Generac Gn - 410, GN - 320, Gn - 360 User Manual

4.5 (6)
GENERAC®ENGINES
Overhead Valve Industrial
Owner’s Manual
Manual No.A8927
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Revision 0 (11/16/98) Printed in U.S.A.
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RULES FOR SAFE OPER ATION

If you don’t understand any portion of this manual, contact Generac for a demonstration of actual starting, operating and servicing procedures.
Throughout this publication and on tags and decals affixed to the generator, DANGER,WARNING and CAUTION blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These safety warnings cannot eliminate the hazards that they indicate. Strict compliance with the special instructions while performing the service plus “common sense” are major measures to prevent accidents.
The following definitions apply to DANGER, WARNING, CAUTION and NOT E blocks found throughout the manual.
Study these RULES FOR SAFE OPERATION carefully before operating or servicing this equipment. Become familiar with the OWNER’S MANUAL and with the engine.The engine can operate safely, efficiently and reliably only if it is properly operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.
Generac cannot possibly anticipate ever y possible circumstance that might involve a hazard. The warnings in this manual and on tags and decals affixed to the equipment, are therefore, not all­inclusive.If you use a procedure, work method or operating technique Generac does not specifically recommend, you must satisfy yourself that it is safe for you and others.You must also make sure the procedure, work method or operating technique that you choose does not render the engine to be unsafe.
These safety symbols indicate the following:
DANGER: After this heading you can read handling, installing, operating or servicing instructions that, if not strictly complied with, will result in personal injury.
WARNING: After this heading you can read handling, installing, operating or servicing instructions that, if not strictly complied with, may result in personal injury.
CAUTION: After this heading you can read instructions for handling, installing, operating or servicing the g enerator that, if not strictly complied with, may result in damage to equipment and/or property.
NOTE: After this heading you can read explanatory statements that
require special emphasis. These symbols indicate the following:
Points out important safety infor mation and, if not followed, could endanger personal safety and/or property of yourself and others.
P
otential explosion hazard.
DANGER: Do not tamper with the engine governed speed. High operating speeds are dangerous and increase the risk of personal injury or damage to the equipment. Operating at low speeds with heavy load may shorten the engine’s life.
BEFORE OP ERATING
• Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE. Do not permit smoking, open flames, sparks or
heat in the area while handling gasoline. Avoid spilling gasoline on a hot engine. Comply with all of the laws regulating storage and handling of gasoline.
• Store gasoline and other fuels only in containers designed and approved for the storage of such materials.
• Pressure can build up in the fuel tank. Loosen the fuel tank slowly to relieve any pressure in the tank.
• Add gasoline and other fuels in a clean, well-ventilated area. Wipe up any spilled gasoline immediately. If gasoline has been spilled, let it dry completely before starting the engine.
Potential fire hazard.
Potential electrical shock hazard.
WWAARRNNIINNGG::
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
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• Do not overfill the fuel tank.Always allow room for fuel expansion. If the tank is overfilled, the fuel can overflow onto a hot engine and cause a FIRE or an EXPLOSION.
• Allow at least two (2) feet of clearance on all sides of the engine, even while operating it outdoors, or you could damage the engine.
• Thoroughly inspect the engine for loose or damaged parts before each use.Do not use the engine until adjustments or repairs are made.
• Check the oil level in the engine before each use.
• Inspect the engine periodically. Repair or replace all damaged or defective parts immediately.
• Inspect fuel system frequently for leaks or damage.Repair or replace any damaged or leaking component immediately. Never attempt to change, alter or modify the engine fuel system in any way that might affect safety or compliance with applicable codes and standards.
WHILE OP ERATING
This engine was designed and manufactured for specific applications. Do not attempt to modify the equipment or use it for any application for which it was not designed.
• Engine exhaust gases contain DEADLY carbon monoxide gas.This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Operate this equipment only in the open air where adequate ventilation is available.
• Do not insert any object through the cooling slots of the engine.You could damage the equipment or injure yourself.
• Do not operate the engine faster than the speed necessary to operate the equipment. Do not run the engine at high speed when not operating the equipment.
• This engine requires an adequate flow of cooling air for its continued proper operation. Never operate the equipment inside any room or enclosure where the free flow of cooling air into and out of the equipment might be obstructed. Without sufficient cooling air flow, the engine quickly overheats, damaging the engine or nearby property.
• Do not smoke around the engine.Wipe up any fuel or oil spills immediately. Never leave oily or fuel soaked rags around the engine. Keep the area around the engine clean and free of debris.
• Keep hands, feet, clothing, etc., away from moving parts of this engine.
• Never operate the engine (a) in the rain; (b) in any enclosed compartment; (c) if the engine speed changes; (d) if the engine sparks; (e) if flame or smoke is obser ved while the engine is running.
• Never wor k on this engine or handle any electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRIC SHOCK will result.
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This engine meets the 1998 and later California emissions regulations.To ensure that your engine continues to meet these regulations, refer to the following information and instructions in this owner’s manual.
SERVICE IN FORMATION
Service on this engine within and after the warranty period can be performed by any authorized service dealer.Ser vice technicians are factory trained and capable of handling all service needs.
When contacting an authorized service dealer or the factory about parts and ser vice, always supply the complete model number and serial number of your unit as given on its data plate decal.
The warranty and replacement parts for this engine are included in the owner’s manual.
When ordering engine components, you must provide the authorized service dealer with the engine identification number, which is located on the engine identification decal. See the illustration below for the location of the decal.

