Owner’s
Manual
• SAFETY
• ASSEMBLY
ULTRA SOURCE
Portable Generator
• OPERATION
• TROUBLESHOOTING
• ELECTRICAL DATA
• PARTS
• WARRANTY
AUTHORIZED DEALER SUPPORT:
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODEL: 004582-2
15,000 Watt Portable Generator
1-800-333-1322
Table of Contents
Commercial-Industrial-Residential Portable Generator System
Safety Rules .................................................................. 1
Section 1 – General Information ................................. 4
1.1 Unpacking ............................................................................. 4
1.1.1 Accessory Box ........................................................ 4
1.2 Assembly .............................................................................. 4
1.2.1 Assembling the Wheel Kit ....................................... 4
1.2.2 Assembling the Handle ........................................... 4
1.2.3 Battery Connection ................................................. 5
Section 2 – Operation .................................................. 6
2.1 Know The Generator ............................................................ 6
2.2 Cord Sets and Connector Plugs ........................................... 7
2.2.1 120 VAC, 20 Amp, Duplex Receptacle ................... 7
2.2.2 120 VAC, 20 Amp, GFCI Receptacle ...................... 7
2.2.3 120 VAC, 30 Amp Receptacle ................................ 7
2.2.4 120/240 VAC, 30 Amp, Receptacle ........................ 8
2.2.5 12 Volt DC, 10 Amp Receptacle ............................. 8
2.2.6 120/240 VAC, 50 Amp, Receptacle ........................ 8
2.3 How To Use The Generator .................................................. 8
2.3.1 Grounding The Generator .......................................8
2.3.2 Connecting Electric Loads ...................................... 9
2.4 Don’t Overload The Generator ............................................. 9
2.5 Wattage Reference Guide .................................................... 9
2.6 Before Starting The Generator ........................................... 10
2.6.1 Adding Engine Oil ................................................. 10
2.6.2 Adding Gasoline ................................................... 10
2.7 To Start The Engine ............................................................ 11
2.8 Stopping The Engine .......................................................... 11
2.9 Automatic Idle Control ........................................................ 12
2.10 Cold Weather Operation/De-Icer ........................................ 12
2.11 Low Oil Pressure Shutdown System .................................. 12
2.11.1 Initial Start-up ....................................................... 12
2.11.2 Sensing Low Oil Pressure .................................... 12
2.11.3 Restarting ............................................................. 12
2.12 Charging a Battery ............................................................. 12
Section 3 – Maintenance ...........................................13
3.1 Maintenance Schedule ....................................................... 13
3.2 Product Specifications ........................................................ 13
3.2.1 Generator Specifications ...................................... 13
3.2.2 Engine Specifications ........................................... 13
3.3 General Recommendations ................................................ 14
3.3.1 Generator Maintenance ........................................ 14
3.3.2 To Clean The Generator ....................................... 14
3.3.3 Engine Maintenance ............................................. 14
3.3.4 Checking Oil Level ................................................ 14
3.3.5 Changing The Oil & Oil Filter ................................ 14
3.3.6 Replacing The Spark Plug ................................... .15
3.4 Service Air Cleaner ............................................................ 15
3.5 Clean Spark Arrestor Screen ............................................. 15
3.6 Adjusting Valve Clearance .................................................. 16
3.7 General .............................................................................. 16
3.8 Long Term Storage ............................................................. 17
3.9 Other Storage Tips ............................................................. 17
Section 4 – Troubleshooting ......................................18
4.1 Troubleshooting Guide ........................................................ 18
Section 5 – Electrical Data ........................................ 19
Section 6 – Exploded Views and Parts Lists .......... 22
Section 7 – Warranty .................................................. 32
INTRODUCTION
Thank you for purchasing this model by Generac Power Systems, Inc.
This model is a compact, high performance, air-cooled, engine driven
generator designed to supply electrical power to operate electrical
loads where no utility power is available or in place of utility due to a
power outage.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest
Authorized Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or carelessly.
Observe them carefully. Their definitions are as follows:
DANGER
After this heading, read instructions that, if
not strictly complied with, will result in serious
personal injury, including death and/or property
damage.
After this heading, read instructions that, if not
strictly complied with, may result in serious
personal injury and/or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements that require
special emphasis.
These safety warnings cannot eliminate the hazards that they indicate.
Common sense and strict compliance with the special instructions
while performing the service are essential to preventing accidents.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates is as follows:
This symbol points out important safety
information that, if not followed, could endanger
personal safety and/or property of others.
This symbol points out potential explosion
hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use of the
equipment. We strongly recommend that the operator read this
manual and thoroughly understand all instructions before using
the equipment.
We also strongly recommend instructing other users to properly
start and operate the unit. This prepares them if they need to
operate the equipment in an emergency.
Always disconnect spark plug wires and place
the wires where they cannot contact the spark
plugs to prevent accidental starting when
setting up, transporting, adjusting or making
repairs to the generator.
•
The generator produces dangerously high voltage that can cause
extremely hazardous electrical shock. Avoid contact with bare
wires, terminals, etc. Never permit any unqualified person to
operate or service the generator.
•
Never handle any kind of electrical cord or device while standing
in water, while barefoot or while hands or feet are wet. Dangerous
electrical shock will result.
•
The National Electric Code requires the frame and external
electrically conductive parts of the generator be properly connected
to an approved earth ground. Local electrical codes may also
require proper grounding of the generator. Consult with a local
electrician for grounding requirements in the area.
•
Use a ground fault circuit interrupter in any damp or highly
conductive area (such as metal decking or steel work).
•
Do not use worn, bare, frayed or otherwise damaged electrical
cord sets with the generator.
•
Operate generator only on level surfaces and where it will not be
exposed to excessive moisture, dirt, dust or corrosive vapors.
•
Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE.
Do not permit smoking, open flames, sparks or heat in the vicinity
while handling gasoline. Avoid spilling gasoline on a hot engine.
Comply with all laws regulating storage and handling of gasoline.
•
Never add fuel while unit is running.
Do not overfill the fuel tank. Always allow room
for fuel expansion. If tank is over-filled, fuel can
overflow onto a hot engine and cause FIRE or
an EXPLOSION.
Never store generator with fuel in tank where gasoline vapors
•
might reach an open flame, spark or pilot light (as on a furnace,
water heater or clothes dryer). FIRE or EXPLOSION may result.
Generator 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.
Allow at least two (2) feet of clearance on all sides of generator or
•
damage could be done to the unit. Never operate the unit inside
any room or enclosure where the free flow of cooling air into and
out of the unit might be obstructed. Review the “Cold Weather
Operation” section.
NEVER operate the generator indoors, in an attached garage
or near an open window.
1
IMPORTANT SAFETY INSTRUCTIONS
Commercial-Industrial-Residential Portable Generator System
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's
installation site. Safety should be stressed to all operators and potential operators of this equipment.
Never start or stop the unit with electrical loads connected to
•
receptacles AND with connected devices turned ON. Start
the engine and let it stabilize before connecting electrical
loads. Disconnect all electrical loads before shutting down the
generator.
Do not insert objects through unit's cooling slots.
•
Never operate generator: indoors or in any enclosed compartment;
•
in rain; if connected electrical devices overheat; if electrical output
is lost; if engine or generator sparks; if flames or smoke are
observed while unit is running; if unit vibrates excessively.
NOTE:
This generator is equipped with a spark arrestor muffler. The
spark arrestor must be maintained in effective working order by
the owner/ operator. In the State of California, a spark arrestor is
required by law (Section 4442 of the California Public Resources
Code). Other states may have similar laws. Federal laws apply
on federal lands.
Despite the safe design of this generator,
operating this equipment imprudently,
neglecting its maintenance or being careless
can cause possible injury or death. Permit only
responsible and capable persons to operate or
maintain this equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
DANGER
GENERAL HAZARDS
Study these SAFETY RULES carefully before installing, operating or
servicing this equipment. Become familiar with this manual and with
the unit. The generator can operate safely, efficiently and reliably only
if it is properly installed, operated and maintained. Many accidents
are caused by failing to follow simple and fundamental rules or
precautions.
The engine exhaust from this product
•
contains chemicals known to the state
This product contains or emits chemicals
•
known to the state of California to cause
cancer, birth defects or other reproductive harm.
The manufacturer cannot anticipate every possible circumstance that
might involve a hazard. The warnings in this manual, and on tags and
decals affixed to the unit are, therefore, not all inclusive. If using a
procedure, work method or operating technique that the manufacturer
does not specifically recommend, ensure that it is safe for others. Also
make sure the procedure, work method or operating technique utilized
does not render the generator unsafe.
WARNING:•
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:•
Never operate in an enclosed area or indoors.
•
For safety reasons, the manufacturer recommends that the
•
maintenance of this equipment is carried out by an Authorized
Dealer.
The engine exhaust fumes contain carbon monoxide, which
•
can be DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death. This
exhaust system must be properly maintained. Do nothing that
might render the exhaust system unsafe or in noncompliance with
any local codes and/or standards.
Keep hands, feet, clothing, etc., away from drive belts, fans, and
•
other moving or hot parts. Never remove any drive belt or fan guard
while the unit is operating.
Adequate, unobstructed flow of cooling and ventilating air is critical
•
to correct generator operation. Do not alter the installation or
permit even partial blockage of ventilation provisions, as this can
seriously affect safe operation of the generator. The generator
MUST be operated outdoors.
When working on this equipment, remain alert at all times. Never
•
work on the equipment when physically or mentally fatigued.
Inspect the generator regularly, and contact the nearest Authorized
•
Dealer for parts needing repair or replacement.
