Stanley G5000S User manual

®
Owner's Manual
This manual contains important safety instructions for gasoline generator models: G5000S, G8000S
that should be followed during installation and maintenance of the generator and batteries.
READ SAFETYWARNINGS AND OPERATING INSTRUCTIONS CAREFULLY,SAVE THESE NSTRUCTIONS.
Contents:
2-3
3
4
5
6-7
8
9
10-11
12
13
14-15
16
STANLEYProduct Lines
Missing Parts RequestForm
Warnings
Warnings and Specifications
ComponentIdentification
Wheel Kit Installation & Battery Commissioning
Controls
Operatingthe Generator
Maintenance
Maintenance, Transporting and Storage
Troubleshooting
Warranty and Service
DONOT RETURNTHIS GENERATOR
TO THE STORE
or go to
HAVE QUESTIONS OR NEED HELP?
call our help-line: [1] 919-550-3259
www.portablegenerator911.com or www.GXiOutdoorPower.com
Have the following information ready when you call us:
Date of Purchase:
Location of Purchase:
Serial #:
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
I of 16

STANLEY Product Lines Models: G5000S&GS000S
Walk Behind Turf and Brush Mowers
• 36" Brush Mower
• HONDAGXV530V-twin engine
• Hydro Drive
• Convertible deck-- easily converts to a finish mower.
Zero-Turn Commercial Mowers
• 54" and62"
• HONDAGXV530V-twin engine
• Hydro Drive
Commercial Walk Behind Mowers
• 36" and 54" deck
• HONDA GXV530 V-twin engine
• Belt drive or Hydro Drive
100" Tow Behind Mower
Model: 100TS
• Commercial duty STANLEYtow behind mower
• HONDA GXV530 V-twin engine cuts up to 100inches.
• 52in. brush cut or a 52in. finish cut mower with wings up.
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
2of16

STANLEY Product Lines Models: G5000S&GS000S
Electric
Q
@
@
@
@
Pressure Washer
1450 psi to 1800 psi electric pressure washers
20 ff of high pressure hose and 35ft. cord with GFC[ protection
Sleek and unique, high quality, stainless steel finish
13Amps, 120V
Auto-stop shut off system pronongs pump nife
Generator Cord Accessories
240V,10/4,heavy duty extension cords with L14-30connectors at each end.
This cord reduces harmfu/ vo/tage drops experienced when using most
120Vextension cords. Available in 15'and 25' lengths and can becombined to
reach the desired length.
Missing Parts Request Form
Please indicate the part thatyou are missing:
[] Hardware bag
[] Wheel Kit
[] Other
[] Dateof purchase
Name
Address
Phone
Email
Model #:
[] 5000
[] 6500
[] 6500EL
[] 8000
[] Serial #:
Comments:
IMPORTANT: Please include a copy your receipt. Without a receipt, your order will be
delayed.
E-mail • customerservic [email protected]
Fax: [phone]
Please scan and attach your proof of purchase to your e-mail.
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
3of16

