20080303 Model # AC-G0003 5500 Surge Watts / 5000 Running Watts PORTABLE GENERATOR INSTRUCTION MANUAL Thank you for purchasing this high quality ACDelco Model AC-G0003 5500 Surge Watts / 5000 Running Watts Portable Generator. This manual provides important information on properly operating and maintaining this ACDelco Model AC-G0003 5500 Surge Watts / 5000 Running Watts Portable Generator. Every effort has been made to ensure the accuracy of this manual.
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ACDelco Model AC-G0003 5500 Surge Watts / 5000 Running Watts Portable Generator FEATURES: • 5500 Surge Output • 5000 Running Watts • 120/240 Volt Operation • 13 HP Engine, 4 Stroke OHV • Air Cooled • 6.5 Gal.
TABLE OF CONTENTS RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS.................................................................................................... 5 IMPORTANT SAFETY INSTRUCTIONS................................................................................................................................. 6 PACKAGE CONTENTS.........................................................................................................................................................
RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS What You Need to Know About Safety Instructions Warning and Important Safety Instructions appearing in this manual are not meant to cover all possible conditions and situations that may occur. Common sense, caution and care must be exercised when operating or cleaning tools and equipment. Always contact your dealer, distributor, service agent or manufacturer about problems or conditions you do not understand. This is the safety alert symbol.
Notice Regarding Emissions: Engines certified to comply with California and U.S. EPA emission regulations for SORE (Small Off Road Equipment) are certified to operate on regular unleaded gasoline and may include the following emission control systems: Three-Way Catalyst (TWC) (if equipped), and Engine Modifications (EM). Legal Requirements: Federal and/or State Occupational Safety and Health Administration (OSHA) regulations, local codes, and/or ordinances may apply to the intended use of this generator.
Powerful Voltage: This generator produces powerful voltage, which can result in electrocution. • ALWAYS ground this generator before using it. (See “Ground the Generator” section in this manual). • Only electrical devices should be plugged into this generator, either directly or with an extension cord. NEVER connect a building electrical system to this generator without a qualified electrician. Such connections must isolate generator power from utility power and comply with local electrical laws and codes.
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In addition to the previously described safety information, familiarize yourself with all safety and hazard placards on this generator.
PACKAGE CONTENTS The following items are supplied with this ACDelco Model AC-G0003 5500 Surge Watts / 5000 Running Watts Portable Generator. Verify that all items are included. STOP! If there are missing items, call 1-866-460-9437, Monday - Friday, 8 AM - 4 PM Central Time for customer service. DO NOT RETURN THIS GENERATOR TO THE RETAILER.
GENERATOR COMPONENTS Observe the locations and functions of the various components and controls of this generator. (1) 120/240 Volt AC Outlet - Used for connecting electrical devices that run on 120 and/or 240 Volt, 60 Hz, single phase, AC current. (2) Ground Terminal - Used for connecting grounding wires to properly ground this generator. (3) 120 Volt AC Outlet - Used for connecting electrical devices that run on 120 Volt, 60 Hz, single phase, AC current.
PREPARING THE GENERATOR FOR USE Using this Generator for the First-Time STOP! The following section describes the required steps for preparing this generator for the first use. Failure to correctly perform these steps can damage this generator and/or shorten its life. If still unsure about how to perform any of these steps after reading this section, call 1-866-460-9437 Monday - Friday, 8 AM - 4 PM Central Time for customer service.
Step 2 - Add Gasoline Gasoline and gasoline fumes are highly flammable and explosive. Handling fuel can result in serious injury or burns. • Do not fill the fuel tank near a heat, sparks or an open flame. Keep gasoline away from appliance pilot lights, barbecues, electric appliances, power tools, etc. • Do not overfill the fuel tank. Always check for fuel spills and immediately wipe them up. Spilled fuel is a fire hazard and causes environmental damage.
Step 3 - Ground the Generator Failure to properly ground this generator can result in electrocution. Ground this generator by tightening the grounding nut against a grounding wire as illustrated in Figure 3. A No. 12 AWG (American Wire Gauge) stranded copper wire is generally an acceptable grounding wire. The other end of this grounding wire should be connected to a copper or brass grounding rod that is driven into the earth. Grounding codes can vary by location.
Step 2 - Verify Gas Level Before starting this generator, verify that there is sufficient gasoline in the fuel tank. The fuel gauge, located on the top of this generator, indicates the gas level currently in the fuel tank. If necessary, add fresh unleaded gasoline with an octane rating of 87 or higher according to “Step 2 - Add Gasoline” of the “Using this Generator for the First Time” section of this manual. Model AC-G0003 Fuel Tank Capacity (gals /L) Model AC-G0003 Fuel Type 6.5 / 24.
6. Slowly pull on the recoil starter handle, shown in Figure 6, until a slight resistance is felt. Then pull briskly to start the engine. Gently return the cord into the generator to avoid damage to the starter or housing. Never allow the cord to snap back. 7. If the engine fails to start, repeat step 6. NOTE: After repeated attempts to start the engine, consult the troubleshooting guide before attempting again. If problems persist, call 1-866-460-9437, Monday - Friday, 8 AM - 4 PM Central Time. 8.
The total running wattage requirement of the electrical devices connected to a generator should not exceed the rated wattage of the generator itself. To calculate the total wattage requirement of the electrical devices to be connected, look up the rated (running) wattage of each device and add these numbers together to find the total wattage that all of the devices together will draw from the generator.
