Owner`s Manual

ULTRA SOURCE
Portable Generator
Owner’s
Manual
• SAFETY
• ASSEMBLY
GENERAC POWER SYSTEMS, INC.
P.O. Box 297 • Whitewater, WI 53190
• OPERATION
• TROUBLESHOOTING
• ELECTRICAL DATA
• PARTS
• WARRANTY
AUTHORIZED DEALER SUPPORT:
Part No. 0E0226 Rev. F
Printed in USA
5.04, 10.04
1-800-333-1322
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODELS:
004451 (12,500 WATT)
004582 (15,000 WATT)
Table of Contents
Commercial-Industrial-Residential Portable Generator System
Safety Rules ..............................................1-3
Section 3 – Maintenance............................14
Section 1 – General Information ................4
3.1
Maintenance Schedule ................................................14
1.1
Unpacking ....................................................................4
1.1.1 Accessory Box..................................................4
3.2
1.2
Assembly ......................................................................4
1.2.1 Assembling the Wheel Kit ................................4
1.2.2 Assembling the Handle ....................................5
1.2.3 Battery Connection ..........................................5
Product Specifications ................................................14
3.2.1 Generator Specifications ................................14
3.2.2 Engine Specifications ....................................14
3.3
General Recommendations ........................................15
3.3.1 General Maintenance ......................................15
3.3.2 To Clean The Generator..................................15
3.3.3 Engine Maintenance ......................................15
3.3.4 Checking Oil Level ..........................................15
3.3.5 Changing The Oil & Oil Filter ..........................15
3.3.6 Replacing The Spark Plug ........................15-16
Section 2 – Operation ..................................6
2.1
Know The Generator ....................................................6
2.2
Cord Sets and Connector Plugs ....................................7
2.2.1 120V AC, 20 A, Duplex Receptacle ..................7
2.2.2 120V AC, 20 A, GFCI Receptacle ......................7
2.2.3 120V AC, 30 A Receptacle ............................7-8
2.2.4 120/240V AC, 30 A, Receptacle........................8
2.2.5 12 VDC, 10 Amp Receptacle ............................8
2.2.6 120/240V AC, 50 A, Receptacle........................8
3.4
Service Air Cleaner......................................................16
3.5
Clean Spark Arrestor Screen ......................................16
3.6
Adjusting Valve Clearance ..........................................17
3.7
General ......................................................................18
3.8
Long Term Storage ....................................................18
How To Use The Generator ..........................................9
2.3.1 Grounding The Generator ................................9
2.3.2 Connecting Electric Loads ................................9
3.9
Other Storage Tips ......................................................18
2.4
Don’t Overload The Generator ......................................9
4.1
2.5
Wattage Reference Chart ............................................10
2.6
Before Starting The Generator ....................................10
2.6.1 Adding Engine Oil ..........................................10
2.6.2 Adding Gasoline ............................................11
2.3
2.7
To Start The Engine ....................................................11
2.8
Stopping The Engine ..................................................12
2.9
Automatic Idle Control ................................................12
2.10 Cold Weather Operation/De-Icer ................................12
2.11 Low Oil Pressure Shutdown........................................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 ......................................................13
Section 4 – Troubleshooting ....................19
Troubleshooting Guide................................................19
Section 5 – Notes ..................................20-21
Section 6 – Electrical Data ..................22-23
Section 7 – Exploded Views and
Parts Lists..........................24-33
Section 8 – Warranty ............................34-36
Section 8 – Warranty
INTRODUCTION
Commercial-Industrial-Residential Portable Generator System
Thank you for purchasing this model of the GUARDIAN® product
line 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.
GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR GUARDIAN®
“12,500 WATT AND 15,000 WATT PORTABLE GENERATORS”
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 2 (two) years. Commercial applications are warranted for 1 (one) year. Rental applications are warranted for
90 (ninety) 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):
If you do not understand any portion of this manual, contact your
nearest GENERAC/GUARDIAN® 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 you to special instruction about a particular operation
that may be hazardous if performed incorrectly or carelessly.
Observe them carefully. Their definitions are as follows:
------------- DANGER -------------
• 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).