WARNINGS Models: G5000S&G8000S
This owner's manual is considered a permanent part ofthe generator
andshould remainwith the generator if resold. The information and
specifications included inthis publication were in effect atthe time of
approval for printing.
GXiOutdoor Power, LLC,reserves the right to discontinue or change
specifications or design at anytime without notice andwithout incur-
ring any obligation whatever. No part of this publication may be repro-
duced without written permission.
EMISSION CONTROLSYSTEM INFORMATION
The U.S.and California CleanAir Acts
EPAand California regulations require all manufacturers to furnish
written instructions describing the operation and maintenance of emis-
sion control systems.Thefollowing instructions and procedures must
befollowed in order to keepthe emissions from your STANLEYengine
within the emission standards. Maintenance, replacement, or repair of
the emission control devices and systemsmay be performed by any
engine repair establishment or individual, using parts that are
"certified" to EPAstandards.
SAFETYLABEL LOCATIONS
These labels warn you of potential hazardsthat can cause serious
injury. Readthem carefully. Ifa label comes off or becomes hardto
read, contact your STANLEYgenerator dealer for a replacement.
SAFETYINFORMATION
STANLEYgenerators are designedto givesafe and dependable
service if operated according to instructions. Readand under-
stand this owner's manual before operating your generator.
OPERATORRESPONSIBILITY
Know howto stop the generator quickly in case of emergency. Under-
standthe useof all generator controls, output receptacles, and con-
nections. Be sure that anyone who operates the generator receives
proper instruction. Donot let children operate the generator.
The engine exhaust from this product contains chemicals known to
the State of California to cause cancer, birth defects or other re-
productive harm.
CARBONMON0XlOE GAS
Exhaust contains poisonous carbon monoxide, a colorless and
odorless gas. Breathing exhaust can cause loss of consciousness
and may lead to death. To keep exhaust gas from accumulating,
use in an area with adequate ventilation. DONOT use this genera-
tor in a garage, basement, crawlspace, enclosed shed, or any
other area that does not have adequate ventilation. DO NOT use
this generator near ventilation ducts or open windows that may
allow exhaust gasses to enter your home or business. ONLY
operate this generator outdoors.
Fire and Burn Hazards
The exhaust system gets hot enough to ignite some materials.
•Keepthe generator at least 3 feet (1meter) away from buildings
andother equipment during operation.
• Do not enclose the generator in any structure.
• Do not smoke when refueling.
• Keepflammable materials away from the generator.
• The muffler becomesvery hot during operation and remains hot for
awhile after stopping the engine. Be careful not to touch the muf-
fler while it is hot.
• Letthe engine cool before storing the generator indoors.
• Refuel in a well ventilated area with the engine stopped.
•Fuelvapors are extremely flammable and may ignite after the en-
gine has started. Make surethat any spilled fuel has been wiped
up before starting the generator.
Electocution hazard - Electricity can cause DEATH or SERIOUS
INJURY.
• Do not operate the generator in standing water.
• This product is not safe to operate when partially or totally sub-
merged in water.
• Ensure proper drainage in the region surrounding this generator.
• Properly ground the generator andverify ground is in place be-
fore each use. Grounding regulations vary by location, consult a
qualified local electrician for proper grounding instructions.
• Power cords and electrical equipment pose arisk of shock and
electrocution, especially if they are operated in wet conditions.
Inspect all equipment prior to every use and use only as directed
bythe manufacturer.
• Use a cord with GFCIprotection when using the power outdoors
or when moisture is present.
• Generators vibrate in normal use. During and after the use ofthe
generator, inspect the generator aswell as extension cords and
power supply cords connected to itfor damage resulting from
vibration. Have damaged items repaired or replaced as neces-
sary. Donot use plugs or cords that show signs of damage such
as broken or cracked insulation or damaged blades.
NEVERSTART ORSTOPTHE ENGINE WITH DEVICESCONNECTED
TO THE GENERATOR.
Rev. 4/2011
Generator must be installed by a qualified electrician and con-
nected to transfer equipment as a separately derived system in ac-
cordance with the National Electrical Code, NFPA 70. The generator
shall be connected through transfer equipmentthat switches all
conductors other than the equipment grounding conductor. The
frame of the generator shall be connected to an approved grounding
electrode.
Improper connections to a building electrical system can allow
electrical current from the generator to backfeed into the utility
lines. Such backfeed may electrocute utility company workers or
others who contact the lines during a power outage, and the gen-
erator may explode, burn, or cause fires when utility power is re-
stored.
Ground System
STANLEYportable generators have a system ground that connects gen-
erator frame components to the ground terminals in the AC output re-
ceptacles. Thesystem ground is connected to the AC neutral wire.
Special Requirements
There may beFederal or State Occupational Safety and Health Admini-
stration (0SHA) regulations, local codes,or ordinances that apply to the
intended use ofthe generator. Please consult a qualified electrician,
electrical inspector, orthe local agency havingjurisdiction.
This generator does not meet US Coast Guard regulation 33 0FR-183
and should not be used on marine applications. 4of16
STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.

AC Applications
WARNINGS Models: G5000S&G8000S
Before connecting an appliance or power cord to the generator:
1. Make sure that appliances are in good working order.
Faultyappliances or power cords can create a potential for
electrical shock. If an appliance beginsto operate abnor-
mally,becomes sluggish or stops suddenly,turn it off imme-
diately.
2. Disconnectthe appliance, and determine whetherthe prob-
lemisthe appliance, or ifthe rated load capacity of the
generator has been exceeded.
3. Make sure thatthe electrical rating ofthe tool or appliance
doesnot exceed that ofthe generator. Never exceed the
maximumpower rating of the generator. Power levels be-
tween rated and maximum may be usedfor no morethan 30
minutes.
Substantial overloading will open the circuit breaker. Ex-
ceeding the time limit for maximumpower operation or
slightly overloading the generator may not switch the circuit
breaker or circuit protector OFF,but will shorten the service
life of the generator.
Limit operation requiring maximumpower to 30minutes. For
continuous operation (longer than 30minutes), do not exceed
80%of the rated power balanced equally on the A&B sides of
the Alternator.
Failure to properly follow maintenance instructions and pre-
cautions can cause serious injuries or death. Always follow
the inspection and maintenance recommendations and
schedules in this owner's manual.
Safety Precautions:
Make sure the engine is off before you begin anymaintenance
or repairs. This will eliminate several potential hazards:
° Carbon monoxide poisoning from engine exhaust.
Be sure there is adequateventilation whenever you
operate the engine.
° Burns from hot parts.
Letthe engine and exhaust system cool before touch-
ing.
° Injury from moving parts.
Do notrun the engine unless instructed to do so.
Inthe State of California a spark arrestor is required by law.
Otherstates may have similar laws. Federallaws applyon all
federal lands. If you equip the muffler with a spark arrestor, it
must be maintained in effective working order. See page 11.
Rapid retraction of the recoil starter cord can pull the
starter cord back faster than you can let go. When starting
the engine, pull the cord slowly until resistance is felt then
pull rapidly to avoid kickback.
Changing the speed of the generator by adjusting the governor can cause damage to the genera-
tor, devices attached to the generator, and may result in bodily injury. Do not adjust or tamper
with the engine speed setting.
Rev. 4/2011
Generator G8000S
Ratedfrequency 60 Hz
Ratedvoltage 120V/240V
Max continuous output power 8.0kW (Max)
ACoutput (Max.) 33.3A
Enginetype OHV4-Stroke
displacement 401cc
Compression ratio 8.0:1
Rated rotation speed 3600RPM
Rated power 15Hp
Starting system Recoil and electric starter
Rotation direction Counter clockwise
Fueltype Unleaded gasoline
Low oil shutdown Yes
Fueltank size 12gallons
Oiltype/Capacity SAE 10W-301.1quarts
Grossweight 2351bs(107kg)
Battery 12AH 12VDC
Integrated voltmeter Yes
Product Specifications
G5000S
60Hz
120V/240V
5.0kW (Max.)
20.8A
OHV4-Stroke
279cc
8.2:1
3600RPM
10Hp
Recoil
Counter clockwise
Unleaded gasoline
Yes
12gallons
SAE10W-300.9quarts
207Ibs (94kg)
N/A
Yes
STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
5of16

