connected to it.
• DO NOT exceed the generator’s wattage/
amperage capacity.
• Start generator and let engine stabilise
before connecting electrical loads.
• Turn electrical loads OFF and disconnect
from generator before stopping generator.
NOTE: Improper treatment of
generator could damage it and
shorten its life.
• Use generator only for intended uses.
• If you have questions about intended use,
ask dealer or contact local service center.
• Operate generator only on level surfaces.
• DO NOT expose generator to excessive
moisture, dust, dirt, or corrosive vapor.
• DO NOT use in the rain.
• DO NOT insert any object through cooling
slots.
• If connected devices overheat turn
them off and disconnect them from
generator.
- or if electrical output is lost.
- or if equipment sparks, smokes, or emits
ames.
- or if unit vibrates excessively.
Unpacking the
Generator
• Set the carton on a rigid at surface.
• Remove everything from carton except
generator.
•Open carton completely by cutting each
corner from top to bottom.
• Leave generator on carton to install wheel
kit.
Packing Contents
1 x Owner’s Manual
4 x Wheels
1 x Handle Assembly
2 x Wheel Axles
1 x Hardware Bag
1 x Extension Housing

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GT5500D
Warning Labels
Warning labels on the machine are to remind
you of the safety regulations.
Rated Power: 5.0kW
Rated Frequency:50Hz
Phase: Single
RatedVoltage: 230V
Rated Current: 21.7A
Weight: 112kg
Quality Class: A
Power Factor: 1.0
Class: G1
Serial # andYear of
Manufacture on Crankcase
Low power generator set
EN 12601

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GT5500D
Symbols and Meanings
Voltage
Current
Frequency
(1Hz = 60r/min)
Power
Engine speed
Load transfer
efciency
Generator
Output power
performance rate
Conforms
to relevant
standards for
electromagnetic
compatibility
This is an electrical de-
vice. Follow
instructions or electric
shock may occur.
Do not touch while operat-
ing.
High temperatures and
open re could cause fuel
tank to explode. Operate
cautiously.
Equipment will get hot du-
ing operation. Be careful
not to scald skin.
Ensure generator is
safely grounded
before operating.
Do not use the plug or
electric device in the rain
or get generator wet.
Add engine oil
Add fuel
Wear hearing,eye and
breathing protection.
The rating plate on your tool may show symbols. These represent important information about
the product or instructions on its use.

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GT5500D
Read the safety instructions before using the generator.
Only ll the generator in well-ventilated areas and keep it away
from open ames sparks and cigarettes. Spilled fuel should
be soaked up immediately. Switch off the engine and let it cool
down before lling the generator. Fuel is easily ammable and
may even explode under
certain circumstances.
Gases such as carbon monoxide (colourless and odourless
gas) are produced during operation which may lead to
suffocation. Only use the generator in well ventilated areas.
Warning! Dangerous voltages are present when the
generator is in operation. Generator must always be
switched off before performing maintenance works.
Wear ear protection when operating the generator.
Disconnect all devices from the connections before
performing maintenance works, before leaving the device
and after switching it off.
The generator may not be connected to the public power
supply. When the device is falsely connected there is a
risk of re material damage and even a fatal electric shock
being suffered by the operator as is also the case when
performing works on the public power supply.

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GT5500D
(1) AC Output
(2) Output Indicator
(3) AC Circuit Breaker
(4) Ground Terminal
(5) Wheel
(6) Foot
(7) Dipstick
(8) Oil Sensor
(9) Speed Control
(10) Fuel Injection Pump
(11) Fuse Link
(12) Engine Switch
(13) Oil Pressure Indicator
(14) Air Filter
(15) Recoil Starter
(16) Handrail Pipe
(17) Oil Drain Bolt
(18) Starter Motor
(19) Battery
(20) Mufer
(21) Fuel Gauge
(22) Fuel Tank Cap
(23) Fuel Tank
Parts Diagram

