Generac 190-220 User Manual

Manual No. A8926

GENERAC® ENGINES

Overhead Valve

Industrial

Owner’s Manual

Model No. 190/220 (6.5/7.8 Horsepower)

THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS, WHICH, IF NOT FOLLOWED, COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THE MANUAL BEFORE ATTEMPTING TO OPERATE THIS UNIT.

Revision 0 (11/16/98)

Printed in U.S.A.

Generac GN-190/220 Engine

If you don’t understand any portion of this manual, contact				RULES FOR SAFE OPERATION
Generac for a demonstration of actual starting, operating and
servicing procedures.				Study these RULES FOR SAFE OPERATION carefully before
Throughout this publication and on tags and decals affixed to				operating or servicing this equipment. Become familiar with the
the generator, DANGER, WARNING and CAUTION blocks are				OWNER’S MANUAL and with the engine. The engine can
used to alert you to special instruction about a particular				operate safely, efficiently and reliably only if it is properly
operation that may be hazardous if performed incorrectly or				operated and maintained. Many accidents are caused by failing
carelessly. Observe them carefully.				to follow simple and fundamental rules or precautions.
These safety warnings cannot eliminate the hazards that they				Generac cannot possibly anticipate every possible circumstance
indicate. Strict compliance with the special instructions while				that might involve a hazard. The warnings in this manual and on
performing the service plus “common sense” are major				tags and decals affixed to the equipment, are therefore, not all-
measures to prevent accidents.				inclusive. If you use a procedure, work method or operating
The following definitions apply to DANGER, WARNING,				technique Generac does not specifically recommend, you must
				satisfy yourself that it is safe for you and others. You must also
CAUTION and NOTE blocks found throughout the manual.
				make sure the procedure, work method or operating technique
These safety symbols indicate the following:				that you choose does not render the engine to be unsafe.
		DANGER: After this heading you can read handling,				DANGER: Do not tamper with the engine governed speed.
		installing, operating or servicing instructions that, if not
						High operating speeds are dangerous and increase the
		strictly complied with, will result in personal injury.
						risk of personal injury or damage to the equipment.
		WARNING: After this heading you can read handling,				Operating at low speeds with heavy load may shorten the
						engine’s life.
		installing, operating or servicing instructions that, if not
		strictly complied with, may result in personal injury.			BEFORE OPERATING
		CAUTION: After this heading you can read instructions for
				•	Gasoline is highly FLAMMABLE and its vapors are
		handling, installing, operating or servicing the generator			EXPLOSIVE. Do not permit smoking, open flames, sparks or
		that, if not strictly complied with, may result in damage to
					heat in the area while handling gasoline. Avoid spilling
		equipment and/or property.
					gasoline on a hot engine. Comply with all of the laws
NOTE: After this heading you can read explanatory statements that					regulating storage and handling of gasoline.
require special emphasis.				•	Store gasoline and other fuels only in containers designed
These symbols indicate the following:					and approved for the storage of such materials.
		Points out important safety information and, if not followed, could		• Pressure can build up in the fuel tank. Loosen the fuel tank
		endanger personal safety and/or property of yourself and others.			slowly to relieve any pressure in the tank.
				•	Add gasoline and other fuels in a clean, well-ventilated area.
		Potential explosion hazard.			Wipe up any spilled gasoline immediately. If gasoline has
		Potential fire hazard.			been spilled, let it dry completely before starting the engine.

Potential electrical shock hazard.	WARNING:

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

— 2 —

Generac GN-190/220 Engine

•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 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.

• 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 observed while the engine is running.

•Never work 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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Generac GN-190/220 Engine

This engine meets the 1998 and later California emissions	TABLE OF CONTENTS
regulations. To ensure that your engine continues to meet
these regulations, refer to the following information and	RULES FOR SAFE OPERATION ........................................	2-3
instructions in this owner’s manual.
	GENERAL INFORMATION..................................................	4-5
	Service Information ..................................................................	4
SERVICE INFORMATION
	Engine Identification Decal Location ........................................	4
Service on this engine within and after the warranty	Oil and Fuel Information ............................................................	5
period can be performed by any authorized service
dealer. Service technicians are factory trained and	OPERATION ........................................................................	6-7
capable of handling all service needs.	Before Starting the Engine ........................................................	6
When contacting an authorized service dealer or the	Starting the Engine ................................................................	6-7
factory about parts and service, always supply the	Stopping the Engine ..................................................................	7
complete model number and serial number of your unit as	Low Pressure Shutdown System ..............................................	7
given on its data plate decal.
	MAINTENANCE ................................................................	8-13
The warranty and replacement parts for this engine are
included in the owner’s manual.	General Maintenance Recommendations ................................	8
	Service and Adjustments ....................................................	8-10
	Carburetor Adjustments ..........................................................	11
	Checking/Adjusting Valve to Rocker Arm Clearance ..............	11
When ordering engine components, you must provide the	Retorquing Head Bolts ............................................................	12
authorized service dealer with the engine identification number,	Maintenance Schedule............................................................	12
which is located on the engine identification decal. See the	Storage Instructions ................................................................	13
illustration below for the location of the decal.	Specifications ..........................................................................	13

Generac Corporation
Eng. Identif. No. XXXXXX
Displacement	XXXXXX
	Decal

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

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Generac GN190/220 Engine

OIL AND FUEL INFORMATION

The recommended oils include the following:

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.

•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.

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 dirty oil, can cause premature engine wear and failure.

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 TANK.

— 5 —

Generac GN-190/220 Engine

OPERATION AND MAINTENANCE

STARTING THE ENGINE

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

Perform 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.

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.

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

RUNU

SSTOP

LLOWWO I L OIL

INDICATORI C A T O R

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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Generac GN-190/200 Engine

A	If the engine FAILS TO START, go to Step 3.	2.	Grasp the recoil handle (see Figure 4) and pull it slowly until
B.	If the engine STARTS, go to Step 4.		you feel slight resistance, then PULL QUICKLY. Repeat
			pulling the recoil handle three (3) times, if necessary.
	Figure 4 — Recoil Handle	3.	If the engine FAILS TO START, 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
	Recoil		seconds.
		2.	Turn off the engine by moving the RUN/STOP SWITCH to
	Handle
			the STOP position.
		3.	Close the fuel shut-off valve, if so equipped.
		LOW PRESSURE SHUTDOWN SYSTEM

3.Move the choke lever to the HALF CHOKE POSITION, and pull the recoil handle (Figure 4) two (2) times.

•If the engine STILL FAILS TO START, repeat Steps 1-3.

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.

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	R U N
I
OH
V I	ST O P
	LO W
	O IL
	IN D
	IC ATO R

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 start. 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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Generac GN-190/220 Engine

GENERAL MAINTENANCE

RECOMMENDATIONS

The owner/operator is responsible for making sure that all periodic 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.

2.When the oil is drained, install and tighten the oil drain plug.

3.If your engine is equipped with an oil filter, use the 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.

4.Remove the oil fill plug and insert a clean funnel into the 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.

5.When the crankcase is filled to the proper level, install and tighten the oil fill plug.

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).

Figure 6 — Oil Filter and Drain Plug

Oil Filter

Drain Plug

— 8 —

SERVICING THE AIR CLEANER.

Your equipment’s air cleaner is one of the most important areas to maintain. This engine will not run 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.