Component Identification Models: G5000S& G8000S
FuelTank Fuel Cap
Choke Lever
Air Filter
Generator models may have
different features and/or options than
shown in these diagrams. STANLEYre-
serves the right to alter product features
and specifications without notice.
Fuel Valve
Main Breaker
_ON/OFFSwitch
Recoil Starter (Assembly)
Remote Generator Panel
Digital Meter
On/Off & Start Switch
(electric start option)
Main Breaker
20V
Twist Lock Connector
Pull OutHandle Bars Carburetor
Valve Cover
Ground Lug
Alternator
Exhaust Pipe Muffler Guard
Battery (electric start option only)
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
6of16

Component Identification Models: G5000S& G8000S
Access panel latches
Alternator
Weather Shield
EngineSerial Number stamped
onthe engine block
Access Panel
Additional equipment required to safely operate this generator:
1. Gascan.
2. Unleaded gasoline.
3. SAE10W-3O -1.1quartsf_rSTANLEY11hp_13hp_14hp_and15hpengines__.9quartsrequiredf_rSTANLEY1_HP.
4. An oil fill funnel.
5. Gasolinefuel stabilizer (for storing your generator).
6. 120Vand/or 240Vextension cords.
7. An adjustable wrench or a 12mmsocket for oil changes.
Note: A spark arrestor was supplied with your generator and must be installed for usewithin the State of California. See supplemental instructions.
Rev. 4/2011 7 of 16
STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.

Wheel Kit Assembly Models: G5000S&G8000S
Pre-assembled wheel/axle
assembly.
Two pre-assembled, retractable, handle bars,one on
eachside ofthe generator frame. Twist to lock/
unlock. Pull or pushto extend /retract.
Insert eachfoot assembly through
holes in the frame. Tighten nut with
13ramwrench or socket.
Insert eachaxle and tighten the
boltto secure in place using a 13
mmwrench or socket.
Commissioning the Battery
The battery is an optional feature. The battery is used to start a
generator equipped with an electric starter. Not all generators are
sold with batteries. Please verify with your retailer if you believe
the battery is missing.
Battery Terminals
Lead acid storage batteries contain sulfuric acid which can cause
serious injuries. The battery also gives off explosive gases. Keep
sparks, flames and cigarettes away. Provide adequate ventilation
when charging or using batteries. Battery posts, terminals and
related accessories contain lead and lead compounds. Avoid spills
of electrolyte and wash hands thoroughly after handling.
Use gloves and safety glasses when handling and installing lead
acid batteries.
If you get electrolyte in your eyes, flush your eyes with clean wa-
ter for 15minutes and seek medical attention. Keep out of reach of
children.
Battery
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
8of16

Controls Models: G5000S&G8000S
The engine was shipped without engine oil. DONOT START THE
ENGINEWITHOUT FILLING THE ENGINEWITH 01L. Use SAE 10W-
30 for normal conditions and SAE 5W-30 when the ambient tem-
perature is below 32° F.
Choke Rod
The choke is usedto
provide an enriched
fuel mixture when
starting acold engine.
Itcan be opened and
closed by operating
the choke rod manu-
ally. Pull the rod out
toward CLOSEDto
enrich the mixture for
cold starting. Open
once the engine is
running.
Fuel Valve Lever
Thefuel valve is lo-
cated between the fuel
tank and carburetor.
When the valve lever is
in the ON position,fuel
is allowed to flow from
the fuel tank to the
carburetor. Besure to
return the fuel valve
leverto the OFFposi-
tion after stopping the
engine.
CHOKE ROD
SED
Turn clockwise
to turn fuel valve
Oil.
Engine Switch
To start and stop the engine.
Recoil Starter
Tostart the engine, pullthe starter grip lightly until resistance isfelt,
then pull briskly.
NOTICE:
Do not al/ow the starter grip to snap back against the engine. Return it
gently to prevent damage to the starter.
The recoil starter is used to start the engine if the generator is not
equipped with a 12volt battery to operate the starter motor,or if the
battery does not contain adequate chargeto operate the starter motor.
0il Alert System
The 0il Alert system isdesigned to prevent engine damage caused by
an insufficient amount of oil in the crankcase. Before the oil level in the
crankcase canfall below asafe limit, the 0il Alert system will automati-
cally stop the engine (the engine switch will remain in the ONposition).
The 0il Alert system should nottake the place of checking the oil level
before each use. Ifthe engine stops and will not restart, checkthe
engine oil level (see page 14)before troubleshooting in other areas.
Ground Terminal
The generator ground terminal is connected to the
frame of the generator, the metal non-current-
carrying parts ofthe generator, and the ground
terminals of each receptacle.
Before using the ground terminal, consult a qualified electrician,
electrical inspector or local agency having jurisdiction for local
codes or ordinances that apply to the intended use of the genera-
tor.
EngineON/0FF/Start Switch
(electric start shown)
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
9of16