TABLE OF CONTENTS

RULES FOR SAFE OPERATION ..........................................2-3

GENERAL INFORMATION ....................................................4-5

Service Information ..................................................................4
Engine Identification Decal Location ........................................4
Oil and Fuel Information............................................................5
OPERATION ..........................................................................6-7
Before Starting the Engine........................................................6
Starting the Engine ................................................................6-7
Stopping the Engine..................................................................7
Low Pressure Shutdown System ..............................................7
MAINTENANCE ..................................................................8-13
General Maintenance Recommendations ................................8
Service and Adjustments ....................................................8-10
Carburetor Adjustments ..........................................................11
Checking/Adjusting Valve to Rocker Ar m Clearance ..............11
Retorquing Head Bolts ......................................................11-12
Maintenance Schedule............................................................12
Storage Instructions ................................................................13
Specifications ..........................................................................13
Generac Corporation
Eng. Identif. No. XXXXXX Displacement XXXXXX
PARTS LISTS & EXPLODED VIEWS ..............................14-21
WARRANTIES ..................................................................22-24
California Emission Control Warranty Statement ....................22
Emission Control System Warranty ........................................23
Generac Engine Warranty ........................................Back Cover
Decal
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OIL AN D FU EL I NFOR MATION
NOTE: BE SURE TO READ THESE INSTRUCTIONS
CAREFULLY BEFORE ATTEMPTING TO START OR OPERATE THIS EQUIPMENT. Using old or improper oil or fuel can cause engine damage.
CAUTION: Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in engine damage.
RECOMMENDED OI L T YP E
Using the proper type and weight of oil in the crankcase is extremely important. Check the oil before each use and change the oil regularly. Failure to use the correct oil, or using dir ty oil, can cause premature engine wear and failure.
The recommended oils include the following:
• During summer months: SAE 10W-30,
• During winter months: SAE 5W-20 or 5W-30. DO NOT USE
SAE 10W-40.
The crankcase oil capacity is about 1500 ml (51 oz.) with the oil filter.Without the filter, the oil capacity is 1350ml (46 oz.). Use no special additives.
RECOMMENDED FUEL TYPE
Use clean, fresh, regular UNLEADED gasoline with this engine.
CAUTION: Do not overfill the fuel tank. Always allow room for fuel expansion.
WARNING: NEVER FILL THE FUEL TANK INDOORS. OR WHEN THE ENGINE IS RUNNING OR HOT. DO NOT LIGHT A CIGARETTE OR SMOKE WHEN FILLING THE FUEL T ANK.
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OPER ATION AND MAI NTENANCE
It is the owner’s/operator's responsibility to perform all safety checks; to make sure that all maintenance for safe operation is performed promptly; and to have the engine checked by an authorized dealer periodically. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.
Proper maintenance and care of your engine assures a minimum number of problems and keeps your operating expenses at a minimum. See your authorized dealer/distributor for service aids and accessories.
BEFOR E STARTI NG TH E ENGI NE
Perfor m the following tasks before trying to start the engine:
ADDING ENGINE OIL
1. Remove the yellow oil fill cap from the crankcase (Figure 1).
2. Add engine oil until the oil level is to the point of overflowing.
STARTI NG THE ENGI N E
1. Open the fuel shut-off valve, if so equipped.
2. If your unit is equipped with the IDLE/CONTROL feature, locate the IDLE/CONTROL ON/OFF SWITCH on the control panel, and set it to the OFF (O) position.
3. Locate the RUN/STOP SWITCH (Figure 2) next to the engine cylinder head and push it to RUN.
Figure 2 — RUN/STOP SWITCH
CHOKE
OHVI
RUN / STOP SWITCH
LOW OIL LIGHT
LOWOIL
Figure 1 — Oil Fill Cap
Oil Fill Cap
CHECKING ENGINE OIL
1. Check the engine oil level before starting the engine each time after the initial start. If the oil level is below the point of overflowing, fill to the proper level.
ADDING FUEL
1. Fill the fuel tank using clean, fresh UNLEADED gasoline.
If your engine is equipped with a choke, use the following instructions:
1. Place the choke lever in the FULL CHOKE POSITION (Figure 3) by sliding it to the left (towards the valve cover), in the direction indicated by the arrow.
Figure 3 — Choke Position
CHOKE LEVER
CHOKE
OHVI
2. Grasp the recoil handle (Figure 4) and pull it slowly until you feel slight resistance, then PULL QUICKLY.
LOWOIL
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A If the engine F AILS TO START , go to Step 3. B. If the engine STARTS, go to Step 4.
Figure 4 — Recoil Handle
Recoil Handle
3. Move the choke lever to the HALF CHOKE POSITION, and pull the recoil handle (Figure 4) two (2) times.
If the engine STILL F AILS T O ST ART, repeat
Steps 1-3.
4. Move the choke lever to the RUN POSITION by sliding it to the right (away from the valve cover and under the arrow).
STOPPI NG TH E ENGI NE
1. Remove the load on the engine, and let it run for 30 seconds.
2. Turn off the engine by moving the RUN/STOP SWITCH to the STOP position.
3. Close the fuel shut-off valve, if so equipped.
LOW PR ESSURE SH UTDOWN SYSTE M
The engine is equipped with a low oil pressure sensor that shuts down the engine automatically when the oil pressure drops below 8 psi ). If the engine shuts down by itself and the fuel tank has enough gasoline, check the engine oil level.
INITIAL STARTU P
A delay built in the shutdown system allows oil pressure to build during starting. The delay allows the engine to run for about 10 seconds before sensing oil pressure.
SENSING LOW PRESSURE
If the system senses low oil pressure during operation, the engine shuts down. As the system shuts down, the low oil light comes ON (see Figure 2, page 6). H ow ever, once the engine stops rotating, this light will go OFF.
5. Allow the engine to warm up for two (2) minutes before using the equipment.
RESTARTI NG TH E ENGI NE
If you try to restart the engine within (five) 5 seconds after it shuts down, the engine may NOT star t. The system needs 5 to 10 seconds to reset.
NOTE: If you do restar t engine after a shutdown and have not
corrected the low oil pressure, the engine will run for about 10 seconds as described above, and then it will stop.
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GENER AL MAINTENANCE
2. When the oil is drained, install and tighten the oil drain
RECOMMEN DATIONS
3. If your engine is equipped with an oil filter, use the
The owner/operator is responsible for making sure that all per iodic maintenance tasks are completed on a timely basis; that all discrepancies are corrected; and that the equipment is kept clean and properly stored. Never operate a damaged or defective engine.
CAUTION: Disconnect the spark plug wire from the spark plug, and place the wire where it cannot come in contact with the spark plug before working on this engine.
CHECKING THE OI L LEVEL
See the BEFORE STARTING THE ENGINE section on page 6 for information on checking the oil level. The oil level should be checked before each use, or at least every eight (8) hours of operation. Keep the oil level maintained.
CHANGING THE OI L AN D OIL F I LTER
Your engine may be equipped with an oil filter. Change the oil and filter after the first eight (8) hours of operation. Change the oil and oil filter (if so equipped) every 50 hours thereafter. If you are using this engine under dirty or dusty conditions, or in extremely hot weather, change the oil more often.
Use the following instructions to change the oil while the engine is still warm:
1. Clean the area around the oil drain plug, remove the plug and
drain the oil completely into a suitable container (Figure 5).
4. Remove the oil fill plug and insert a clean funnel into the
5. When the crankcase is filled to the proper level, install
Your equipment’s air cleaner is one of the most important areas to maintain.This engine will not r un properly and may get damaged if it is run with a dirty air cleaner system.
Clean or replace the paper air filter (Figure 6) every 50 hours of operation or once a year, whichever comes first. Clean or replace the filter more often if the engine is operated under dusty or dirty conditions. Clean the foam pre-filter every 25 hours of operation, or sooner under dusty or dirty conditions.
plug.
following instructions:
A. Place a suitable container beneath the oil filter and
turn the filter counterclockwise to remove the filter.
B. Coat the gasket of a new filter with engine oil. Turn
the new filter clockwise until the gasket contacts the filter adapter, then tighten an additional 3/4 turn.
plug opening. Fill the crankcase with the recommended oil until the oil level is at point of overflowing. Approxi­mately 1350ml (46 oz.) are required without an oil filter; 1500ml (51 oz.) with an oil filter.POUR SLOWLY.
and tighten the oil fill plug.
SERVICING THE AI R CLEAN ER
.
Figure 5 — Oil Filter and Drain Plug
Oil Filter
Drain Plug
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