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GT5500D
Parts Explained
Fuel Tank
Is used to hold fuel, use diesel fuel only.
Fuel Tank Cap
Is used to seal fuel tank - do not open it
when machine is in operation.
Fuel Gauge
Indicates fuel level in the fuel tank.
AC Output
Provides the power supply. Refer to model’s
parameter table for its rated power. Load of
each socket cannot exceed its rated current
and total power of electric device cannot
surpass rated power of the generator.
Do not start up several electric devices
simultaneously but switch on another one
after stable operation of one electric device.
AC Circuit Breaker
Will activate to protects the electric device
when current exceeds the allowed current.
Output Indicator
Indicates the power supply status and will
light up when the equipment is in operation.
Engine Switch
Starts up and switches off the engine.
Wheels
For ease of use when moving the generator.
Battery
For starting up the generator. If not used
for three months the battery may need
charging.
Dipstick
For measuring engine oil level. Ensure
oil level is between MIN and MAX in the
dipstick of oil ller cap before use. Oil can be
added after removing the oil ller cap
Oil Drain Bolt
Unscrew this bolt when replacing the engine
oil. Drain out the old engine oil and dispose
of it properly according to local laws avoiding
damage to the environment
Foot
It is to support the generator.
Grounding Terminal
Is for earthing the generator. Refer to Page
12 for more information.
Handrail Pipe
Handle when lifted has a self locking
structure and can be used to move the
generator.
Starter Motor
Is to start up the engine.
Air Filter
Is to lter air and remove impurities in the air
entering the cylinder.
Mufer
Eliminates noise during operation and also
discharges high temperature exhaust
Do not touch it to avoid burns.

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GT5500D
Preparation before
Operating
NOTE: Pre-operation checks should
be made each time before operating.
WARNING: The engine and mufer
will be very hot after the engine has
been running. Avoid touching the
engine and mufer while they are
still hot with any part of your body or
clothing during inspection or repair.
Ground (Earth) Terminal
The Ground (Earth) terminal purpose is to
connect the generator frame to a ground-
ing point such as an earth stake to prevent
against electric shock from the generator
frame in the case of a short circuit or other
electrical malfunction of the generator or
the connected load. It is not required to be
connected for operation of the generator,
it is an additional safety feature. If in doubt
if grounding protection is required for your
application, please check with a registered
electrician as to your local regulations.
Assembling the
Generator
Wheel assemblies are included for the
convenience of moving the generator. You
will need the following tools:
Please install the handle, rubber feet and
wheel on the base plate and tighten the
bolt as shown in the following picture:

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GT5500D
Adding Engine Oil
The generator has been shipped without
engine oil.
WARNING: Do not start the engine
until lled with sufcient engine oil.
Do not tilt the generator when adding
oil. This could result in overlling and
damage to the engine.
Recommended engine oil:
10W-30 Diesel Oil
Recommended engine oil grade:
API Service SE type or higher
Engine oil quantity: 1.6 L
NOTE: Improper treatment of
generator could damage it and
shorten its life. DO NOT attempt
crank or start the engine before it
has been properly serviced with the
recommended oil. This could result in
an engine failure.
• Place generator on a at, level surface.
• Remove oil cap and dipstick. Wipe
dipstick clean.
• Using a funnel, slowly ll oil into engine
through the oil lter until it reaches the full
mark on the dipstick (1).
• Stop lling occasionally to check oil level.
Be careful do not over ll.
Oil Viscosity
Select the appropriate engine oil viscos-
ity based on the ambient temperature and
use the SAE Service Grade Viscosity in the
Chart
40
30
20
15W-40
10W-30
20
-20oC -10oC 0oC 10oC 20oC 30oC 40oC
Adding Fuel
• Fuel is highly ammable and poisonous.
Check SAFETY INFORMATION on pgs
4 - 6 carefully before lling.
• Do not overll the fuel tank, otherwise it
may overow when the fuel warms up and
expands.
• After lling the fuel, make sure the fuel
fuel cap is tightened securely.
• Immediately wipe off spilled fuel with a
clean dry cloth.
•USE DIESEL FUEL ONLY. The use of
any other fuel will cause severe damage
to internal engine parts.
• Total fuel tank capacity = 14.5 litres.
WARNING: Keep away from re and
heat when lling. Do not ll when
operating generator.
• Install oil ll cap and fasten the cap
properly.
• Check engine oil level before starting
each time thereafter.
Service Categories: API - CD or higher
ACEA - E3, E4 and E5, JASO - DH-1

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GT5500D
Insert the key into the key switch, Turn the
start switch to the ‘START’ position.
Release the key as
soon as the engine
starts, it will return
to the ‘ON’ position.
If the engine
doesn’t start, Wait
at least 30 seconds
before you attempt
to start the engine
again.
Starting in Cold Weather
(Heating function is optional) When the
engine is difcult to start in cold weather,
turn the start switch
to the ‘HEATER’
position for about
10--20 seconds and
then release.
Do not exceed
this level
Connecting the Battery
Connect the battery wire to the battery - red
for positive and green for negative.
Make sure the
nut is screwed
tightly. Do not
make contact
between positive
and negative
electrodes.
Turn On the Fuel Tap
Turn the fuel tap to ‘ON’ and let the fuel ow
into the fuel pump.
Set Engine Speed Control to Start
Starting
the Generator
Move the lever (1)
to the right and click
into ‘RUN’ position
(2).