After this heading, you can read instructions that, if
not strictly complied with, will result in personal injury
or property damage.
------------- WARNING ------------After this heading, you can read instructions that, if
not strictly complied with, may result in personal
injury or property damage.
------------- CAUTION ------------After this heading, you can read instructions that, if
not strictly complied with, could result in damage to
equipment and/or property.
NOTE: After this heading, you can 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 follows:
This symbol points out important safety
• 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® POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
36
READ THIS MANUAL THOROUGHLY
information that, if not followed, could endanger
personal safety and/or property of you and 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 Owner’s Manual and thoroughly
understand all instructions before using this
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.
CAUTION! Always disconnect spark plug wire and place the
wire where it cannot contact the spark plug to prevent accidental
starting when setting up, transporting, adjusting or making
repairs to your 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 your
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 overfilled, 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 2 feet of clearance on all sides of generator or
you could damage 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 “Cold Weather
Operation” on page 12.
1
IMPORTANT SAFETY INSTRUCTIONS
Section 8 – Warranty
Commercial-Industrial-Residential Portable Generator System
THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted
SAVE
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: in rain; in any enclosed
compartment; 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: Your 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.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar with this
Owner’s 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.
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
GENERAC® cannot possibly 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 you use a procedure, work method or
operating technique GENERAC® does not specifically recommend,
you must satisfy yourself that it is safe for you and others. You
also must make sure the procedure, work method or operating
technique that you choose does not render the generator unsafe.
2
------------- DANGER ------------ 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
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 1995 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 is...
(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:
machines. Ensure all steps are taken to render
the machine safe before attempting to work on
the generator.
(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.
Parts of the generator are rotating and/or hot during
(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.
operation. Exercise care near running generators.
GENERAL HAZARDS • For safety reasons, GENERAC® recommends that the
installation, initial start-up and maintenance of this equipment
is carried out by a GENERAC®/GUARDIAN® 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 installed properly, in strict
compliance with applicable codes and standards. Following
installation, you must do nothing that might render the system
unsafe or in noncompliance with such codes and 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 you are physically or
mentally fatigued.
• Inspect the generator regularly, and contact your nearest
GENERAC®/GUARDIAN® 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.
(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 or approved modifications 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 RCS 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) Standby Generator
Part 2
35
Section 8 – Warranty
IMPORTANT SAFETY INSTRUCTIONS
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 one 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 and exhaust system. Generac will repair your
engine at no cost to you for diagnosis, replacement parts arid 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 Facility.
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/ox "grey market" parts not made, supplied or approved by Generac.
You are responsible for contacting a. Generac Authorized Warranty Facility 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 Facility. To locate the
Generac Authorized Warranty Service Facility 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
Commercial-Industrial-Residential Portable Generator System
ELECTRICAL HAZARDS
EXPLOSION 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 you must work
around an operating unit, stand on an insulated, dry surface
to reduce shock hazard.
• 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.
• 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.
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.
• 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.
1. NFPA No. 70,
ELECTRIC CODE.
• 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 nonconducting 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.
3. AGRICULTURAL WIRING HANDBOOK, available from the Food
and Energy Council, 909 University Avenue, Columbia, MO
65201.
• 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.
• Gasoline is extremely EXPLOSIVE.
STANDARDS INDEX
NFPA
HANDBOOK
OF
NATIONAL
2. Article X, NATIONAL BUILDING CODE, available from the
American Insurance Association, 85 John Street, New York,
N.Y. 10038.
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 always must
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
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 you have any question pertaining to fire
extinguishers, consult your local fire department.
Part 1
34
3
Section 1 – General Information
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Frame, Handle & Wheel Kit – Drawing No. 0E0695-A
ITEM PART NO.
1.1 UNPACKING
1.2 ASSEMBLY
• Set the palleted carton on a rigid flat surface.
• Remove staples along bottom of carton that fasten carton to
pallet. Open carton from top.
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.
• Remove all packaging material.
1.2.1 ASSEMBLING THE WHEEL KIT
• Remove separate accessory box.
• Remove generator from shipping pallet by removing bolts
through the shipping brackets.
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.
Figure 1 - Bracket Removal
Note:The wheel kit is not intended for over-the-road use.