Operating the Generator Models: G5000S&GS000S
CARBONMONOXIDE GAS
Using a generator indoors CANKILLYOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO).This is a
poison you cannot see or smell. If you can smell the genera-
tor exhaust, you are breathing CO.But even if you cannot
smell the exhaust, you could be breathing CO.
NEVERuse a generator inside homes, garages, crawl-
spaces, or other partly enclosed areas. Deadly levels of
carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOTsupply enough fresh
air.
ONLYuse a generator outside and far away from windows,
doors, and vents. These openings can pull in generator ex-
haust.
Evenwhen you use a generator correctly, COmay leak into
the home. ALWAYS use a battery-powered or battery-
backup COalarm in the home.
If you start to feel sick, dizzy, or weak after the generator
has been running, move to fresh air RIGHTAWAY. See a
doctor. You could have carbon monoxide poison.
Electocution hazard - Electricity can cause DEATH or SERIOUS IN-
JURY.
• Do not operate the generator in standing water.
• This product is not safe to operate when partially or totally submerged
in water.
• Ensure proper drainage in the region surrounding this generator.
• Properly ground the generator and verify ground is in place before
each use. Grounding regulations vary by location, consult a qualified
local electrician for proper grounding instructions.
• Power cords and electrical equipment pose a risk of shock and elec-
trocution, especially if they are operated in wet conditions. Inspect all
equipment prior to every use and use only as directed by the manu-
facturer.
• Use a cord with GFCIprotection when using the power outdoors or
when moisture is present.
• Generators vibrate in normal use. During and after the use of the gen-
erator, inspect the generator as well as extension cords and power
supply cords connected to itfor damage resulting from vibration. Have
damaged items repaired or replaced as necessary. Do not use plugs
or cords that show signs of damage such as broken or cracked insula-
tion or damaged blades.
NEVERSTARTORSTOPTHEENGINEWITH DEVICESCONNECTEDTO
THEGENERATOR.
Step 1.
Ensureall electrical loads are removed from the generator. Disconnect
all the extension cords and ensurethe main breaker isin the OFFposi-
tion. Removeall flammable materials and debris from the area. Make
sure the generator islevel.
Step 2.
Checkthe oil level.
•Putthe generator on a level surface with the engine stopped.
•Removethe oil filler cap.
•Checkthe oil level. Ifthe oil level is low, fill it until the oil isover-
flowing. It will take approximately 0.9- 1.5quarts of oil depending
on the model of generator.
Ifadditional oil is need,SAE 10W-30engine oil is recommended for
mostgeneral purpose applications. In cold weather climate, use SAE
5W-30.
UPPER LEVEL
OIL FILLER HOLE
OIL FILLER CAP /
Step 3.
Make surethere isfuel in the gasoline tank. Look at the fuel level indi-
cated by removingthe fuel cap to inspectthe contents ofthe fuel tank.
Thefuel filter can also be inspected oncethe fuel cap isremoved.
Ensurethe fuel filter is clean of dirt anddebris. Tightly secure the fuel
cap after your inspection is complete.
Fuel can damage paint and plastic. Be careful notto spill fuel when
filling your fuel tank. Damage caused byspilling fuel is not covered
under warranty. Use unleaded gasoline with a pump octane rating of
86or higher. This engine is certified to operate on unleaded gasoline.
Unleaded gasoline produces fewer engine and spark plug deposits and
extends exhaust system life. Never use stale or contaminated gasoline
or an oil/gasoline mixture.Avoid getting dirt or water in the fuel tank.
FUELSTRAINERSHOULDER
DO NOT overfill the tank. Leave a 1inch air gap inthe tank. Gaso-
line is highly flammable and explosive. You can be burned or seri-
ously injured when refueling.
•Stop engine and keep heat, sparks, and flame away.
•Refuel only outdoors.
• Wipe up spills immediately.
This portable generator is nottor use with gasoline/ethanol blends
o
with over 15% ethanol.
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
10 of 16