Before performing any maintenance on the generator, disconnect
•
its battery cables to prevent accidental start up. Disconnect the
cable from the battery post indicated by a NEGATIVE, NEG or (–)
first. Reconnect that cable last.
Never use the generator or any of its parts as a step. Stepping on
•
the unit can stress and break parts, and may result in dangerous
operating conditions from leaking exhaust gases, fuel leakage, oil
leakage, etc.
2
IMPORTANT SAFETY INSTRUCTIONS
Commercial-Industrial-Residential Portable Generator System
ELECTRICAL HAZARDS
•
All generators covered by this manual produce dangerous electrical
voltages and can cause fatal electrical shock. Utility power delivers
extremely high and dangerous voltages as does the generator
when it is in operation. Avoid contact with bare wires, terminals,
connections, etc., while the unit is running. Ensure all appropriate
covers, guards and barriers are in place before operating the
generator. If work must be done around an operating unit, stand on
an insulated, dry surface to reduce shock hazard.
•
Do not handle any kind of electrical device while standing in water,
while barefoot, or while hands or feet are wet. DANGEROUS
ELECTRICAL SHOCK MAY RESULT.
•
The National Electrical Code (NEC) requires the frame and external
electrically conductive parts of the generator to be connected to an
approved earth ground. Local electrical codes also may require
proper grounding of the generator electrical system.
•
In case of accident caused by electric shock, immediately shut
down the source of electrical power. If this is not possible,
attempt to free the victim from the live conductor. AVOID DIRECT
CONTACT WITH THE VICTIM. Use a non-conducting implement,
such as a rope or board, to free the victim from the live conductor.
If the victim is unconscious, apply first aid and get immediate
medical help.
•
Never wear jewelry when working on this equipment. Jewelry can
conduct electricity resulting in electric shock, or may get caught in
moving components causing injury.
EXPLOSION HAZARDS
•
Do not smoke around the generator. Wipe up any fuel or oil spills
immediately. Ensure that no combustible materials are left on or
near the generator, as FIRE or EXPLOSION may result. Keep the
area surrounding the generator clean and free from debris.
•
Gasoline is extremely EXPLOSIVE.
STANDARDS INDEX
In the absence of pertinent standards, codes, regulations and laws,
the published information listed below may be used as a guideline
for operation of this equipment. Always reference the latest revision
available for the standards listed.
1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC
CODE.
2. Article X, NATIONAL BUILDING CODE, available from the
American Insurance Association, 85 John Street, New York, N.Y.
10038.
3. AGRICULTURAL WIRING HANDBOOK, available from the Food
and Energy Council, 909 University Avenue, Columbia, MO
65201.
4. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM
STANDBY ELECTRICAL SYSTEMS, available from the American
Society of Agricultural Engineers, 2950 Niles Road, St. Joseph,
MI 49085.
5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS
CODE.
FIRE HAZARDS
For fire safety, the generator must be operated and maintained
•
properly. Operation must always comply with applicable codes,
standards, laws and regulations. Adhere strictly to local,
state and national electrical and building codes. Comply with
regulations the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is
operated in accordance with the manufacturer’s instructions and
recommendations. Do not alter the construction of the generator
or change controls which might create an unsafe operating
condition.
Keep a fire extinguisher near the generator at all times. Extinguishers
•
rated “ABC” by the National Fire Protection Association are
appropriate for use on the standby electric system. Keep the
extinguisher properly charged and be familiar with its use. If there
are any questions pertaining to fire extinguishers, consult the local
fire department.
3
Section 1 – General Information
Commercial-Industrial-Residential Portable Generator System
1.1 UNPACKING
•
Set the palleted carton on a rigid flat surface.
•
Remove staples along bottom of carton that fasten carton to pallet.
Open carton from top.
•
Remove all packaging material.
•
Remove separate accessory box.
•
Lift carton off the generator.
•
Remove generator from shipping pallet by removing bolts through
the shipping brackets (Figure 1).
Figure 1 - Bracket Removal
Shipping
Bracket (x4)
1.2 ASSEMBLY
The generator requires some assembly prior to using it. If problems
arise when assembling the generator, please call the Generator
Helpline at 1-800-333-1322.
1.2.1 ASSEMBLING THE WHEEL KIT
The wheel kit is designed to greatly improve the portability of the
generator. A socket wrench with a 9/16” socket, a 1/2” socket, a
1/2” wrench and a pair of pliers are the tools that will be needed for
assembly of the wheel kit.
NOTE:
The wheel kit is not intended for over-the-road use.
•
Refer to Figure 2 and install the wheel kit as follows:
•
Place the generator on a hard flat surface.
•
Stand at the engine end of the unit and gently tilt the generator
forward, high enough to place wooden blocks beneath the cradle.
This will allow space to install the wheel assemblies.
•
Attach an axle bracket assembly with attached sleeve to either side
of the frame. Ensure the sleeve faces outward.
•
Slide the axle through the sleeves on the axle brackets.
•
Slide one wheel with flat washer to the outside and a spacer to the
inside onto each end of the axle. Make sure the air inflation valve
on the wheel is facing outward.
•
Insert retaining pins and using pliers, bend out the ends to prevent
the pins from falling out of the axle. Remove the wooden blocks.
1.1.1 ACCESSORY BOX
Check all contents. If any parts are missing or damaged locate an
authorized dealer at 1-800-333-1322.
Contents include:
Wheel Axle • Bolt-on tubular handle
•
2 – Washers • 2 – Pneumatic Wheels
•
2 – Wheel Spacers • 2 – Axle Bracket Assemblies
•
2 – Cotter Pins • Bolt-on Foot
•
2 – Spark Plugs • Spark Plug Wrench
•
Air Filter • Oil Filter
•
Pre-cleaner • Battery Charge Cable
•
6 – Carriage Bolts, Washers, Nuts
•
1.2.2 ASSEMBLING THE HANDLE
Attach the handle by aligning one side of the handle on the cradle,
•
then spread the handle around the cradle and let it spring into
place. Secure the handle to the frame using the 5/16’ hex head
bolts provided. Check each fastener to ensure that it is secure.
Using the handle, lift the unit high enough to place wooden blocks
•
under the unit. Attach the front support foot to the underside of the
cradle using the 3/8” carriage bolts provided.
Remove the shipping brackets from the cradle, if it has not already
•
been done.
4
Section 1 - General Information
Commercial-Industrial-Residential Portable Generator System
Figure 2 - Handle Assembly
1.2.3 BATTERY CONNECTION
The battery shipped with the generator has been provided fully
•
charged. Caution must be taken when connecting the battery.
NOTE:
A battery may lose some of it’s charge when not in use for
prolonged periods of time.
Cut the tie wrap cable holding the RED and BLACK battery cables
•
to the stator.
Connect the RED battery cable to the battery Positive terminal (+).
•
After making sure that the connection is tight, slip the rubber boot
over the terminal connection.
Connect the BLACK battery cable to the battery Negative terminal
•
(–). Make sure the connection is tight.
Double check all connections to ensure they are in the correct
•
location and secure. See Figure 3.
Figure 3 - Battery Connections
Negative
Cable
Positive
Cable
5
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
2.1 KNOW THE GENERATOR
Read the Owner’s Manual and Safety Rules before operating this
generator.
Compare the generator to Figures 4 through 6 to become familiarized
with the locations of various controls and adjustments. Save this
manual for future reference.
Figure 4 - Control Panel
1. 12 Volt DC, 10 Amp Receptacle – This receptacle allows the
capability to recharge a 12 volt DC storage battery with provided
battery charge cables.
2. 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies electrical
power for the operation of 120 Volt AC, 20 Amp, single-phase, 60
Hz electrical lighting, appliance, tool and motor loads.
3. 120 Volt AC, 20A Duplex GFCI Receptacle – Supplies ground
fault protected electrical power for operation of 120 volt AC 20
amp, single-phase, 60 Hz electric lighting, appliances, tools and
motor loads.
4. 120 Volt AC, 30 Amp Locking Receptacle – Supplies electrical
power for the operation of 120 Volt AC, 30 Amp, single-phase, 60
Hz electrical lighting, appliance, tool and motor loads.
5. 120/240 Volt AC, 30 Amp Locking Receptacle – Supplies
electrical power for the operation of 120 and/or 240 Volt AC, 30
Amp, single-phase, 60 Hz, electrical lighting, appliance, tool and
motor loads.
6. 120/240 Volt AC, 50 Amp Receptacle (Located on underside
of control panel)– Supplies electrical power for the operation of
120/240 Volt AC, 50 Amp, single-phase, 60 Hz, welder or motor
loads.
7. Air Cleaner – Filters intake air as it is drawn into the engine.
8. Choke Knob – Used when starting a cold engine.
9. Winter/Summer Valve – See “Cold Weather Operation/De-icer”
section.
Figure 5 - Generator Controls
11
7
15
10. Circuit Breakers (AC) – Each receptacle is provided with a
push-to-reset circuit breaker to protect the generator against
electrical overload. (50 amp uses toggle reset)
11. Fuel Tank – Tank holds 16 U.S. gallons of fuel.
12. Grounding Lug – Ground the generator to an approved earth
ground here. See "Grounding the Generator" for details.
13. Idle Control Switch – The idle control runs the engine at normal
(high) speeds when there is an electrical load present and runs
the engine at idle (low) speeds when a load is not present.
14. Start/Run/Stop Switch – Controls the operation of the
generator.
15. Oil Fill – Use this point to add oil to engine.
16. Fuse - 10 Amp (Located at rear of control panel) – Protects
the DC control circuit from overload. If this fuse element has
melted open the engine will not be able to crank and start.