• Lift carton off the generator.
• Refer to Figure 2 shown on opposite page and install the wheel
kit as follows:
• Place the generator on a hard flat surface.
Shipping
Bracket
(x4)
• 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.
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:
• Owner’s Manual
• Bolt-on tubular handle
• Wheel Axle
• 2 – Pneumatic Wheels
• 2 – Axle Bracket Assemblies
• 2 – Washers
• 2 – Wheel Spacers
• 2 – Cotter Pins
• Bolt-on Foot
• 6 – Carriage Bolts, Washers, Nuts
• Battery Charge Cable
• Spark Plug Wrench
• 2 Spark Plugs.
• Air Filter
• Pre-cleaner
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
QTY.
057058
4
0D5315
4
0D4570
1
0D22850SRV 1
045771
4
022129
10
022145
14
0D4565
1
0D3545
2
022287
2
022473
2
022097
2
022127
2
0388040AK0 1
0D4575
1
0D5202
1
0D5199
4
029809
1
0C3168
1
0D5198
1
0E0317
1
0D2498
1
027007
2
0D5303
4
042909
2
090388
4
064101
6
039214
6
0D9165
1
0D2496
1
DESCRIPTION
SCREW HHC M6-1.0 X 55
RUBBER TANK MOUNT
CAP, FUEL WITH GAUGE & VENT
KIT, FUEL TANK
NUT HEX M8-1.25
WASHER LOCK M8-5/16
WASHER FLAT 5/16
BRACKET BATTERY
BOLT,BATTERY J-BOLT
SCREW HHC 1/4-20 X 3/4 G5
WASHER FLAT 1/4
WASHER LOCK M6-1/4
NUT HEX 1/4-20
BATTERY CABLE, RED
BATTERY U1
NUT WING 5/16-18 BRASS
WASHER FLAT 5/16 BRASS
NUT HEX 5/16-18 BRASS
5/16 SPECIAL L/WASH
SCREW HHC 5/16-18 X 1.5 BRASS
BRACKET FRONT FOOT (15 kW)
BRACKET FRONT FOOT (12.5 kW)
VIB MOUNT
WASHER FLAT .25ID X 1"OD
SCREW HHC M8-1.25 X 30
SCREW HHTT M6-1.0 X 12
NUT LOCK FL 3/8-16
BOLT CARR 3/8-16 X 1
AXLE, 3/4"DIA X 30" (15 kW)
AXLE, 3/4"DIA X 27.25" (12.5 kW)
ITEM PART NO.
29
QTY.
045900
045900
0D7668
2
4
2
0D2495
2
31
32
33
34
35
36
0D4999
0D4044
0D3700
0D2497
022532
027028
2
2
4
1
4
6
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
0D2271
052762
051713
049226
051716
050190
078299
080270
0D5142
096021
048031C
030340
075763
075763A
0E0318
030795
1
4
8
4
4
2
1
1
1
2
2
18"
1
1
2
2
30
DESCRIPTION
WASHER FLAT 3/4" (15 kW)
WASHER FLAT 3/4" (12.5 kW)
12.3" PNEUM WHEEL 3/4" AXLE
(15 kW)
10" PNEUM WHEEL 3/4" AXLE
(12.5 kW)
PIN COTTER 1/8 X 1-1/4
BRACKET, WHEEL SPACER
NUT FLANGE M6-1.0 NYLOK
HANDLE
SCREW HHC 5/16-18 X 2-1/2 G5
NUT LOCK HEX 5/16-18 NYLON
INSERT
FRAME
SCREW HHC M5-0.8 X 45 G8.8
WASHER FLAT M5
WASHER LOCK M5
NUT HEX M5-0.8
WASHER FLAT 1"
BUSHING TANK DEXTOR
VALVE, PLASTIC TANK
AIR DEFLECTOR
GROMMET .75 X .06 X .50
CLAMP HOSE BAND ¼
HOSE ¼ ID
BOOT BATTERY CABLE
BOOT STARTER CABLE
SPACER, AXLE (15 kW)
SCREW HHC 5/16"-18 X 1"
• Insert retaining pins and using pliers, bend out the ends to
prevent the pins from falling out of the axle. Remove the
wooden blocks.
