Generac 190-220 User Manual
GENERAC®ENGINES
Overhead Valve
Industrial
Owner’s Manual
Manual No.A8926
Model No. 190/220 (6.5/7.8 Horsepower)
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Revision 0 (11/16/98) Printed in U.S.A.
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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.
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.
RULES FOR SAFE OPERATION
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.
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 OPERATING
• 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.
• Do not insert any object through the cooling slots of the
• Do not operate the engine faster than the speed necessary to
• This engine requires an adequate flow of cooling air for its
• Do not smoke around the engine.Wipe up any fuel or oil spills
• Keep hands, feet, clothing, etc., away from moving parts of this
• Never operate the engine (a) in the rain; (b) in any enclosed
WHILE OPERATING
• 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.
• Never wor k on this engine or handle any electrical device while
engine.You could damage the equipment or injure yourself.
operate the equipment. Do not run the engine at high speed
when not operating the equipment.
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.
immediately. Never leave oily or fuel soaked rags around the
engine. Keep the area around the engine clean and free of
debris.
engine.
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.
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 INFORMATION
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 ............................................................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 AND FUEL INFORMATION
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 star t the engine
before it has been properly serviced with the
recommended oil may result in engine damage.
RECOMMENDED OIL TYPE
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 770 ml (29 oz.) with the oil
filter.Without the filter, the oil capacity is 620ml (21 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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OPERATION AND MAINTENANCE
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.
BEFORE STARTING THE ENGINE
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.
STARTING THE ENGINE
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
RUN
RUN
STOP
STOP
LOW OIL
LOW OIL
INDICATOR
INDICATOR
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 Positions
CHOKE
2. Grasp the recoil handle (Figure 4) and pull it slowly until you
feel slight resistance, then PULL QUICKLY.
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A If the engine FAILS 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).
5. Allow the engine to warm up for two (2) minutes before
using the equipment.
If this engine is equipped with a primer bulb, use
the following instructions.
1. Press the primer bulb three (3) times, waiting two (2)
seconds between each push (Figure 5).
Figure 5 — Pressing the Primer Bulb
H
V
OOHH VV II
I
R
UN
S
O
T
P
L
O
W
O
I
L
IND
ICATOR
2. Grasp the recoil handle (see Figure 4) and pull it slowly until
you feel slight resistance, then PULL QUICKLY. Repeat
pulling the recoil handle three (3) times, if necessary.
3. If the engine FAILS TO ST ART, repeat Steps 1 and 2.
4. Allow the engine to warm up for two (2) minutes before using
the equipment.
STOPPING THE ENGINE
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 PRESSURE SHUTDOWN SYSTEM
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 STARTUP
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 ). However, once the engine
stops rotating, this light will go OFF.
RESTARTING THE ENGINE
If you try to restart the engine within 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 restart 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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GENERAL MAINTENANCE
2. When the oil is drained, install and tighten the oil drain
RECOMMENDATIONS
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 OIL 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 OIL AND OIL FILTER
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 6).
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 7) 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 620ml (21 oz.) are required without an oil filter;
770ml (29 oz.) with an oil filter.POUR SLOWLY.
and tighten the oil fill plug.
SERVICING THE AIR CLEANER
.
Figure 6 — Oil Filter and Drain Plug
Oil Filter
Drain Plug
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