Connect only electrical devices that are in good working order. Faulty devices or power cords present the risk of electrical shock. Immediately turn off and disconnect any device that commences to operate abnormally, sluggish or abruptly stops. Determine if the problem was the device or the rated load capacity of this generator has been exceeded. NOTE: Plug appliances into the correct outlet. Connect standard 120 Volt, single phase, 60 Hz loads to the 120 Volt outlet.
DC Usage The DC outlet is only for recharging 12 Volt automotive-type batteries. Do not connect any other device to this outlet. Use this generator only for recharging 12 Volt batteries. NEVER attempt to jumpstart a car with this generator. Failing to use the correct procedure can cause a battery to explode, seriously injuring anyone nearby. Keep heat, sparks, flame and smoking materials away from the battery. To connect 12 Volt batteries to the DC outlet: 1.
MAINTENANCE/CARE Proper routine maintenance of this generator is essential for safe, economical, and trouble-free operation. It will help prolong the life of this generator as well as help reduce air pollution. Perform maintenance checks and procedures according to the schedule in Figure 10. STOP! If you have questions about any maintenance procedures described in this manual, call 1-866-460-9437 , Monday - Friday, 8 AM - 4 PM Central Time.
Figure 11 - Checking the Oil Changing/Adding Oil The oil level in this generator should be checked before each use. (See Figure 10.) When the oil level is low, add oil until the level is sufficient to operate this generator. The oil capacity for this ACDelco Model AC-G0003 5500 Surge Watts / 5000 Running Watts Portable Generator engine is 1.2 Qt. (38 fluid oz.) (1.13 L).
Figure 12 - Draining Oil Figure 13 - Adding Oil Air Filter Maintenance Routine maintenance of the air filter helps maintain proper airflow to the carburetor. Occasionally verify that the air filter is free of excessive dirt. The air filter will require more frequent cleaning when operating this generator in extremely dusty areas. 1. Unhinge the clasps at the top and bottom of the air filter cover as shown in Figure 14. 2. Remove the sponge-like elements from the casing. 3.
3. Using a rag or brush, clean the cup of all sediment. 4. Reinstall the fuel filter cup. Figure 15 - Removing the Fuel Filter Cup Spark Plug Maintenance The spark plug is essential for proper engine operation. The spark plug should be intact, free of deposits, and properly gapped. A bad or incorrectly installed spark plug can cause engine damage. Model AC-G0003 Spark Plug Type Model AC-G0003 Spark Plug Gap (in/mm) F6TC 0.028-0.031/0.7-0.8 To inspect the spark plug: 1.
Figure 16 - Removing the Spark Plug Emptying the Fuel Tank Figure 17 - Measuring the Spark Plug Gap To store this generator for extended time, drain the gasoline from the fuel tank. To drain gasoline from this generator: 1. Turn the fuel valve to the “off” position. 2. Remove the fuel filter cup. (See “Fuel Filter Cup Cleaning” earlier in this section.) 3. Empty the fuel filter cup of any fuel. 4. Place a receptacle underneath this generator to catch gasoline as it drains. 5.
TROUBLESHOOTING IMPORTANT: If trouble persists, call our customer help line at 1-866-460-9437, Monday - Friday, 8 AM - 4 PM Central Time. Symptom Engine will not start. Cause Engine switch is set to "off." Fuel valve is turned to "closed." Choke is open. Engine is out of gasoline. Engine is filled with contaminated and/or old gasoline. Spark plug is dirty. Spark plug is broken. Generator is not on level surface. Engine runs but there is no electrical output.
SPECIFICATIONS ACDelco Model AC-G0003 5500 Surge Watts / 5000 Running Watts Portable Generator Generator Type Brush, Revolving Magnetic Field, Self Exciting, 2-Pole, Single Phase AC Output Rated Wattage (W) Surge Wattage (W) Rated Voltage (V) Rated Amperage 5000 5500 120/240 20.5A+20.5A at 120 V 20.5A at 240 V 60 Single Rated Frequency (Hz) Phase DC Output Voltage (V) Circuit Breaker Amperage (A) 12 8.3 Dimensions and Weight Dimensions (in.) Gross Weight (lbs) Net Weight (lbs) 26.8 Length, 20.
EXPLODED VIEW AND PARTS LIST Model AC-G0003 5500 Surge Watts / 5000 Running Watts Portable Generator 27
PARTS LIST Item Part Qty Description Item Part Qty Description 1 188FD 1 Gasoline engine 50 37880 1 Low oil indicator 2 41100 1 Frame complete 51 37310/2.8GF-3 1 Control panel 3 41310/4GF-3 2 Bottom rubber mount A 52 37320 1 Block panel 4 41320/2.8GF-3 2 Bottom rubber mount B 53 GB5787-86 10 Bolt 6 mm × 12 mm 5 GB6177.
MODEL AC-G0003 5500 SURGE WATTS / 5000 RUNNING WATTS PORTABLE GENERATOR WIRING DIAGRAM Model AC-G0003 5500 Surge Watts / 5000 Running Watts Portable Generator 29
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WARRANTY LIMITED WARRANTY for ACDelco Generators from New Buffalo Corporation. Remember to save your receipt and to accurately fill out and mail your product registration card. You must provide proof of purchase for all warranty work. ACDelco generators are warranted to be free from defects in materials and workmanship for a period of one (1) year from date of original purchase. Generators used for Commercial or Rental use have a warranty period of 90 days from date of original purchase.
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PORTABILITY KIT INSTALLATION The manufacturer recommends when using your ACDelco generator for recreational or utility functions that you properly install the Portability Kit included with your generator purchase. All ACDelco generator models include a Portability Kit for optional installation. Portability Kits are not required for ACDelco generators to properly operate. Model # AC-G0003 5500 Watt Generator Step 1 1.
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