1.2.2 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 you have not
already done so.
33
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Section 1 - General Information
Commercial-Industrial-Residential Portable Generator System
Frame, Handle & Wheel Kit – Drawing No. 0E0695-A
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.
• Cut the tie wrap cable holding the RED and BLACK battery
cables to the stator.
Figure 3 - Battery Connections
Negative
Cable
Positive
Cable
• 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 at right.
32
5
Section 2 – Operation
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Control Panel – Drawing No. 0E0227B
OPERATION
7)
12 Volt DC, 10 Amp Receptacle – This receptacle
allows the capability to recharge a 12 volt DC storage battery
with provided battery charge cables.
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.
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.
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.
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.
120/240 Volt AC, 50 Amp Receptacle – Supplies
electrical power for the operation of 120/240 Volt AC, 50
Amp, single-phase, 60 Hz, welder or motor loads.
Air Cleaner – Filters intake air as it is drawn into the engine.
8)
Choke Knob – Used when starting a cold engine.
1)
2.1 KNOW THE GENERATOR
2)
Read the Owner’s Manual and Safety Rules before
operating this generator.
Compare the generator to this illustration to become familiarized
with the locations of various controls and adjustments. Save this
manual for future reference.
Figure 4 - Control Panel
3)
4)
5)
6)
Winter / Summer Valve – See “Cold Weather Operation.”
(Section 2, page 12.)
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)
9)
11) Fuel Tank – Tank holds 16 U.S. gallons of fuel.
Figure 5 - Generator Controls
7
12) Grounding Lug – Ground the generator to an approved
earth ground here. See page 9 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.
11
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
087968
090418
0D6640
090987
0D2502
068868
022985
043182
051714
075207A
075207
0D4969
043437
0D4968
0D4966
0D1004E
1
1
1
6
1
2
2
10
6
4
2
1
1
1
1
1
32
33
34
35
36
37
38
39
40
41
42
43
44
022158
023897
057405
022473
022097
049813
065795
0D4804
0C1085
051715
022264
048505
087962
1
1
1
1
1
1
2
2
4
18
18
1
1
17
18
19
20
051716
022152
0D5045
067680
8
8
1
1
21
0D4409
1
22
23
24
25
26
27
052844
0F3100
0D2691
023484L
0A1661
048766
1
1
1
1
2
1
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
036261
0A2769
032300
028578
055444
075475
049815
0A2053
055440
045770
0D5734
074908
075235
080823
038150
0D6140
2
1
1
1
1
2
4
1
2
1
2
18
1
2
14
1
28
0D3550
1
29
30
31
049939
070370
030468
1
1
1
61
62
63
64
075476
027565
058000K
0F3101
2
A/R
2
1
SWITCH, ROCKER -/0
OUTLET, 12VDC SNAP
COVER, GOVERNOR CONTROL
SCREW PPHM M3-0.5 X 12
PANEL, SHEET METAL
OUTLET 30A 120V RECEPT
WASHER FLAT #6
WASHER LOCK M3
NUT HEX M3-0.5 G8
CIRCUIT BREAKER 30A
CIRCUIT BREAKER 20A
OUTLET 50A 125/250V
OUTLET 30A 125/250V
OUTLET 20A 120V DPLX
OUTLET 20A 120V GFCI
CIRCUIT BREAKER 50A 400V
2POLE
NUT HEX M5-0.8 G8
WASHER LOCK #10
DIN RAIL 59.5mm LONG
ASSEMBLY VOLTAGE REGULATOR
60HZ
ELECTRONIC GOVERNOR / IDLE
CONTROLLER
RELAY PNL 12VDC SPST 30A
RELAY 3PDT 12VDC
CONTROL PANEL BOX
BUSHING SNAP
RIVET POP .156 X .160-.164 / #20
BLOCK TERMINAL 20A 2 X 6 X
1100V
BLOCK DOUBLE ROW TERMINAL 8
POSITION
RECTIFIER MSC 12A 600V
WASHER MICA .203
WASHER STEP NYLON .20
NUT HEX #10-32
WASHER FLAT #10