Operating the Generator Models: G5000S&G8000S
Step 4.
Setthe fuel valve lever to the ON position by rotating it clockwise.
Step 5.
Pullthe choke lever to the CLOSEDposition. See page 7 for a diagram
ofthe choke lever.
Step 6.
Turn the generator ON/OFFswitch to the "ON" position.
Step 7.
Start the engine
1. Ifyou have an electric starter, turn the switch to the STARTposi-
tion, hold it there for 5 seconds and let it cometo rest inthe ON
position once the engine has started.
2. Ifyou are usingthe recoil starter, pull slightly onthe cord until you
feel some pressure. Onceyou feel the back-pressure building,
rapidly pull the cord.
Step 8.
Oncethe generator is running, pushthe choke lever into the OPENposi-
tion.
Step 9.
Letthe generator warm up for approximately 3minutes before applying
any electrical loads.
Step 10.
Apply loads to the generator one at atime, allowing the generator to
stabilize after you add each incremental load. Add the loads with the
largest surge power requirement first. This would include refrigerators,
air-conditioners, large motors, and pumps. Add smaller loads once the
generator has stabilized with the larger loads.
ALWAYS UNPLUGAPPLIANCES AND REMOVEALL ELECTRICAL
LOADS BEFOREREFUELING.THEN FOLLOWSTEPS2 - 10.
For power outages, permanently installed stationary generators are
better suited for providing backup power to the home. Evena properly
connected portable generator can becomeoverloaded. This may result
in overheating or stressing the generator components, possibly leading
to agenerator failure.
To determine maximum load that you may safely connectto this
generator:
1. Calculatethe maximumcontinuous power required byadding up
the running power of each appliance. Thetotal running power of
your appliances cannot exceed the maximumoutput power of this
generator.
2. Calculate the surge power by:
i) Adding up the running power of each appliance with an* and
in bold below.
ii) Multiplying the total by1.5.
iii) Adding this to the total running power calculated in step 1
above.
The surge power requirements of your appliances cannot exceed
the surge power rating of this generator.
Typical Residential Loads
Appliance Running Power
Light bulbs (each) 75Watts
Stove element (each) 1000Watts
Microwave 1500Watts
Coffeemaker 700Watts
Television 750Watts
VCR 250Watts
Computer& monitor 800Watts
Space heater 1500Watts
Washing machine 1000Watts
NGclothes dryer 750Watts
Electric clothes dryer 5500Watts
Dishwasher 1850Watts
Water heater 5000Watts
Electric furnace 5000Watts
Toaster 1200Watts
Box fan* 750Watts
Window A/C - 8000 BTU* 2400Watts
Central A/C (per ton)* 2800Watts
Furnace blower* 850Watts
2 hp well pump* 2000Watts
Refrigerato r* 1000Watts
Freezer* 1000Watts
STOPPINGTHE GENERATOR
Connecting aload larger than this generator's power rating maydam-
agethe circuit breakers, alternator and sensitive appliances.
Continuously loading this generator above 80%of its maximumoutput
power will shorten the life of the generator.
Balance the load evenly between the A andB outlets to maximizethe
output power.
Appliances with electric motors require an additional150%
power when they are starting up (indicated by an * and in bold in
the following chart ).
In normal use:
1. Turn the AC circuit breaker to the OFFposition (if applicable).
2. Disconnect all loads and extension cords.
3. Allowthe engine to run with no load for 3 minutes.
4. Turnthe engine switch to the OFFposition.
5. Turnthe fuel valve lever to the OFFposition.
6. AIIowthe generator to cool off before touching any engine or alter-
nator components. It maytake as long as 30minutes before the
generator is cool enoughto touch safely.
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
11 of 16

Maintenance Models: G5000S&G8000S
MAINTENANCE
The Importance of Maintenance
Goodmaintenance isessential for safe, economical, and trouble-free
operation. It will also help reduce air pollution.
To helpyou properly care for your generator, the following pages
include a maintenance schedule, routine inspection procedures, and
simple maintenance procedures using basic hand tools. Other ser-
vice tasks that are more difficult, or require special tools, are best
handled byprofessionals and are normally performed by aSTANLEY
technician or other qualified mechanic.
The maintenance schedule applies to normal operating conditions. If
you operate your generator under severe conditions, such as sus-
tained high-load or high-temperature operation, or useit in unusually
wet or dusty conditions, consult your servicing dealerfor recommen-
dations applicable to your individual needs and use.
Maintenance, replacement, or repair of the emission control
devices and systems may be performed by any engine repair
establishment or individual, using parts that are "certified" to
EPAstandards.
MaintenanceSchedule
Item Before each 20hrs or 50 hrs or 100 hrs or 300 hrs or
use every 3every 3every 6 every 1
month months months year
Enghle oil (Check) X
Engine Oil (Change) X
Air Cleaner (Check) X
Air Cleaner Wash X
Fuel filter Cup (Clean) X
Spark Plug (Clean) X
Spark Plug (Change) X
Optional Spark Arrestor (Clean) X
Valve Clearance (Adjust) X*
Fuel Tank and Filter (Clean) X_
Fuel Tube (Check) Every 2 yrs (replace if necessary)*
Combustion Chamber (Clean) After every 250 hrs*
Should be performed by an authorized STANLEY service center,
Replacement Parts
The emission control systems onyour STANLEYengine were designed,
built, andcertified to conform with EPAand California emission regula-
tions. We recommend the use of genuine STANLEYparts whenever
you have maintenance done. These original-design replacement parts
are manufactured to the same standards as the original parts, soyou
can be confident oftheir performance. The use of replacement parts
that are not ofthe original design and quality may impair the effective-
ness of your emission control system.
A manufacturer of an aftermarket part assumesthe responsibility that
the part will not adversely affect emission performance. The manufac-
turer or rebuilder ofthe part must certify that use ofthe part will not
result in a failure ofthe engine to comply with emission regulations.
Engine Oil Change
Drain the oil while the engine is warm to assure rapid and complete
draining.
1. Removethe drain plug and sealing washer, remove the oilfiller
cap, anddrain the oil.
2. Reinstall the drain plug and sealing washer. Tighten the plug se-
curely.
3. Refill with the recommended oil (SAE10W-30) and check the oil
level.
Dispose of used motor oil in a manner that is compatible with the envi-
ronment. Do not throw it in the trash, pour it onthe ground, or down a
drain.
Air Cleaner Service
A dirty air cleaner will restrict air flow to the carburetor. To prevent
carburetor malfunction, service the air cleaner regularly. Service more
frequently when operating the generator in extremely dusty areas.
NOTICE:
Never run the generator without the air filter. Rapidengine wear will
result.
1. Unsnapthe air cleaner cover clips, removethe air cleaner
cover, and removethe element.
2. Wash the air cleaner element in a solution of household de-
tergent and warm water, then rinse thoroughly, or wash in
nonflammable or high flashpoint solvent. AIIowthe air cleaner
elementto dry thoroughly.
3. Soak the air cleaner element in clean engine oil and squeeze
out the excess oil. The engine will smoke during initial startup
iftoo muchoil is left inthe air cleaner element.
4. Reinstallthe air cleaner element and the cover.
Fuel Filter Cleaning
Thefuel filter cup/screen prevents dirt which may be in the fuel
from entering the carburetor. Thefuel filter should be inspected
and cleaned on a regular basis. For best results, clean the filter
with gasoline and atoothbrush or blowthe debris out ofthe filter
with air pressure.
Spark Plug Service
Inorder to service the spark plug, you will need aspark plug
wrench. Recommended spark plugs: BPR5ES(NGK) and W16EPR-
U(DENSO).To ensure proper engine operation, the spark plug
mustbe properly gapped andfree of deposits.
If the engine has been running, the muffler will be very hot. Be
careful not to touch the muffler.
1. Removethe spark plug cap.
2. Cleananydirtfrom around the spark plug base.
3. Useaspark plug wrench to removethe spark plug.
PLUG CAP _PARK PLUG WRENCH
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
12 of 16