Figure 6 - Engine Control Panel
14
8
12
9
6
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
2.2 CORD SETS AND CONNECTION PLUGS
2.2.1 120 VAC, 20 AMP, DUPLEX RECEPTACLE
This is a 120 Volt outlet protected against overload by a 20 Amp
push-to-reset circuit breaker (Figure 7). Use each socket to power
120 Volt AC, single phase, 60 Hz electrical loads requiring up to a
combined 2400 watts (2.4 kW) or 20 Amps of current. Use only high
quality, well-insulated, 3-wire grounded cord sets rated for 125 Volts
at 20 Amps (or greater).
Keep extension cords as short as possible, preferably less than 15
feet long, to prevent voltage drop and possible overheating of wires.
Figure 7 - 120 Volt AC, 20 Amp, Duplex Receptacle
2.2.2 120 VAC, 20 AMP, GFCI RECEPTACLE
This unit is equipped with a ground fault circuit interrupter (GFCI). This
device meets applicable federal, state and local codes (Figure 8).
A GFCI receptacle is different from conventional receptacles. In the
event of a ground fault, a GFCI will trip and quickly stop the flow of
electricity to prevent serious injury.
Definition: Instead of following its normal safe path, electricity passes
through a persons body to reach the ground. For example, a defective
appliance can cause a ground fault.
A GFCI receptacle does NOT protect against circuit overloads, short
circuits, or shocks. For example, electric shock can still occur if a
person touches charged electrical wires while standing on a nonconducting surface, such as a wood floor.
Figure 8 - 120 VAC, 20 Amp GFCI Receptacle
Testing the GFCI: Test the GFCI outlet every month as follows:
Plug a test lamp into the receptacle.
•
Start the generator, the test lamp should be on.
•
Press the “Test” button located on the front of the receptacle to
•
trip the device.
This should stop the flow of electricity making the lamp shut off.
•
The yellow trip indicator should now be on.
To restore the flow of electricity, press the “Reset” button on the
•
front of the receptacle. If the GFCI does not perform in this manner,
do not use the receptacle. Contact a local service dealer.
This outlet is protected against overload by a 20A push-to-reset
•
circuit breaker. Use the outlet to power 120V AC, single-phase,
60 Hz, electrical loads requiring up to a combined 2400 watts (2.4
kW) or 20 amps of current.
2.2.3 120 VAC, 30 AMP RECEPTACLE
Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire cord
set rated for 125 Volts AC at 30 Amps (or greater) to the plug (Figure
9).
Figure 9 - 120 VAC, 30 Amp Receptacle
7
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads
requiring up to 3600 watts (3.6 kW) of power at 30 Amps. The outlet
is protected by a 30 Amp push-to-reset circuit breaker.
2.2.4 120/240 VAC, 30 AMP RECEPTACLE
Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4wire grounded cord set to the plug and to the desired load. The cord
set should be rated for 250 Volts AC at 30 Amps (or greater) (Figure
10).
Figure 10 - 120/240 VAC, 30 Amp Receptacle
Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads
requiring up to 3600 watts (3.6 kW) of power at 30 Amps or 240 Volt
AC, 60 Hz, single phase loads requiring up to 7200 watts (7.2 kW)
of power at 30 Amps. The outlet is protected by two 30 Amp push-toreset circuit breakers.
2.2.5 12 VOLT DC, 10 AMP RECEPTACLE
This receptacle permits recharging a 12 Volt automotive or utility style
storage battery with the battery charge cables provided (Figure 11).
This receptacle can not recharge 6 Volt batteries and can not be
used to crank an engine having a discharged battery. See the section
"Charging a Battery" before attempting to recharge a battery.
Figure 12 - 120/240 VAC, 50 Amp Receptacle
50 A
Use this receptacle to operate 120/240 Volt AC, 60 Hz electrical loads
requiring up to 12,000 watts (12.0 kW) of power. This receptacle is
protected by a 50 Amp 2-pole circuit breaker.
2.3 HOW TO USE THE GENERATOR
If there are any problems operating the generator, please call the
generator helpline at 1-800-333-1322.
2.3.1 GROUNDING THE GENERATOR
The National Electrical Code requires that the frame and external
electrically conductive parts of this generator be properly
connected to an approved earth ground (Figure 13). Local
electrical codes may also require proper grounding of the unit. For
that purpose, generally, connecting a No. 10 AWG (American Wire
Gauge) stranded copper wire to the grounding wing nut and to an
earth-driven copper or brass grounding rod (electrode) provides
adequate protection against electrical shock. However, local codes
may vary widely. Consult with a local electrician for grounding
requirements in the area.
Figure 13 - Grounding the Generator
Figure 11 - 12 Volt DC, 10 Amp Receptacle
2.2.6 120/240 VAC, 50 AMP RECEPTACLE
Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire cord
set rated for 250 Volts AC at 50 Amps to the plug (Figure 12).
8
Generator Ground Lug
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
Proper grounding of the generator will help prevent electrical
shock in the event of a ground fault condition in the generator or in
connected electrical devices. Proper grounding also helps dissipate
static electricity, which often builds up in ungrounded devices.
2.3.2 CONNECTING ELECTRICAL LOADS
DO NOT connect 240 Volt loads to 120 Volt receptacles. DO NOT
connect 3-phase loads to the generator. DO NOT connect 50 Hz loads
to the generator.
Let engine stabilize and warm up for a few minutes after starting.
•
Plug in and turn on the desired 120 or 240 Volt AC, single phase,
•
60 Hz electrical loads.
Add up the rated watts (or amps) of all loads to be connected
•
at one time. This total should not be greater than (a) the rated
wattage/amperage capacity of the generator or (b) circuit breaker
rating of the receptacle supplying the power. See "Don't Overload
the Generator" below.
2.4 DON’T OVERLOAD THE GENERATOR
Overloading a generator in excess of its rated wattage capacity can
result in damage to the generator and to connected electrical devices.
Observe the following to prevent overloading the unit:
Add up the total wattage of all electrical devices to be connected
•
at one time. This total should NOT be greater than the generator's
wattage capacity.
The rated wattage of lights can be taken from light bulbs. The rated
•
wattage of tools, appliances and motors can usually be found on a
data plate or decal affixed to the device.
If the appliance, tool or motor does not give wattage, multiply volts
•
times ampere rating to determine watts (volts x amps = watts).
Some electric motors, such as induction types, require about three
•
times more watts of power for starting than for running. This surge
of power lasts only a few seconds when starting such motors.
Make sure to allow for high starting wattage when selecting
electrical devices to connect to the generator:
1. Figure the watts needed to start the largest motor.
2. Add to that figure the running watts of all other connected loads.
The Wattage Reference Guide is provided to assist in determining
how many items the generator can operate at one time.
NOTE:
All figures are approximate. See data plate on appliance for
wattage requirements.
2.5 WATTAGE REFERENCE GUIDE
Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Running Watts
*Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1700
*Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800
*Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000
Battery Charger (20 Amp). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Chain Saw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Circular Saw (6-1/2"). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 to 1000
*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5750
*Clothes Dryer (Gas). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150
Coffee Maker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750
*Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
*Compressor (3/4 HP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
*Compressor (1/2 HP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400
Curling Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
*Dehumidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650
Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Electric Range (per element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250
*Freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..700
*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875
*Garage Door Opener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 to 750
Hair Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100
Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800
Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200
Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Microwave Oven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 to 1000
*Milk Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100
Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . . . . . . . . . . . . . 400
Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . . . . . . . . . . . . . . . 225
Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . . . . . . . . . . . . . 150
*Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Paint Sprayer, Airless (handheld) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Radio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 200
*Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
*Submersible Pump (1-1/2 HP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800
*Submersible Pump (1 HP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
*Sump Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 to 1050
*Table Saw (10") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750 to 2000
Television . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500
Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650
Weed Trimmer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
* Allow 3 times the listed watts for starting these devices.
9
5W -3 0
Sy nt he ti c 5 W- 30
SA E 30 , 1 0W -3 0
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
2.6 BEFORE STARTING THE GENERATOR
Prior to operating the generator, engine oil and gasoline will need to
be added, as follows:
2.6.1 ADDING ENGINE OIL
NOTE:
When adding oil to the engine crankcase in the future, use only
high quality detergent oil rated with API service classification
SG, SH or SL SAE 30 weight. Use no special additives.
SAE 30, 10W-30
Synthetic 5W-30
5W-30
Select the oil’s viscosity grade according to the expected operating
temperature. Do not use SAE 10W-40.
NOTE:
Synthetic oil should only be used after first oil change.
Above 40°F, use SAE 30, synthetic 5W-30 or SAE 10W-30.
•
Below 40°F, use synthetic 5W-30 or 5W-30.
•
Although multi-viscosity oils (5W-30, 10W-30, etc.) improve starting
in cold weather, these multi-viscosity oils will result in increased oil
consumption when used above 32°F. Check the engine oil level more
frequently to avoid possible damage from running low on oil.
Place generator on a level surface.
•
Clean area around oil fill and remove oil fill cap and dipstick.
•
Wipe dipstick clean.
•
Slowly fill engine with oil through the oil fill opening until it reaches
•
the full mark on the dipstick. Stop filling occasionally to check oil
level. DO NOT OVERFILL.
Install dipstick. Install oil fill cap and finger tighten securely.
•
Check engine oil level before starting each time thereafter.
•
2.6.2 ADDING GASOLINE
Never fill fuel tank indoors. Never fill fuel tank
when engine is running or hot. DO NOT light a
cigarette or smoke when filling the fuel tank.
Do not overfill the fuel tank. Always leave room
for fuel expansion.
•
Use regular UNLEADED gasoline with the generator engine. Do
not use premium gasoline. Do not mix oil with gasoline.