RESISTOR 25R 5% 25W
WASHER FLAT 1/4
WASHER LOCK M6-1/4
NUT HEX M6-1.0 G8
RECTIFIER-BATTERY CHARGER
TRANSFORMER, IDLE CURRENT
SCREW PPHM M3-0.5 X 8
NUT HEX M4-0.7 G8
WASHER LOCK M4
CIRCUIT BREAKER 6 X 1
CIRCUIT BREAKER 10 X 1 12VDC
1/4"QC
RIVET POP .125 X .129-.133 / #30
LUG GRND 8 TABS
HOLDER FUSE
FUSE 10A X AGC10
HEATSINK
SCREW PPHM M4-0.7 X 10
SCREW HHC M5-0.8 X 16 G8.8
SCREW HHC M6-1.0 X 65 G8.8
SCREW HHC M5-0.8 X 25 G8.8
SCREW HHC M5-0.8 X 10 G8.8
SPACER .25 X .50 X 1.5
SCREW HHTT M5-0.8 X 10
SCREW PPHM M5-0.8 X 30
SCREW PPHM M5-0.8 X 50
WASHER FLAT #8
GASKET, PORTABLE CONTROL
PANEL
SCREW PPHM M4-0.7 X 16
TAPE ELEC UL PERMACEL
NUT TRIC M5-0.8
RELAY BASE 3PDT 12VDC
Figure 6 - Engine Control Panel
15
12
14
6
8
9
31
Section 2 – Operation
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Control Panel – Drawing No. 0E0227B
Figure 8 - 120 VAC, 20 Amp GFCI Receptacle
38
Keep extension cords as short as possible, preferably less than 15
feet long, to prevent voltage drop and possible overheating of wires.
7
42
22
41
18
50
33
29
34
37
36
25
17
45
35
54
4
53
Figure 7 - 120 Volt AC, 20 Amp, Duplex 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.
59
42
41
• 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.
15
13
41
• 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.
14
2.2.2 120V AC, 20 AMP, GFCI RECEPTACLE
This unit is equipped with a ground fault circuit interrupter (GFCI).
This device meets applicable federal, state and local codes.
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.
• This outlet is protected against overload by a 20A push-toreset circuit breaker. Use the outlet to power 120V AC, singlephase, 60 Hz, electrical loads requiring up to a combined 2400
watts (2.4 kW) or 20 amps of current.
2.2.3 120V AC, 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.
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 non-conducting surface, such as a wood floor.
2
1
5
60
43
42
41
44
9
8
3
21
56
11
9
10
8
6
64
63
20
18
17
23
12
40
39
59
42
8
26
27
46
59
16
42
28
41
9 8
18
17
55
19
30
49
52
4
51
47,48
17
18
24
58
This is a 120 Volt outlet protected against overload by a 20 Amp
push-to-reset circuit breaker. 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, wellinsulated, 3-wire grounded cord sets rated for 125 Volts at 20 Amps
(or greater).
31
32
2.2.1 AC, 20 AMP, DUPLEX RECEPTACLE
61
57
62
2.2 CORD SETS AND CONNECTION
PLUGS
30
7
Section 2 – Operation
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Generator – Drawing No. 0D4488-D
Figure 9 - 120 VAC, 30 Amp Receptacle
2.2.5 12 VOLT DC, 10 AMP RECEPTACLE
This receptacle allows you to recharge a 12 Volt automotive or
utility style storage battery with the battery charge cables
provided. 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" (page 12) before attempting
to recharge a battery.
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
23
24
25
26
27
28
29
0A2038
022237
022511
022131
051731
022145
049820
1
5
4
4
4
21
4
30
079246
5
31
32
33
34
35
36
37
38
39
40
41
42
43
022129
022259
059637
0D5100
0D5823
0C8565
0D5833
0D5834
090388
022473
N/A
0D5133
0D5133A
18
12
2
1
1
4
1
1
3
5
1
1
44
45
46
045764
0D6214
066849
1
1
2
3
0D21330SRV
Figure 11 - 12 Volt DC, 10 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.
The outlet is protected by a 30 Amp push-to-reset circuit breaker.
2.2.4 120/240V AC, 30 AMP RECEPTACLE
Use a NEMA L14-30 plug with this receptacle. Connect a suitable
4-wire 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).