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GT5500D
Turning off the Engine Switch
Turn off
the engine
switch and
the generator
unit will be
shut down
immediately.
Close the Fuel Tap
Turn off the fuel
tap after the
shutting down
the generator
WARNING: The surface temperature
of the generator is still high after
shutting down and should not be
moved or operated before cooling
down in order to avoid scalding.
Warming up the Engine
After starting, Warm up the engine without
load for about 3 minutes.
Connecting the Load
Access electric equipment and turn the
circuit breaker to ‘ON’.
Please note that
when several
loads are used
at the same
time do not
use the next
one unless the
former one is
running normally. The total power of the
loads should not exceed the rated power of
the unit.
Disconnecting the Load
Disconnect
the electric
equipment from
the control
panel of the
generator.
Shutting Down
the Generator
Set Engine Speed Control to Stop
After 30 seconds of no-load running press
down the stop button (2) ,the speed control
lever (1) will
automatically
return to the
‘STOP’ position.

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GT5500D
Maintenance
Perform maintenance as shown below.
More frequent service is required when
operating in adverse conditions.
Daily:
Before Operation:
• Nuts&Bolts - check and tighten
• EngineOil - Check and top-up
• OilLeakage - Check
• AirFilter - Check - Clean or replace
• Battery - Check
Maintenance Schedule
Transporting
Preventing Fuel Spillage
To prevent fuel spillage when transporting
or during temporary storage, the generator
should be secured upright in its normal oper-
ating position with the engine switch OFF.
The fuel tap should be turned OFF.
• Do not overll the tank.
• Do not operate the generator while
it is on a vehicle.Take the generator off
the vehicle and use it in a well ventilated
place.
Transporting the Generator
• Take care not to drop or strike the
generator when transporting.
To transport the generator, lift by the correct
lifting eyes as shown below.
• Do not place heavy objects on the
generator.
Correct
Lifting
Eyes
• When transporting the generator by
loading it on to a vehicle,secure to the
generator frame as shown.
Daily:
Before and After Operation:
• OilLeakage - Check
After 20 Hrs:
• EngineOil - Replace
• OilFilter- Replace if damaged
• Intake,ExhaustValves&Head
Clearance - Adjust *
• AirCleanerElement- Service
frequently when used in dusty areas

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GT5500D
Every 100 Hrs:
• EngineOil - Replace
• OilFilter- Replace if damaged
• AirCleanerElement- Service
frequently when used in dusty areas
Every 200 Hrs:
• AirCleanerElement- Clean or
replace
• FuelTank- Drain and Clean
Every 500 Hrs:
• FuelPiping- Check and replace if
damaged
• Intake,ExhaustValves&Head
Clearance - Adjust *
Every 1000 Hrs:
• FuelFilter- Check and replace
• FuelInjectionNozzle - Check *
• FuelInjectionPump - Check *
• IntakeExhaustValveSeals - Check *
and lap
• PistonRings - Replace *
* Indicates that special tools and skills are required.
General Recommendations
The warranty of the generator does not
cover items that have been subjected to
operator abuse or negligence. To receive full
value from the warranty, the operator must
maintain the generator as instructed in this
manual.
Some adjustments will need to be made
periodically to properly maintain the
generator.
Generator maintenance consists of keeping
the unit clean and dry. Operate and store
the unit in a clean dry environment where it
will not be exposed to excessive dust, dirt,
moisture or any corrosive vapours. Cooling
air slots in the generator must not become
clogged with debris.
• Check for any foreign materials while
changing the engine oil and report to
repair agent if necessary
• Check the cleanliness of the generator
frequently and clean when dust, dirt, oil,
moisture or other foreign substances are
visible on its exterior surface.
CAUTION: Never insert any object or
tool through the air cooling slots, even
if the engine is not running.
NOTE: DO NOT use a garden hose
to clean generator. Water can enter
the engine fuel system and cause
problems. In addition, if water enters
the generator though cooling air slots,
some water will be retained in voids
and crevices of the rotor and stator
winding insulation. Water and dirt build-
up on the generator internal windings
will eventually decrease the insulation
resistance of these windings.
NOTE: If you are not familiar with
maintenance work, have a GT
POWER Service Dealer do it for safety.
WARNING: Stop the engine before
starting maintenance work.