Maintenance Models: G5000S&G8000S
Visually inspect the spark plug. Discard
it if the insulator is cracked, chipped or
fouled.
Measure the plug gapwith a feeler
gauge. Correct as necessary bycare-
fully bending the side electrode. The
gap should be: 0.028to 0.031in (0.70to
0.80mm)
6. Checkthat the spark plug washer is in good condition, and thread
the spark plug in byhand to prevent cross-threading.
7. After the spark plug is seated, tighten with a spark plug wrench to
compressthe washer.
If installing a new spark plug,tighten 1/2turn after the spark plug seats
to compressthe washer. If reinstalling a used spark plug,tighten 1/8to
1/4turn after the spark plug seats to compress the washer.
NOTICE:
The spark plug must be securely tightened. An improperly tightened
spark plug can becomevery hot and could damagethe engine. Use
only the recommended spark plugs or equivalent.
Optional Spark Arrestor Maintenance
Ifthe generator has been running,the muffler will be very hot.Allow it
to cool before proceeding. Thespark arrester mustbe serviced
every 50 hours to keep it functioning as designed.
Cleanthe spark arrester as follows:
1. Loosenthe screw bythe exhaust port of the muffler and remove
the spark arrester.
2. Usea brush to removecarbon deposits from the spark arrester
screen. Inspect the screen for breaks or tears and replace it if
necessary.
3. Install the spark arrester in the reverse order of removal.
SPARK ARRESTER SCREEN
\\\\
SCREW
SPARKARRESTOR
Optional Starter Motor Fuse Replacement
Ifthe fuse is blown, the starter motor won't operate. Turnthe engine
switch to the OFFposition. Removethe fuse holder cover and replace
the fuse. The specified fuse is 10A.
NOTICE:
Never usea fuse with a
different rating from that
specified. Serious damage
to the electrical system or
fire may result.
FU,_ HOLDER
lm "
TRANSPORTING
When transporting the generator, turn the engine switch and the fuel
valve OFF.Keepthe generator levelto preventfuel spillage. Fuelvapor
or spilled fuel may ignite.
Take care notto drop or strike the generator when transporting. Donot
place heaw objects on the generator. When transporting the generator
byloading it onto avehicle, secure to the generator frame as shown.
Contact with a hot engine or
exhaust system can cause
serious burns or fires. Let the
engine cool before transport-
ing or storing the generator.
STORING
Before storing the unit for an extended period:
1.Be surethe storage area isfree of excessive humidity and dust.
2.Service according to the table below:
STORAGE TIME Recommended Service Procedure to prevent hard starting:
1to 2 months Fill with fresh gasoline and add gasoline stabilizer*,
2months to 1year Fill with fresh gasoline and add gasoline stabilizer*,
Drain the carburetor float bowl,
Fill with fresh gasoline and add gasoline stabilizer*,
Drain the carburetor float bowl.
1year or longer Remove the spark pklg, Put a tablespoon of engine oil into the cylinder, Turn the engine
slowly with the recoil sta rter to distribute the oil, Reinstall the spark plug,
Change the engine oil
After removal from storage, drain the stored gasoline into a suitable container, and fill with
fresh gasoline before starting,
Use gasoline stabilizers that are formulated to extend storage life, Contact your authorized STANLEY generator dealer
for conditioner recommendations,
Storage Preparation
1. Drainthe carburetor by loosening the drain screw. Drain the gaso-
line into asuitable container. Place 4ounces of fuel stabilizer in
the fuel tank.
2. Changethe engine oil (page 10).
3. Removethe spark plug,and pour about atablespoon of clean
engine oil intothe cylinder. Turn the engine several revolutions
slowly with the recoil starter to distribute the oil, then reinstall the
spark plug.
4. Slowly pullthe starter grip until resistance isfelt. Atthis point,the
piston is coming up on its compression stroke and boththe intake
and exhaust valves are closed. Storing the engine inthis position
will help to protect itfrom internal corrosion.
Gasolineis extremely flammable and is explosive under certain
conditions. Perform this task in a well-ventilated area with the
engine stopped. Do not smoke or allow flames or sparks inthe
area during this procedure.
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
13 of 16