•
Clean area around fuel fill cap, remove cap.
•
Slowly add unleaded regular gasoline to fuel tank. Be careful not
to overfill. Allow about 1/2" of tank space for fuel expansion, as
shown here (Figure 14).
•
Install fuel cap and wipe up any spilled gasoline.
Figure 14 - Fuel Tank
IMPORTANT: It is important to prevent gum deposits from forming
in fuel system parts such as the carburetor, fuel hose or tank during
storage. Alcohol-blended fuels (called gasohol, ethanol or methanol)
can attract moisture, which leads to separation and formation of acids
during storage. Acidic gas can damage the fuel system of an engine
while in storage. To avoid engine problems, the fuel system should
be emptied before storage of 30 days or longer. See the "Storage"
section. Never use engine or carburetor cleaner products in the fuel
tank as permanent damage may occur.
10
Commercial-Industrial-Residential Portable Generator System
2.7 TO START THE ENGINE
Never start or stop engine with electrical
devices plugged into the receptacles AND
devices turned on.
Unplug all electrical loads from the unit's receptacles before
•
starting the engine.
Make sure the unit is in a level position.
•
Open the fuel shut-off valve (Figure 15).
•
Figure 15 - Fuel Shut-off Valve
Section 2 – Operation
•
Move engine CHOKE knob outward to “Full Choke” position
(Figure 17).
Figure 17 - Full Choke Position
Locate the Idle Control ON/OFF switch on the control panel and
•
set it to the “OFF” position(Figure 16).
Figure 16 - Idle Control Switch
To start engine, press and hold the Start/Run/Stop switch in the
•
“Start” position. The engine will crank and attempt to start. When
the engine starts, release the switch to the run position.
When the engine starts, move choke knob to “1/2 Choke” position
•
until the engine runs smoothly and then fully in to the “Run” position.
If engine falters, move choke knob back out to “1/2 Choke” position
until the engine runs smoothly and then to “Run” position.
NOTE:
If engine fires, but does not continue to run, move choke lever to
“Full Choke” and repeat starting instructions.
IMPORTANT: Do not overload the generator. Also, do not overload
individual panel receptacles. These outlets are protected against
overload with push-to-reset-type circuit breakers. If amperage rating
of any circuit breaker is exceeded, that breaker opens and electrical
output to that receptacle is lost. Read “Don’t Overload the Generator”
carefully.
2.8 STOPPING THE ENGINE
Shut off all loads, then unplug the electrical loads from generator
•
panel receptacles. Never start or stop the engine with electrical
devices plugged in and turned on.
Turn “Off” the Idle Control switch (if on).
•
Let engine run at no-load for several minutes to stabilize the
•
internal temperatures of engine and generator.
Move Start/Run/Stop switch to “Off” position.
•
Close fuel valve.
•
11
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
2.9 AUTOMATIC IDLE CONTROL
This feature is designed to greatly improve fuel economy. When
this switch is turned “On,” the engine will only run at its normal fast
governed engine speed when electrical load is connected. When
the load is removed, the engine will run at a reduced speed of 2100
RPM. With the switch “Off,” the engine runs at the normal fast engine
speed all the time. Always have the switch OFF when starting and
stopping the engine.
2.10 COLD WEATHER OPERATION/ DE-ICER
Under certain weather conditions (temperatures below 40° F (4°
C) and a high dew point), the engine may experience icing of the
carburetor and/or the crankcase breather system. To eliminate this
problem, this generator engine is fitted with a winter/summer valve.
This directs hot air into the carburetor during cold weather operation.
Always make sure the winter/summer valve is in the correct location
relative to the weather conditions.
2.11 LOW OIL 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 10 psi. If
the engine shuts down by itself and the fuel tank has enough gasoline,
check engine oil level.
2.11.1 INITIAL START-UP
A delay built into the low oil shutdown system allows oil pressure to
build during starting. The delay allows the engine to run for about 10
seconds before sensing oil pressure.
2.11.2 SENSING LOW OIL PRESSURE
If the system senses low oil pressure during operation, the engine
shuts down.
2.11.3 RESTARTING
If trying to restart the engine within 10 seconds after it shuts down, the
engine may NOT start. The system needs 5 to 10 seconds to reset.
If the engine is restarted after such a shutdown and the low oil
pressure has not been corrected, the engine will run for about 10
seconds as described above and then stop.
2.12 CHARGING A BATTERY
DANGER
Storage batteries give off explosive hydrogen
gas while recharging. An explosive mixture will
remain around the battery for a long time after
it has been charged. The slightest spark can
ignite the hydrogen and cause an explosion.
Such an explosion can shatter the battery and
cause blindness or other serious injury.
DANGER
Do not permit smoking, open flame, sparks
or any other source of heat around a battery.
Wear protective goggles, rubber apron and
rubber gloves when working around a battery.
Battery electrolyte fluid is an extremely caustic
sulfuric acid solution that can cause severe
burns. If spill occurs flush area with clear water
immediately.
This generator has the capability of recharging a discharged 12 Volt
automotive or utility style storage battery. Do not use the unit to
charge any 6 Volt batteries. Do not use the unit to crank an engine
having a discharged battery.
This battery charger is a pulse type designed to provide a quality
charge current into the battery. The voltage measured at the outlet
should be 8-12 VDC. This is normal and does not indicate a faulty
charging system.
To recharge 12 Volt batteries, proceed as follows:
Check fluid level in all battery cells. If necessary, add ONLY distilled
•
water to cover separators in battery cells. Do not use tap water.
If the battery is equipped with vent caps, make sure they are
•
installed and are tight.
If necessary, clean battery terminals.
•
Connect battery charge cable connector plug to panel receptacle
•
identified by the words "12-VOLT D.C."
Connect battery charge cable clamp with red handle to the positive
•
(+) battery terminal.
Connect battery charge cable clamp with black handle to the
•
negative (-) battery terminal.
Start engine. Let the engine run while battery recharges. Engine
•
idle control switch must be in off position for battery charging.
When battery has charged, shut down engine.
•
NOTE:
Use an automotive hydrometer to test battery state of charge and
condition. Follow the hydrometer manufacturer's instructions
carefully. Generally, a battery is considered to be at 100% state
of charge when specific gravity of its fluid (as measured by
hydrometer) is 1.260 or higher.
12
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
3.1 MAINTENANCE SCHEDULE
Follow the calendar intervals. More frequent service is required when operating in adverse conditions noted below.
Operation Maintenance Daily Every Season Every Season Every Season
Check Oil Level
Service Air Pre-Cleaner **
Change Oil and Oil Filter‡ *
Clean Spark Arrestor Screen
Check Valve Clearance ***
Service Air Cleaner **
Replace Spark Plugs
‡ Change oil after first 8 hours of operation then every season.
* Change oil and oil filter every month when operating under heavy load or in high temperatures.
** Clean more often under dirty or dusty operating conditions. Replace air cleaner parts if very dirty.
*** Check valve clearance and adjust if necessary after first 50 hours of operation and every 100 hours thereafter.
3.2 PRODUCT SPECIFICATIONS
3.2.1 GENERATOR SPECIFICATIONS
MODEL GPS 15,000
Model # 004582-2
Rated Max. Power 15.0 kW
Surge Power 22.5 kW
Rated AC Voltage 120/240
Rated Max AC Load
Current @ 240V 62.5 Amps
Current @ 120V 125.0 Amps
Rated Frequency 60 Hz @ 3600 RPM
Phase Single Phase
Rated DC Voltage 12 Volts
Rated Max DC Load
Current @ 12 Volts 10 Amperes
3.2.2 ENGINE SPECIFICATIONS
Rated Horsepower
@ 3600 RPM 30
Displacement 992cc
Spark Plug Type Champion RC14YC or Equivalent
Spark Plug Gap 0.040 inch or (1.01 mm)
Gasoline Capacity 16 U.S. gallons
Oil Type Summer – SAE 30 or 10W-30 or Synthetic 5W-30 Winter – 5W-30 or Synthetic 5W-20
Oil Capacity w/ Filter Change = 1.7 Qts. w/o Filter Change = 1.4 Qts.
Run Time/Fuel 10 Hours / 1.6 gallons per hour
Consumption-1/2 Load
13
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
3.3 GENERAL RECOMMENDATIONS
The warranty of the generator does not cover items that have been
subjected to operator abuse or negligence. To receive full value from
the warranty, the operator must maintain the generator as instructed
in this manual.
Some adjustments will need to be made periodically to properly
maintain the generator.
All adjustments in the Maintenance section of this manual should
be made at least once each season. Follow the requirements in the
"Maintenance Schedule".
NOTE:
Once a year replace the spark plug and replace the air filter. A
new spark plug and clean air filter assure proper fuel-air mixture
and help the engine run better and last longer.
3.3.1 GENERATOR MAINTENANCE
Generator maintenance consists of keeping the unit clean and dry.
Operate and store the unit in a clean dry environment where it will not
be exposed to excessive dust, dirt, moisture or any corrosive vapors.
Cooling air slots in the generator must not become clogged with snow,
leaves, or any other foreign material.
Check the cleanliness of the generator frequently and clean when
dust, dirt, oil, moisture or other foreign substances are visible on its
exterior surface.
Never insert any object or tool through the air
cooling slots, even if the engine is not running.
NOTE:
DO NOT use a garden hose to clean generator. Water can enter
the engine fuel system and cause problems. In addition, if water
enters the generator through cooling air slots, some water will
be retained in voids and crevices of the rotor and stator winding
insulation. Water and dirt buildup on the generator internal
windings will eventually decrease the insulation resistance of
these windings.