2.2.6 120/240 VOLT AC, 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 10 - 120/240 VAC, 30 Amp Receptacle
Figure 12 - 120/240 VAC, 50 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-to-reset circuit breakers.
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.
8
0C6934
1
0D2123
1
0D2134
0D2136
0D21320SRV 1
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
0D2135
0C6043B
0D2492
0D2726
0C4138
0D3547
031971
0C3168
0D1838
0D3549
0C7038E
032712
0D4662
0C7038D
0C7758
0388050AF0
0C2417A
082121C
066386
0C2824
1
1
1
2
1
1
3
1
4
1
4
1
1
6
1
1
1
1
1
ADAPTOR, ENGINE
STATOR 12.5KW
STATOR 15KW
STATOR 18KW
ASSEMBLY, ROTOR WITH FAN
12.5KW
ASSEMBLY, ROTOR WITH FAN
15KW
ROTOR 18KW
CARRIER, REAR BEARING
EXHAUST MANIFOLD
MUFFLER
GASKET, EXHAUST
COVER, ALTERNATOR AIR IN
BEARING
5/16 SPECIAL LOCK WASHER
SCREW IHHC 3/8-24 X 15.50 G5
SCREW IHHC M8-1.25 X 400 G8.8
BRACKET, ALT MOUNTING
SCREW HHTT #10-32 X 1.75
SCREW HHTT M8-1.2 X 20
ENGINE MOUNTING PLATE
RUBBER MOUNT
BATTERY CABLE, BLACK
EARTH STRAP 3/8X 3/8
CLIP-J VINYL COAT .625 ID
ASSEMBLY, BRUSH HOLDER
SCREW TAP-R #10-32 X 9/16
WASHER FLAT 3/8 ZINC
WASHER LOCK 3/8
SCREW HHC 3/8-16 X 1-1/4 G5
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M8-1.25 X 50 G8.8
WASHER FLAT 5/16 ZINC
NUT LOCK HEX M8-1.25 NYLON
INSERT
SCREW HHC M6-1.0 X 16 WITH
LOCK WASHER
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW TAPTITE 3/8-16 X 3/4 BP
SHIELD, MUFFLER HEAT
U-BOLT & SADDLE
SCREW SHC M8-1.25 X 18
PANEL, MUFFLER BOX BACK
PANEL, MUFFLER BOX END
SCREW HHTT M6-1.0 X 12
WASHER FLAT 1/4
NOT USED
SPARK ARRESTOR SCREEN
RETAINER, SPARK ARREST
SCREEN
SCREW HHTT M4-0.7 X 8
SHIELD, RUBBER MOUNT
SCREW HHTT M5-0.8 X 16
29
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
Generator – Drawing No. 0D4488-D
2.3.2 CONNECTING ELECTRICAL LOADS
2.3 HOW TO USE THE GENERATOR
If you have any problems operating your 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. 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
your area.
Figure 13 - Grounding the Generator
Generator Ground Lug
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).
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.
• 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 you allow for this high starting
wattage when selecting electrical devices to connect to your
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 on page 10 is provided to assist
you in determining how many items your generator can operate
at one time. (Note: All figures are approximate. See data plate on
appliance for wattage requirements.)
28
9
Section 7 — Exploded Views and Parts Lists
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589E
ITEM PART #
2.5 WATTAGE REFERENCE GUIDE
Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts
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.
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
• Above 40°F, use SAE 10W-30 or SAE 30.
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 SF or SG SAE 30
weight. Use no special additives.
Select the oil’s viscosity grade according to the expected
operating temperature. Do not use SAE 10W-40.
• Below 40°F, use synthetic 5W-20 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 your
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.
10
66
67
68
69
70
71
72
QTY.