Troubleshooting Models: G5000S&G8000S
Symptom:
Engine won't start
Recoil is hard to pull
Engine starts, but then shuts off
after running for short time
Engine runs: rough/vibrating/
oscillating
Rev. 4/2011
Potential Causes
Fuelvalve off/out offuel
EngineSwitch in off position
Spark arrestor clogged
Chokeis open
Oil leveltoo low
Oilfloat stuck in shipment
Fuelfilter is dirty
Fuelis contaminated
Spark plug boot off/loose
Spark plug fouled or failed
Carburetor clogged
Spark arrestor clogged
Engineflooded with fuel after storage with fuel
valve in on position
Valve clearance too large
Remove/Cleanspark arrestor
Oil leveltoo low
Fuelvalve off/out offuel
Spark plug fouled or failed
Remove/Cleanspark arrestor
Solution
Filltank with fuel andturn fuel valve on
Turn engine switch to on position
Removespark arrestor, clean and replace.
Close choke by pulling choke handle out.
Openchoke after starting.
Fill oilto top of opening with recommended
grade of oil.
Fill oilto top of opening, disconnectthe yel-
low wire from the low oil level switch. The
switch is located on the engine abovethe
oil drain plug. It is a small gold colored box
with ayellow and a blackwire.
Startthe unit and run itfor one hour mini-
mum - this will get enough movement of hot
oil to free thefloat if this isthe cause.
Re-attach the yellow wire and run the unit.
Checkfor fuel flow to carburetor by remov-
ing drain screw. Cleanor replace fuel filter.
Drainfuel tank and carburetor. Replace or
clean filter and carburetor float bowl. Fill
tank with clean fuel.
Press spark plug bootfirmly on spark plug.
Removespark plug, clean or replace
Removefloat bowl and clean components
and jets. Replace carburetor if varnish or
gum hasaccumulated from improper stor-
age.
Remove,clean and replace.
Removespark plug and slowly pull recoil to
discharge excess fuel. Cleanand re-install
spark plug.
Restexhaust valve clearance to .008",call
customer help line.
Remove,clean and replace.
Fill oilto top of opening with recommended
grade of oil.
Filltank with fuel andturn fuel valve on
Removespark plug, clean or replace
Remove,clean and replace.
The choke is not open Pushchoke lever in.
Overloading generator Disconnect some appliances
Air filter is dirty Cleanair filter
Fuelfilter is dirty Checkfor fuel flow to carburetor by remov-
ing drain screw. Cleanor replace fuel filter.
Fuelis contaminated Drainfuel tank and carburetor. Replace or
clean filter and carburetor float bowl. Fill
tank with clean fuel.
14 of 16
STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.

Troubleshooting Models: G5000S&G8000S
Symptom:
Engine runs, low speed, bogs
down under load or does not
maintain 60Hz
Engine oil leak
Potential Causes Solution
Remove/Cleanspark arrestor Remove,clean and replace.
Chokeis not open Pushchoke lever in
Overloading generator Disconnect some appliances/devices
Air filter isdirty Cleanair filter
Fuelfilter isclogged
Fuelfilter isdirty
Fuelis contaminated
Oilfill cap loose or cross threaded
Oil drain plug loose
Debris under oil drain plug gasket Removedrain plug and debris. Inspect gas-
ket for damageand replace if damaged.
Tighten crankcase bolts
Tighten bolt
Oil seals failed, call customer help line
Loosecrankcase bolt(s)
Valve cover bolt loose
Oil leakingfrom shaft
Shut-off valve loose
Contaminateswill clog filter, not allowing
fuel to getto engine
Checkfor fuel flowto carburetor by remov-
ing drain screw. Cleanor replace fuel filter.
Drainfuel tank and carburetor. Replace or
clean filter and carburetor float bowl. Fill
tank with clean fuel.
Wipe all oil off unit, remove bothoil fill caps,
inspect and replace. Tighten securely.
tighten bothdrain plugs
Fuel leak at tank shut-off Tighten nut on shut-off valve/replace shut-
off valve
Fuel leaking out of carburetor Tighten fuel drain screw
Engine runs, Volt meter shows 0
Volts, no power to outlets
Engine runs and volt meter
shows 240VACbut no power
goes to connected devices
Fueldrain screw loose
Carburetor float seat not seating
Breaker tripped
Disconnected or damaged wiring inside unit
Faultyextension cord/power strip
Breaker or GFCItrippedon extension cord or
power strip
Engine speedlow or highVoltage too high/low
Alternator damaged
Speed screw damaged or bent
Alternator phase isdamaged
Flushwith clean fuel
Disconnect all loads andturn breaker to off
and backto on to reset.
Callcustomer helpline
Use different power strip or extension cord
Restbreaker and remove loadsfrom power
strip
Verify frequency reading is 58Hzto 62Hzon
meter. Callcustomer helpline if frequency is
above 58Hz.See engine speedtrouble-
shooting if engine speed is below 58Hz.
Callcustomer helpline
Callcustomer helpline
Voltage is 120VAC on 1 phase Callcustomer helpline
but too high/low on other phase
Rev. 4/2011 STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.
15 of 16