3.3.2 TO CLEAN THE GENERATOR
Use a damp cloth to wipe exterior surfaces clean.
•
A soft, bristle brush may be used to loosen caked on dirt, oil, etc.
•
A vacuum cleaner may be used to pick up loose dirt and debris.
•
Low pressure air (not to exceed 25 psi) may be used to blow away
•
dirt. Inspect cooling air slots and openings on the generator. These
openings must be kept clean and unobstructed.
3.3.3 ENGINE MAINTENANCE
DANGER
When working on the generator, always
disconnect negative cable from battery. Also
disconnect spark plug wires from spark plug
and keep wire away from spark plug.
3.3.4 CHECKING OIL LEVEL
See the “BEFORE STARTING THE GENERATOR” section for
information on checking the oil level. The oil level should be checked
before each use, or at least every eight hours of operation. Keep the
oil level maintained.
3.3.5 CHANGING THE OIL AND OIL FILTER
Change the oil and filter after the first eight hours of operation.
Change the oil every 100 hours thereafter. If running this unit under
dirty or dusty conditions, or in extremely hot weather, change the oil
more often.
NOTE:
Whenever possible, run engine for approximately 5 minutes to
get the engine oil hot. This will aid in draining the oil.
Use the following instructions to change the oil while the engine
is still warm:
Clean area around oil drain hose and plug.
•
Remove oil drain plug from end of hose and oil fill plug to drain oil
•
completely into a suitable container.
When oil has completely drained, install oil drain plug and tighten
•
securely.
Place a suitable container beneath the oil filter and turn
•
filter counterclockwise to remove. Discard according to local
regulations.
Coat gasket of new filter with clean engine oil. Turn filter clockwise
•
until gasket contacts lightly with filter adapter. Then tighten an
additional 3/4 turn.
Fill oil sump with recommended oil. (See “Before Starting the
•
Generator” for oil recommendations).
Wipe up any spilled oil.
•
14
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
3.3.6 REPLACING THE SPARK PLUG
Use Champion RC14YC spark plug or equivalent. The correct air gap
is 1.01 mm (0.040 in.) (Figure 18). Replace the plug once each year.
This will help the engine start easier and run better.
1. Stop the engine and pull the spark plug wire off of the spark
plug.
2. Clean the area around the spark plug and remove it from the
cylinder head.
3. Set the spark plug's gap to 1.01 mm (0.040 in.). Install the
correctly gapped spark plug into the cylinder head.
Figure 18 - Spark Plug Gap
3.4 SERVICE AIR CLEANER
The engine will not run properly and may be damaged if using a dirty
air cleaner. Clean or replace the air cleaner paper filter once a year
(Figure 19). Clean or replace more often if operating under dusty
conditions. Clean foam pre-cleaner every month or more often under
dusty conditions.
Figure 19 - Air Cleaner
Cover
Pre-Cleaner
To clean or replace foam pre-cleaner:
Remove air cleaner cover, then foam pre-filter.
•
Wash pre-cleaner in soapy water. Squeeze pre-filter dry in clean
•
cloth (DO NOT TWIST).
Clean air cleaner cover before re-installing it.
•
To clean or replace paper air filter:
Remove air cleaner cover; then remove foam pre-filter (service if
•
necessary) and remove paper filter.
Clean paper filter by tapping it gently on a solid surface. If the
•
filter is too dirty, replace it with a new one. Dispose of the old filter
properly.
Clean air cleaner cover then slip pre-cleaner over filter. Next insert
•
new paper filter into the base of the air cleaner. Re-install air
cleaner cover.
NOTE:
To order a new air filter, please contact the nearest authorized
service center at 1-800-333-1322.
3.5 CLEAN SPARK ARRESTOR SCREEN
The engine exhaust muffler has a spark arrestor screen. Inspect and
clean the screen at least once each year (Figure 20). If unit is used
regularly, inspect and clean more often.
NOTE:
If using the generator on any forest-covered, brush-covered
or grass-covered unimproved land, it must equipped with a
spark arrestor. The spark arrestor must be maintained in good
condition by the owner/operator.
Clean and inspect the spark arrestor as follows:
Remove the screen retaining bracket by removing the screw.
•
Slide the spark arrestor screen out from the tail pipe.
•
Inspect screen and replace if torn, perforated or otherwise
•
damaged. DO NOT USE a defective screen. If screen is not
damaged, clean it with commercial solvent.
Replace the screen and the retaining bracket.
•
Figure 20 - Spark Arrestor
Filter
Base
15
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
3.6 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, check the valve clearance in
the engine and adjust if necessary.
Important: If feeling uncomfortable about doing this procedure or the
proper tools are not available, please take the generator to the nearest
service center to have the valve clearance adjusted. This is a very
important step to insure longest life for the engine.
To check valve clearance:
Make sure the engine is at room temperature (60° - 80° F).
•
Make sure that the spark plug wire is removed from the spark plug
•
and out of the way.
Remove the four screws attaching the valve cover.
•
Make sure the piston is at Top Dead Center (TDC) of its
•
compression stroke (both valves closed). To get the piston at
TDC, remove the intake screen at the front of the engine to gain
access to the flywheel nut. Use a large socket and socket wrench
to rotate the nut and hence the engine in a clockwise direction
while watching the piston through the spark plug hole. The piston
should move up and down. The piston is at TDC when it is up as
high as it can go.
Insert a 0.002 - 0.004 inch (0.05 - 0.1mm) feeler gauge between
•
the rocker arm and valve stem. Correct clearance is when a slight
drag is felt when sliding the gauge back and forth. If the clearance
is either excessively loose or tight the rocker arms will need
adjusting.
To adjust valve clearance:
Loosen the rocker jam nut (Figure 21). Use an 10mm allen wrench
•
to turn the pivot ball stud while checking clearance between
the rocker arm and the valve stem with a feeler gauge. Correct
clearance is 0.002-0.004 inch (0.05-0.1 mm).
NOTE:
The rocker arm jam nut must be held in place as the pivot ball
stud is turned.
When valve clearance is correct, hold the pivot ball stud in place with
the allen wrench and tighten the rocker arm jam nut. Tighten the jam
nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve
clearance to make sure it did not change.
Figure 21 - Valve Clearance Adjustment
•
Install new valve cover gasket.
•
Re-attach the valve cover.
NOTE:
Start all four screws before tightening or it will not be possible
to get all the screws in place. Make sure the valve cover gasket
is in place.
•
Re-attach the spark plug wire to the spark plug.
•
Repeat the process for the other cylinder.
3.7 GENERAL
The generator should be started at least once every seven days
and be allowed to run at least 30 minutes. If this cannot be done
and the unit must be stored for more than 30 days, use the following
information as a guide to prepare it for storage.
DANGER
NEVER store engine with fuel in tank indoors
or in enclosed, poorly ventilated areas where
fumes may reach an open flame, spark or pilot
light as on a furnace, water heater, clothes dryer
or other gas appliance.
16
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
3.8 LONG TERM STORAGE
It is important to prevent gum deposits from forming in essential fuel
system parts such as the carburetor, fuel hose or tank during storage.
Also, experience indicates that alcohol-blended fuels (called gasohol,
ethanol or methanol) can attract moisture, which leads to separation
and formation of acids during storage. Acidic gas can damage the fuel
system of an engine while in storage.
To avoid engine problems, the fuel system should be emptied before
storage of 30 days or longer, as follows:
•
Remove all gasoline from the fuel tank.
DANGER
Drain fuel into approved container outdoors,
away from open flame. Be sure engine is cool.
Do not smoke.
•
Start and run engine until engine stops from lack of fuel.
•
While engine is still warm, drain oil from crankcase. Refill with
recommended grade.
•
Remove spark plugs and pour about 1/2 ounce (15 ml) of engine
oil into the cylinders. Cover spark plug hole with rag. Press the
“Start” button and allow engine to crank for 2 seconds. Then press
the “Stop” button.
3.9 OTHER STORAGE TIPS:
•
Do not store gasoline from one season to another.
•
Replace the gasoline can if it starts to rust. Rust and/or dirt in the
gasoline will cause problems with the carburetor and fuel system.
•
If possible, store the unit indoors and cover it to give protection
from dust and dirt. BE SURE TO EMPTY THE FUEL TANK.
•
If it is not practical to empty the fuel tank and the unit is to be stored
for some time, use a commercially available fuel stabilizer added to
the gasoline to increase the life of the gasoline.
•
Cover the unit with a suitable protective cover that does not retain
moisture.
DANGER
NEVER cover the generator while engine and
exhaust area are warm.
Avoid spray from spark plug holes when
cranking engine.
Install and tighten spark plugs. Do not connect spark plug wires.
•
Clean the generator outer surfaces. Check that cooling air slots and
•
openings on generator are open and unobstructed.
Store the unit in a clean, dry place.
•
17
Section 4 — Troubleshooting
Commercial-Industrial-Residential Portable Generator System
4.1 TROUBLESHOOTING GUIDE
PROBLEM CAUSE CORRECTION
Engine is running, but no AC
output is available.
1. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
4. Fault in generator.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in good condition.
4. Contact Authorized Service Facility.
Engine runs good but
bogs down when loads are
connected.
Engine will not crank.
Engine will not start; or
starts and runs rough.
Engine shuts down during
operation.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. 10 amp fuse at rear of generator control panel
has melted open.
2. Battery weak or dead.
1. Dirty air cleaner.
2. Out of gasoline.
3. Stale gasoline.
4. Spark plug wire not connected to spark plug.
5. Bad spark plug.
6. Water in gasoline.
7. Overchoking.
8. Low oil level.
9. Excessive rich fuel mixture.
10. Intake valve stuck open or closed.
11. Engine has lost compression.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator” .
3. Contact Authorized Service Facility.
4. Contact Authorized Service Facility.
1. Replace fuse with only an identical 10-amp
replacement fuse.