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GT5500D
after oil is level with the lower thread.
(Generator must be on a level surface)
NOTE: Do not tilt the generator when
adding engine oil. This could result in
overlling and damage to the engine.
Don’t let foreign body fall into engine.
Oil and gasoline could pollute the
environment. Do not throw it in the
rubbish or pour it on the ground.
Dispose of responsibly.
Engine Oil Replacement
Avoid draining the engine oil immediately
after stopping the engine. The oil is hot and
should be handled with care to avoid burns.
1. Place the generator on a level surface
and warm up the engine for several
minutes.
2. Loosen the screw and take off the
engine oil sight glass.
3. Lift and incline the machine; take off the
end cap at the bottom plate of
machine
4. Remove the oil ller cap.
5. Place an oil pan under the engine,
remove the oil drain bolt. Drain the
oil from the oil tank.
6. Check oil ller cap, O-ring, Oil drain
bolt and Oil ller cap packing .Replace
immediately if damaged.
7. Assemble oil drain bolt and oil ller cap
packing.
8. Add oil till to a suitable level tighten oil
ller cap.
9. Assemble the end cap at the bottom of
machine .
10. Insert and screw the oil ller bung in
Air Filter
1. Remove air lter housing clips and front
panel.
2 Remove paper lter and clean with
compressed air carefully. Tap the lter
on the ground sharply to remove debris.
Take care when using compressed air
around the lter element as it is easily
damaged - use low air pressure.
3. Replace element, cover and clip into
place.

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GT5500D
Storage
Long term storage of your machine will
require some preventive procedures to
guard against deterioration.
- Add 5mls of FUELSET fuel conditioner to
the fuel tank if you are not using it daily
- Leave oil and fuel in the generator and
start once every 3 months and run for 5
mins.
- If not used for a period longer than one
year the engine oil and fuel must be
drained and replaced as per instructions
before use.
Valve Clearance
Valve clearance should be done by a GT
Power Registered Service Technician.
The clearances are 0.1mm for the inlet valve
and 0.15mm for the exhaust valve.
The environmental requirements of the
generator are as follows:
Suitable temperature: -10-40o.
Suitable humidity: Lower than 95%.
Suitable altitude: Under 1000 metres (it
should be used with lower power in districts
higher than 1000 metres).
The generator set can only be loaded to the
rated power under the specied environment
conditions. If the environment conditions are
inconsistent with the above standards
or if the cooling conditions of the engine
and generator set are defective (for
example when running in limited areas) it
is necessary to reduce the power. It is also
necessary to reduce the power when the
temperature altitude and relative humidity
exceed the standards.
Environmental
Requirements
Protecting the Generator
The unit should be stored in a clean and dry
place and should be protected from rain
and high
temperature.
Shield the unit
with paper box
or plastic bag
to prevent dust
from entering
the unit.

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GT5500D
Troubleshooting
The generator will not start
• Check diesel fuel is full - top up if
necessary.
• Check switch is on - turn fuel switch to
‘ON’ position.
• Check fuel swich isn’t blocked - Clean
if blocked.
• Check engine oil - top up if necessary.
• Ensure speed control is in the ‘RUN’
position.
• If starter motor does not operate or
rotates too slowly - Clean terminals,
retighten, check battery and re-charge if
necessary.
Generator won’t produce power
• Check circuit breaker is connected
- turn to ‘ON’ position.
• Check plug contacts are connected
- Replace socket if necessary.
Vibration while operating
• Check diesel fuel - ll fuel tank if
necessary.
Generator emits white smoke
• The temperature of the engine may be
too low - Run the engine with no load
for more than 10 minutes.
• The fuel oil may be contaminated
- Replace with clean oil.
Generator emits black smoke
• The air lter may be dirty - Clean the
lter element of the air lter.
• The load may be too high - Reduce
load to the rated limit.
Generator emits blue smoke
• There may be too much engine oil
- Drain some oil.
• The engine oil used may be the wrong
type - Drain oil and replace with
appropriate engine oil.
The power decreases
• The fuel system may be blocked
- Have a qualied GT Power Technician
purge the fuel system and check lters.
• The air lter element may be clogged
- clean or replace air lter element.
If problem persists contact your local
registered GT Power Service Dealer or visit
www.gtpower.co.nz for more information.