Limited Warranty & Service Models: G5000S&G8000S
LENCTH OFWARRANTY:*
PRODUCTS COVEREBBY THIS WARRANTY: (FROM THE DATE OF0RIBINAL RETAIL PURCHASE)
NONCOMMERCIAL/ COMMERCIAL RENTAL
NONRENTAL
Engine 24 months /200hours 6 months /200hours 3 months /200 hours
Battery 3 months 3 months 3 months
Alternator 24 months /200hours 6 months /200hours 3 months /200 hours
Electrical and Frame Components 24 months /200hours 6 months/200 hours 3 months /200 hours
EmissionControls 24 months 24months 24months
*LENGTH OFWARRANTY: All warranty coverage except emission controls expires when the operating hours exceed 200hours.
TO QUALIFYFORTHIS WARRANTY:
The product must be purchased in the United States from a dealer authorized by GXi Outdoor Power, LLC to sell those products. This warranty applies to first retail
purchaser/owner during the applicable warranty time period. SAVEYOURPROOFOFPURCHASERECEIPT.
WHAT STANLEY POWER EQUlPMENTWlLL REPAIROR REPLACEUNDERWARRANTY:
STANLEYwill repair or replace, at its option, any part that is proven to bedefective in material or workmanship under normal use during the applicable warranty
time period subject to the exclusions stated herein. This warranty is void ifthe owner fails to follow the prescribed maintenance and operating procedures de-
scribed in this manual. This specifically refers to ensuring routine oil changes are made, that fuel stabilizer is used for long-term storage, that the generator is not
overloaded, and that the generator loads are distributed evenly between the A and Boutlets. Dirty carburetors, spark plugs, air filters, fuel filters, andfreight or
handling damage are not covered under warranty.
STANLEYhas the right to recover warranty administration costs from the owner if the root cause ofthe malfunction was found to be other than defective material or
workmanship. In particular, this warranty does not cover: contaminants in the fuel or oil; damage caused by not following the prescribed warnings and operating
practices; failure to follow proper maintenance and storage procedures; andphysical damage due to shipping or handling or storage. Damageto the generator that
occurs as a result of connecting a STANLEYgenerator to household wiring without the use of a ULapproved transfer switch device that is connected tothe home or
business and grounded as per applicable local electrical codes, is not covered by this warranty.
Warranty repairs will bemade without charge for parts and labor for the first year. After the first year, this limited warranty covers the costs of replacement parts
only.
TO OBTAIN WARRANTY SERVICE:
You must take the STANLEYPower Equipment product, accessory, replacement part, apparel or the power equipment on which the accessory or replacement part is
installed, and proof of purchase, atyour expense, to any STANLEYPower Equipment service location inthe United States, who is authorized to service that product,
during the service location's normal business hours. Ifyou are unable to obtain warranty service, or are dissatisfied with the warranty service you receive, take the
following steps: First, contact the manager of the service center involved; normally this will resolve the problem. However, if you should require further assistance,
EXCLUSIONS:
THISWARRANTY DOESNOTEXTENDTOPARTSAFFECTEDORDAMAGED BYACCIDENTAND/OR COLLISION,NORMALWEAR, FUELCONTAMINATION, USEIN AN
APPLICATIONFORWHICH THEPRODUCTWAS NOT DESIGNEDORANY OTHERMISUSE,NEGLECT,INCORPORATIONORUSEOF UNSUITABLEATTACHMENTS OR
PARTS,UNAUTHORIZEDALTERATION,ORANY CAUSESOTHERTHAN DEFECTSIN MATERIALORWORKMANSHIP OFTHEPRODUCT.Consumable parts such as oil,
spark plugs, filters, carburetors, are not covered by this warranty.
DISCLAIMER OFCONSEQUENTIAL DAMAGE AND LIMITATION OFIMPLIED WARRANTIES:
STANLEYDISCLAIMS ANY RESPONSIBILITYFORLOSSOFTIME ORUSEOFTHEPRODUCT,TRANSPORTATION,COMMERCIALLOSS,ORANY OTHERINCIDENTAL
ORCONSEQUENTIALDAMAGE. ANY IMPLIEDWARRANTIES ARE LIMITEDTOTHEDURATION OFTHISWRITTEN LIMITEDWARRANTY.
This warranty is void if the manufacturing date and the serial number onthe equipment has been removed or the equipment has been modified.
EMISSION CONTROLSYSTEM INFORMATION
The U.S. and California Clean Air Acts
EPAandCalifornia regulations require all manufacturers to furnish written instructions describing the operation and maintenance of emission control systems. The
following instructions and procedures must befollowed in order to keepthe emissions from your STANLEYengine within the emission standards. Maintenance,
replacement, or repair ofthe emission control devices and systems may be performed by any engine repair establishment or individual, using parts that are
"'certified" to EPAstandards.
The emission control systems onyour STANLEYengine were designed, built, and certified to conform with EPAregulations. We recommend the use of genuine
STANLEYparts whenever you have maintenance done. Theseoriginal-design replacement parts are manufactured to the same standards asthe original parts, so
you can beconfident of their performance. The use of replacement parts that are not ofthe original design andquality may impair the effectiveness of your emission
control system. Amanufacturer of an aftermarket part assumes the responsibility that the part will not adversely affect emission performance. The manufacturer or
re-builder ofthe part must certify that use ofthe part will not result in afailure ofthe engine to comply with emission regulations.
Emission controls are covered by this warranty for all uses for a period of 2years from original retail purchase date, this coverage extends to subsequent owners of
the product with proof of original purchase. For emissions warranty service call 1-800-393-0668or e-mail [email protected].
Rev. 4/2011 16 of 16
STANLEY is a registered trademark ofThe Stanley Works or its affiliates and are used under license by GXiOutdoor Power LLC.
No part of this publication can be printed or copied without written permission.