2. Recharge or replace battery.
1. Clean or replace air cleaner.
2. Fill fuel tank.
3. Drain fuel tank and fill with fresh fuel.
4. Connect wire to spark plug.
5. Replace spark plug.
6. Drain fuel tank; fill with fresh fuel.
7. Put choke knob to No Choke position.
8. Fill crankcase to proper level.
9. Contact Authorized Service Facility.
10. Contact Authorized Service Facility.
11. Contact Authorized Service Facility.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Authorized Service Facility.
Engine lacks power.
Engine “hunts” or falters.
No Battery Charge DC
output.
18
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. Choke is opened too soon.
2. Carburetor is running too rich or too lean.
1. Battery posts are corroded.
2. Battery cable is bad.
3. Battery is defective.
4. Receptacle is bad.
1. See “Don’t Overload the Generator”.
2. Replace air filter.
3. Contact Authorized Service Facility.
1. Move choke to halfway position until engine runs
smoothly.
2. Contact Authorized Service Facility.
1. Clean battery posts.
2. Replace cable.
3. Check battery condition; replace if defective.
4. Contact Authorized Service Facility.
Section 5 — Electrical Data
Electrical Schematic – Drawing No. 0G0733
19
19
Section 5 — Electrical Data
Wiring Diagram – Drawing No. 0G0731
20
Section 5 — Electrical Data
Wiring Diagram – Drawing No. 0G0731
21
Section 6 — Exploded Views and Parts Lists
Handle, Frame & Wheel Kit – Drawing No. 0E0695-B
22
Section 6 — Exploded Views and Parts Lists
Handle, Frame & Wheel Kit – Drawing No. 0E0695-B
ITEM PART NO. QTY. DESCRIPTION
1 057058 4 SCREW HHC M6-1.0 X 55
2 0D5315 4 RUBBER TANK MOUNT
3 0D4570 1 CAP, FUEL WITH GAUGE & VENT
4 0D22850SRV 1 KIT, FUEL TANK
5 045771 4 NUT HEX M8-1.25
6 022129 10 WASHER LOCK M8-5/16
7 022145 14 WASHER FLAT 5/16
8 0D4565 1 BRACKET BATTERY
9 0D3545 2 BOLT,BATTERY J-BOLT
10 022287 2 SCREW HHC 1/4-20 X 3/4 G5
11 022473 2 WASHER FLAT 1/4
12 022097 2 WASHER LOCK M6-1/4
13 022127 2 NUT HEX 1/4-20
14 0388040AK0 1 BATTERY CABLE, RED
15 0D4575 1 BATTERY U1
16 0D5202 1 NUT WING 5/16-18 BRASS
17 0D5199 4 WASHER FLAT 5/16 BRASS
18 029809 1 NUT HEX 5/16-18 BRASS
19 0C3168 1 5/16 SPECIAL L/WASH
20 0D5198 1 SCREW HHC 5/16-18 X 1.5 BRASS
21 0E0317 1 BRACKET FRONT FOOT (15 kW)
0D2498 1 BRACKET FRONT FOOT (12.5 kW)
22 027007 2 VIB MOUNT
23 0D5303 4 WASHER FLAT .25ID X 1"OD
24 042909 2 SCREW HHC M8-1.25 X 30
25 090388 4 SCREW HHTT M6-1.0 X 12
26 064101 6 NUT LOCK FL 3/8-16
27 039214 6 BOLT CARR 3/8-16 X 1
28 0D9165 1 AXLE, 3/4"DIA X 30" (15 kW)
0D2496 1 AXLE, 3/4"DIA X 27.25" (12.5 kW)
29 045900 2 WASHER FLAT 3/4” (15 kW)
045900 4 WASHER FLAT 3/4” (12.5 kW)
30 0D7668 2 12.3" PNEUM WHEEL 3/4" AXLE (15 kW)
0D2495 2 10" PNEUM WHEEL 3/4" AXLE (12.5 kW)
31 0D4999 2 PIN COTTER 1/8 X 1-1/4
32 0D4044 2 BRACKET, WHEEL SPACER
33 0D3700 4 NUT FLANGE M6-1.0 NYLOK
34 0D2497 1 HANDLE
35 022532 4 SCREW HHC 5/16-18 X 2-1/2 G5
36 027028 6 NUT LOCK HEX 5/16-18 NYLON INSERT
37 0D2271 1 FRAME
38 052762 4 SCREW HHC M5-0.8 X 45 G8.8
39 051713 8 WASHER FLAT M5
40 049226 4 WASHER LOCK M5
41 051716 4 NUT HEX M5-0.8
42 050190 2 WASHER FLAT 1”
43 078299 1 BUSHING TANK DEXTOR
44 080270 1 VALVE, PLASTIC TANK
45 0D5142 1 AIR DEFLECTOR
46 096021 2 GROMMET .75 X .06 X .50
47 048031C 2 CLAMP HOSE BAND ¼
48 0F9176 18” HOSE ¼ ID
49 075763 1 BOOT BATTERY CABLE
50 075763A 1 BOOT STARTER CABLE
51 0E0318 2 SPACER, AXLE (15 kW)
52 030795 2 SCREW HHC 5/16”-18 X 1”
23
Section 6 — Exploded Views and Parts Lists
Control Panel – Drawing No. 0G0727-B
24
Section 6 — Exploded Views and Parts Lists
Control Panel – Drawing No. 0G0727-B
ITEM PART NO. QTY. DESCRIPTION
1 087968 1 SWITCH, ROCKER -/0
2 090418 1 OUTLET, 12VDC SNAP
3 0D6640 1 COVER, GOVERNOR CONTROL
4 090987 6 SCREW PPHM M3-0.5 X 12
5 0D8740 1 PANEL, SHEET METAL (15 KW)
0G0309 1 PANEL, SHEET METAL (17.5 KW)
6 068868 2 OUTLET 30A 120V RECEPT
7 0G1093 4 SCREW SFILHM #8-32 X 5/8 LG (17.5 KW
ONLY)
8 043182 4 WASHER LOCK M3
9 0D9784 6 NUT HEX LOCK M3-0.5 NY INS
10 075207A 4 CIRCUIT BREAKER 30A
11 075207 2 CIRCUIT BREAKER 20A
12 0G1493 1 OUTLET 50A 250V (17.5 KW ONLY)
13 043437 1 OUTLET 30A 125/250V
14 0D4968 1 OUTLET 20A 120V DPLX
15 0D4966 1 OUTLET 20A 120V GFCI
16 0D1004E 1 CIRCUIT BREAKER 50A 400V 2POLE
17 0E6480 4 NUT HEX M4-0.5 NYINS
18 022471 4 NUT HEX #8-32 (17.5 KW ONLY)
19 0D5045 1 DIN RAIL 59.5mm LONG
20 0F9719 1 ASSY PCB VREG AIR COOLED
21 0D4409 1 ELECTRONIC GOVERNOR / IDLE
CONTROLLER
22 052844 1 RELAY PNL 12VDC SPST 30A
23 0F3100 1 RELAY 3PDT 12VDC
24 0G0503 1 CONTROL PANEL BOX (15 KW)
0F7424 1 CONTROL PANEL BOX (17.5 KW)
25 023484S 1 BUSHING SNAP
26 0A1661 2 RIVET POP .156 X .160-.164 / #20
27 048766 1 BLOCK TERMINAL 20A 2 X 6 X 1100V
28 0D3550 1 BLOCK DOUBLE ROW TERMINAL 8
POSITION
29 049939 1 RECTIFIER MSC 12A 600V
30 070370 1 WASHER MICA .203
31 030468 1 WASHER STEP NYLON .20
32 022158 1 NUT HEX #10-32
33 023897 1 WASHER FLAT #10
34 057405 1 RESISTOR 25R 5% 25W
35 022473 1 WASHER FLAT 1/4
36 022097 1 WASHER LOCK M6-1/4
ITEM PART NO. QTY. DESCRIPTION
37 049813 1 NUT HEX M6-1.0 G8
38 065795 2 RECTIFIER-BATTERY CHARGER
39 0D4804 2 TRANSFORMER, IDLE CURRENT
40 0C1085 4 SCREW PPHM M3-0.5 X 8
41 051715 12 NUT HEX M4-0.7 G8 (15 KW)
8 NUT HEX M4-0.7 G8 (17.5 KW)
42 022264 14 WASHER LOCK M4
43 048505 1 CIRCUIT BREAKER 6 X 1
44 087962 1 CIRCUIT BREAKER 10 X 1 12VDC 1/4"QC
45 036261 2 RIVET POP .125 X .250 SS
46 0A2769 1 LUG GROUND 8 TABS
47 032300 1 HOLDER FUSE
48 028578 1 FUSE 10A X AGC10
49 055444 1 HEATSINK
50 075475 2 SCREW PPHM M4-0.7 X 10
51 082025 6 NUT HEX LOCK M5-0.8 NYINS
52 0A2053 1 SCREW HHC M6-1.0 X 65 G8.8
53 055440 2 SCREW HHC M5-0.8 X 25 G8.8
54 045770 1 SCREW HHC M5-0.8 X 10 G8.8
55 0G0923 2 SPACER .25 X .50 X 2.5 (17.5 KW)
0D5734 2 SPACER .25 X .50 X 1.5 (15 KW)
56 074908 10 SCREW HHTT M5-0.8 X 10
57 075235 3 SCREW PPHM M5-0.8 X 30
58 077682 2 SCREW PPHM M5-0.8 X 80 (17.5 KW)
080823 2 SCREW PPHM M5-0.8 X 50 (15 KW)
59 038150 14 WASHER FLAT #8 (15 KW)
10 WASHER FLAT #8 (17.5 KW)
60 0D6140 1 GASKET, PORTABLE CONTROL PANEL
61 075476 2 SCREW PPHM M4-0.7 X 16
62 027565 A/R TAPE ELEC UL PERMACEL
63 058000K 2 NUT TRIC M5-0.8
64 0F3101 1 RELAY BASE 3PDT 12VDC
65 0D4969 1 OUTLET 50A 125/250V (15 KW ONLY)
66 0F5483 1 HARNESS, CONTROL PANEL BACK (NOT
SHOWN)
67 0D3546 1 HARNESS, CONTROL PANEL FRONT (NOT
SHOWN)
68 0D5809 1 HARNESS, TERMINAL STRIP TO PCB (NOT
SHOWN)
69 0G0615 1 SPRING RETAINER
25
Section 6 — Exploded Views and Parts Lists
Generator – Drawing No. 0G0742-A
26
Section 6 — Exploded Views and Parts Lists
Generator – Drawing No. 0G0742-A
ITEM PART NO. QTY. DESCRIPTION
1 0C6934 1 ADAPTOR, ENGINE
2 0G1177 1 STATOR 15KW
0D2136 STATOR 17.5KW
3 0G11760SRV 1 ASSEMBLY, ROTOR WITH FAN 15KW
0D21350SRV ASSEMBLY, ROTOR WITH FAN 17.5KW
4 0C6043B 1 CARRIER, REAR BEARING
5 0D2492 1 EXHAUST MANIFOLD
6 0D2726 1 MUFFLER
7 0C4138 2 GASKET, EXHAUST
8 0D3547 1 COVER, ALTERNATOR AIR IN
9 031971 1 BEARING
10 0C3168 3 5/16 SPECIAL LOCK WASHER
11 0D1838 1 SCREW IHHC 3/8-24 X 15.50 G5
12 0D3549 4 SCREW IHHC M8-1.25 X 400 G8.8
13 0C7038E 1 BRACKET, ALT MOUNTING
14 032712 4 SCREW HHTT #10-32 X 1.75
15 0D4662 1 SCREW HHTT M8-1.2 X 20
16 0C7038D 1 ENGINE MOUNTING PLATE
17 0C7758 6 RUBBER MOUNT
18 0388050AF0 1 BATTERY CABLE, BLACK
19 0C2417A 1 EARTH STRAP 3/8X 3/8
20 082121C 1 CLIP-J VINYL COAT .625 ID
21 066386 1 ASSEMBLY, BRUSH HOLDER
22 0C2824 1 SCREW TAP-R #10-32 X 9/16
23 0A2038 1 WASHER FLAT 3/8 ZINC
24 022237 5 WASHER LOCK 3/8
25 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5
26 022131 4 WASHER FLAT 3/8-M10 ZINC
27 051731 4 SCREW HHC M8-1.25 X 50 G8.8
28 022145 21 WASHER FLAT 5/16 ZINC
29 049820 4 NUT LOCK HEX M8-1.25 NYLON INSERT
30 043116 7 SCREW HHC M6-1.0 X 12
31 022129 18 WASHER LOCK M8-5/16
32 022259 12 NUT HEX 5/16-18 STEEL
33 059637 2 SCREW TAPTITE 3/8-16 X 3/4 BP
34 0D5100 1 SHIELD, MUFFLER HEAT
35 0D5823 1 U-BOLT & SADDLE
36 0C8565 4 SCREW SHC M8-1.25 X 18
37 0D5833 1 PANEL, MUFFLER BOX BACK
38 0D5834 1 PANEL, MUFFLER BOX END
39 090388 3 SCREW HHTT M6-1.0 X 12
40 022473 7 WASHER FLAT M6-1/4
41 022097 7 WASHER LOCK M6-1/4
42 0D5133 1 SPARK ARRESTOR SCREEN
43 0D5133A 1 RETAINER, SPARK ARREST SCREEN
44 045764 1 SCREW HHTT M4-0.7 X 8
45 0D6214 1 SHIELD, RUBBER MOUNT
46 066849 2 SCREW HHTT M5-0.8 X 16
27
Section 6 — Exploded Views and Parts Lists
GT-760/990 Engine – Drawing No. 0E8589-W - Part 1
28
Section 6 — Exploded Views and Parts Lists
GT-760/990 Engine – Drawing No. 0E8589-W - Part 1
ITEM PART NO. QTY. DESCRIPTION
1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH
SLEEVE
2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT
3 090388 3 SCREW, TAPTITE M6-1.0 X 12 BP
4 0C5372 1 ASSEMBLY, BREATHER
5 0C3005 1 GASKET, BREATHER COVER
6 0E3372B 1 SEPARATOR, OIL BREATHER
7 0D8067A 1 ASSEMBLY, HEAD #1
8 071983 4 RETAINER, PISTON PIN 20
9 0G0693 1 ASSY, ROCKER COVER W/BARB
10 043790 1 BARBED EL 90 3/8NPT X 3/8
11 0E2950 2 PISTON, LC (GT-990)
0E2985 2 PISTON, HC (GT-760)
12 021533 2 SET, PISTON RING 90MM
13 0E1466 2 PIN PISTON
14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR
16 093064 1 ASSEMBLY, OIL FILL CAP
17 0C2977 1 GASKET, CRANK CASE
18 0C5943 1 SEAL, OIL PASSAGE
19 0E3791E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE (GT-990)
0E3790E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE (GT-760)
20 0E3223 2 ASSEMBLY, CONNECTING ROD (GT-990)
0E3222 2 ASSEMBLY, CONNECTING ROD (GT-760)
21 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8
22 0E6098 1 SCREEN, OIL PICKUP
23 0G1536 1 ASSEMBLY, OIL PUMP
24 0E8152 1 O-RING, 0.49 ID X 0.07 THICK
25 0C3011 2 COVER, OIL RELIEF
26 0C3009 2 SPRING, OIL RELIEF
27 0C3010 2 BALL, 1/2D OIL RELIEF
28 093873 2 WASHER, LOCK RIB M6
29 0F5458 1 SCREW, PLASTITE HI-LOW #10
30 0C5998 1 CLAMP, OIL TUBE
31 0D4497 1 PLUG-CRANKCASE GOVERNOR BORE
ITEM PART NO. QTY. DESCRIPTION
32 0C3971E 1 ASSEMBLY, DIPSTICK WITH HANDLE
33 0D3745 1 TUBE, DIPSTICK
34 0C3027 3 O-RING, OIL CLR
35 0E9842 1 SEAL, 42 I.D. CRANKSHAFT
36 0C5731 1 ASSEMBLY, GEAR COVER W/SLEEVE
37 0C3006 10 SCREW, HHFC M10-1.5 X 55
38 080318 8 SCREW HHFC M6-1.0 X 25
39 0G1839 2 LIFT HOOK, GT990/760
40 0D2723D 1 COVER, ROCKER W/OIL FILL “GENERAC”
TEXT
41 0C2979 2 GASKET, VALVE COVER
42 086515 8 KEEPER, VALVE SPRING
43 0D2274 4 RETAINER, VALVE SPRING
44 0D3867 4 SPRING, VALVE
45 078672 2 SEAL, VALVE STEM D7
46 0C5371 4 WASHER, VALVE SPRING
47 072694 4 STUD, ROCKER ARM PIVOT
48 0C3027 2 O-RING, 3/8” X 1/2”
49 0D5313 4 ROCKER ARM
50 0D3998 4 NUT, HEX M8-1.0 GB YELLOW CHROM
51 0D6024 2 PLATE, PUSH ROD GUIDE
52 0C2976 12 SCREW HHFC M8-1.25 X 65
53 086516 2 VALVE, EXHAUST
54 0C2229 2 VALVE, INTAKE
55 083897 4 TAPPET, SOLID
56 0D8067B 1 ASSEMBLY, HEAD #2
57 0D9853D 4 PUSHROD 147
58 0C2978 2 GASKET, HEAD
59 0D6008 1 KIT GEAR COVER
60 0D4010 1 KIT GASKET
61 0D6007 1 KIT PISTON & RINGS
62 0D4012 1 KIT BREATHER ASSEMBLY
63 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1
64 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2
65 0D4015 1 KIT OIL RELIEF
27 29
Section 6 — Exploded Views and Parts Lists
GT-760/990 Engine – Drawing No. 0E8589-W - Part 2
30
Section 6 — Exploded Views and Parts Lists
GT-760/990 Engine – Drawing No. 0E8589-W - Part 2
ITEM PART NO. QTY. DESCRIPTION
66 0D6592 1 WINGNUT, AIRBOX
67 0D4511 1 PRECLEANER, AIR
68 0D9723 1 ELEMENT, AIR CLEANER
69 0E5302 1 STUD M6-1.0 X 73
70 0D4183 1 ADAPTOR, SPIT BACK
71 0D6327 1 GASKET, SPITBACK
72 0D2774B 1 BASE, AIRBOX
73 0D5125 1 SPRING, WINTER/SUMMER VALVE
74 0D2930 1 VALVE, SUMMER / WINTER
75 0D4612A 1 SNORKEL, AIR INTAKE
76 0D6143 1 TUBE, HEAT RISER 50.8 I.D.
77 0D2775 1 COVER, AIRBOX
78 0D5014A 1 KNOB, AIRBOX 17mm
79 0D5014B 1 KNOB, AIRBOX 95MM
80 049721 1 SCREW HHC M6-1.0 X 35
81 022097 1 WASHER LOCK M6-1/4
82 022473 1 WASHER FLAT 1/4
83 0E8388 4 NUT, HEX FLANGE WHIZ M6-1.0
84 0D6021 4 STUD, METRIC
85 0C9093A 1 HOSE, BREATHER
86 0D4522 1 CONTROLLER ASSEMBLY
87 074908 2 SCREW HHTT M5-0.8 X 10
89 0E3398 1 ASSEMBLY, WIRE
90 0F9035 1 CARBURETOR (GT-990)
0F8603 1 CARBURETOR (GT-760)
91 0D4026 1 GASKET, CARB TO SPACER (GT-990)
0D4024 1 GASKET, CARB/AIRBOX (GT-760)
92 048031C 4 CLAMP HOSE BAND 1/4
93 0F9176 12” HOSE ¼ ID
94 0D4023 1 GASKET, MANIFOLD TO CARB (GT-990)
0D5282 1 GASKET, MANIFOLD TO CARB (GT-760)
95 084409D 1 SLEEVING, FLEXO HW ¾ 3”
96 0D6313 1 FILTER, FUEL
97 070008 4 WASHER FLAT M8
98 070006 4 WASHER LOCK M8
99 049821 4 SCREW SHC M8-1.25 X 30
100 0C9911 1 MANIFOLD, INTAKE
101 051714 1 NUT HEX M3-0.5
102 0D5411 1 ROD, SUMMER / WINTER VALVE
103 0D5445 1 BUSHING, MINI CONTROL PANEL
104 0D5416A 1 KNOB, CONTROL SUMMER / WINTER
105 0D5398 1 CHOKE ASSEMBLY
106 0E6043 2 SCREW TAPTITE M5-0.8 X 8 ZP
107 0D3432 1 PANEL, CONTROL FACE PLATE
108 045756 24 SCREW TAPTITE M6-1.0X 10 YELLOW
CHROME
109 0D4767 1 SWITCH ROCKER
110 0D1142A 1 WRAPPER, LOWER CYLINDER 2
111 0D1143 1 WRAPPER, UPPER CYLINDER 2
112 0F1177 1 ASSEMBLY, GROUND WIRE
ITEM PART NO. QTY. DESCRIPTION
113 022097 4 WASHER LOCK M6-1/4
114 0G3111 4 SCREW TAPTITE M6-1.0 X 25 ZINC
115 0F1338B 1 ASSY, IGN COIL W/DIODE NO ADV
116 0F6263 1 PUMP, IMPULSE
117
118 0G0926 2 SCREW, HHFCS M6-1.0 X 16 G8.8
119 0G0832 1 ELBOW, RUBBER 90 DEG. GASOLINE
120 0E7585A 2 SPARKPLUG, CHAMPION RC14YC
121 0E4271 1 STARTER, DELCO REMY SD80
122 022129 3 WASHER LOCK M8-5/16
123 061906 2 SCREW HHC M8-1.25 X 85 G8.8
124 022145 1 WASHER, FLAT M8
125 0F5467 1 NUT, HEX M8-1.25 YELLOW ZINC
126 0D1131 1 GUARD,FAN
127 0F1169B 1 HOUSING, BLOWER GAS COOLER
128 0C9763 4 NUT, GROMMET 1/4 PLUG
129 0C3034 1 NUT,HEX M24
130 0C3033 1 WASHER, M24
131 0C3032 1 PLATE, FAN
132 0A5992 2 WASHER SHAKEPROOF INT M8 SS
133 051754 2 SCREW HHC M8-1.25 X 12 G8.8
134 0C3031 1 FAN, NYLON
135 0E4997 1 ASSY,GROUND WIRE CONNECTOR
136 045756 4 SCREW TAPTITE M6-1X10 YELLOW
CHROME
137 0C3725A 1 FLYWHEEL ASSEMBLY
138 0F1170A 1 PLATE, BACKING GT990 W/OIL COOL
139 082774 1 KEY, WOODRFF 4 X 19D
140 0C3043 2 GASKET, MANIFOLD / PORT
141 0C9764 4 PLASTITE,1/4-15 X 3/4
142 0E9506 1 COOLER, OIL
143 0F6301 4 CLAMP, HOSE OETIKER 16.5mm
144 0C9806 2 HOSE, 3/8" I.D. X 6" LONG
145 035461 2 BARBED STR 1/4NPT X 3/8
146 070185B 1 OIL FILTER
147 0D3083 1 ASSEMBLY, OIL DRAIN HOSE
149 0C3025 1 SWITCH, OIL PRESS
150 0D4550 1 BRACKET, AIRBOX SUPPORT
151 0C3018 1 WRAPPER, UPPER CYLINDER 1
152 0C3019 1 WRAPPER, LOWER CYLINDER 1
153 046964 1 BRASS ST ELBOW 1/4 NPT
154 0E0409 1 ASSY, ROD, GOV. STEPPER MOTOR
155 0C8563 6 SCREW HHHC M6-1.0 X12
157 0D9784 2 NUT, LOCK HEX M3-0.5 (GT-990)
0E4869 2 NUT, HEX W/TOOTH WASHER M3-0.5 (GT-
760)
160 0D6147 7 SCREW HHFC M6-1.0 X 10mm
161 0F1338A 1 ASSY, IGN COIL W/DIODE NO ADV
162 048031G 1 CLAMP, HOSE BAND GREEN
163 0D6342 2 BALL STUD
31
Section 7 – Warranty
Commercial-Industrial-Residential Portable Generator System
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the
Emission Control System warranty on your new engine. In California, new off-road Large Spark-Ignition (LSI) engines
must be designed, built and equipped to meet the state's stringent anti-smog standards. Generac will warrant the emission
control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved
modification or improper maintenance of your engine.
Your emission control system may include parts such as the carburetor, ignition system, exhaust system and crankcase
ventilation system. Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor, should a
warrantable condition occur.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 2001 and later model year LSI engines are warranted for two years as hereinafter noted. If,
during such warranty period any emission-related component or system on your engine is found to be defective in materials
or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Dealer.
PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES:
As the engine owner, you are responsible for the completion of all required maintenance as listed in your factory supplied
Owner's Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on
your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the
completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage
or responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance
or unapproved modifications, or the use of counterfeit and/or "grey market" parts not made, supplied or approved by
Generac.
You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs. The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service
Dealer. To locate the Generac Authorized Warranty Service Dealer nearest you, call our toll free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the "Generac Limited
Warranties for Generac Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by
Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in
terms between the ECS Warranty and the Generac Warranty, the ECS warranty shall apply except in circumstances where
the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe
important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty
service, evidence must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at one of the
following addresses:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Part 1
32
Section 7 – Warranty
Commercial-Industrial-Residential Portable Generator System
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS warranty) for 2001 and later model year LSI engines:
(a) Applicability: This warranty shall apply to 2001 and later model year engines. The ECS Warranty period shall begin on the date the new engine
or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment and to
each subsequent purchaser/owner that each of its engines are:
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted emissions-
related part to fail to be identical in all material respects to the part as described in the engine manufacturer's application for certification.
The ECS Warranty pertains only to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner's Manual shall be
warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac
according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the
ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for
the ECS Warranty Period. A statement in such written instructions to the effect of "repair or replace as necessary" shall not reduce the ECS
Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty
Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted
for the period of time prior to first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part
shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under
the ECS warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such
emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a
Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for
diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components caused by a failure under warranty of any emission-related part
covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected
demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS warranty maintenance
or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts nay not be used to modify or repair a Generac engine. Such use voids
this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures
of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or "grey market"
part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
1.2) LPG/Natural Gas carburetion assembly and its internal components.
a) Fuel controller (if so equipped)
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
3) Ignition System including:
a) Spark plug
b) Ignition module
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
5) Crankcase Breather Assembly including:
a) Breather connection tube
* Generac engine types covered by this warranty statement include the following:
1) Prepackaged Standby Generator
2) Auxiliary Power Unit (APU) Generator
3) Portable Generator
4) Standby Generator Part 2
33
Section 7 – Warranty
Commercial-Industrial-Residential Portable Generator System
GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR GUARDIAN
®
“15,000 WATT PORTABLE GENERATOR”
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its Guardian generator will be free from defects in materials
and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and testing by
Generac or a Generac Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must be returned
to and examined by the nearest Generac Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory, are to be
borne and prepaid by the purchaser/owner. This warranty applies only to Generac Guardian portable generators and is not transferable.
WARRANTY SCHEDULE
Consumer applications are warranted for two (2) years. Commercial applications are warranted for one (1) year. Rental applications are warranted for 90 days.
CONSUMER APPLICATION
YEARS ONE and TWO - 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):
• Engine - All Components
• Alternator - All Components
NOTE: For the purpose of this warranty "consumer use" means personal residential household use by original purchaser. This does not apply to units used for Prime
Power in place of utility where utility power service normally exists. Once a generator has experienced commercial or rental use, it shall thereafter be considered a
non-consumer use generator for the purpose of this warranty.
All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Generac Guardian portable generators that utilize non-Generac replacement parts.
• Costs of normal maintenance and adjustments.
• Failures caused by any contaminated fuels, oils or lack of proper oil levels.
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper use. As with all mechanical devices, the Generac engines
need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing, lightning, earthquake,
windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent and/or insect infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS
TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the
above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not
allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
GENERAC
P.O. BOX 297 • WHITEWATER, WI 53190
Part No. 0G1086 Rev. C Printed in U.S.A. 03/27/07
®
POWER SYSTEMS, INC.
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