91
0D6592
0D4511
0D9723
0E5302
0D4183
0D6327
0D2774B
0E4870
0D5125
0D2930
0D4612A
0D6143
0D2775
0D5014A
0D5014B
049721
022097
022473
052857
0D6021
0C9093A
0D4522
074908
0E3398
0E2548
0E5077
0D4026
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
2
1
1
1
1
92
93
94
0D4024
048031C
030340
0D4023
1
4
12"
1
0D5282
1
95
96
97
98
99
100
101
102
103
104
086061G
0D6313
070008
070006
049821
0C9911
051714
0D5411
0D5445
0D5416A
1
1
4
4
4
1
1
1
1
1
105
106
107
108
0D5398
0E6043
0D3432
045756
1
2
1
24
109
110
111
112
113
114
0D4767
0D1142A
0D1143
0F1177
022097
092079
1
1
1
1
4
4
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
89
90
DESCRIPTION
WINGNUT, AIRBOX
PRECLEANER, AIR
ELEMENT, AIR CLEANER
STUD M6-1.0 X 73
ADAPTOR, SPIT BACK
GASKET, SPITBACK
BASE, AIRBOX (GT-990)
BASE, AIRBOX (GT-760)
SPRING, WINTER/SUMMER VALVE
VALVE, SUMMER / WINTER
SNORKEL, AIR INTAKE
TUBE, HEAT RISER 50.8 I.D.
COVER, AIRBOX
KNOB, AIRBOX 17mm
KNOB, AIRBOX 95MM
SCREW HHC M6-1.0 X 35
WASHER LOCK M6-1/4
WASHER FLAT 1/4
NUT LOCK FLANGE M6-1.0
STUD, METRIC
HOSE, BREATHER
CONTROLLER ASSEMBLY
SCREW HHTT M5-0.8 X 10
ASSEMBLY, WIRE
CARBURETOR (GT-990)
CARBURETOR (GT-760)
GASKET, CARB TO SPACER
(GT-990)
GASKET, CARB/AIRBOX (GT-760)
CLAMP HOSE BAND 1/4
HOSE ¼ ID
GASKET, MANIFOLD TO CARB
(GT-990)
GASKET, MANIFOLD TO CARB
(GT-760)
SLEEVING 1/2" I.D.
FILTER, FUEL
WASHER FLAT M8
WASHER LOCK M8
SCREW SHC M8-1.25 X 30
MANIFOLD, INTAKE
NUT HEX M3-0.5
ROD, SUMMER / WINTER VALVE
BUSHING, MINI CONTROL PANEL
KNOB, CONTROL SUMMER /
WINTER
CHOKE ASSEMBLY
SCREW TAPTITE M5-0.8 X 8 ZP
PANEL, CONTROL FACE PLATE
SCREW TAPTITE M6-1.0X 10
YELLOW CHROME
SWITCH ROCKER
WRAPPER, LOWER CYLINDER 2
WRAPPER, UPPER CYLINDER 2
ASSEMBLY, GROUND WIRE
WASHER LOCK M6-1/4
SCREW TAPTITE M6-1.0 X 25 BP
ITEM PART NO#.QTY.
DESCRIPTION
115
116
117
118
119
120
121
122
123
124
125
126
127
0F1338B
0C4147
022264
0D6142
0D5399A
0E7585
0E4271
022129
061906
022145
045771
0D1131
0C3022B
1
1
2
2
1
2
1
3
2
1
1
1
1
128
129
130
131
132
133
134
135
136
0C9763
0C3034
0C3033
0C3032
0A5992
051754
0C3031
0E4997
045756
4
1
1
1
2
2
1
1
4
137
138
0C3725A
0C3016A
1
1
139
140
141
142
143
144
145
082774
0C3043
0C9764
0C3026
0C7649
0C9806
035461A
1
2
4
1
4
2
2
146
147
148
149
150
151
152
153
154
070185B
0C7292
0D3083
0C3025
0D4550
0C3018
0C3019
046964A
0E0409
1
1
1
1
1
1
1
1
1
155
157
0C8563
0D9784
0E4869
6
2
2
158
031879
0E4868
0D6098
0D6147
0F1338A
1
1
1
7
1
ASSY, IGN COIL W/DIODE NO ADV
PUMP, IMPULSE
WASHER LOCK M4
SCREW PPHM M4-0.7 X 40
ELBOW, RUBBER 90 DEG.
SPARKPLUG, CHAMPION RC14YC
STARTER, DELCO REMY SD80
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 85 G8.8
WASHER, FLAT M8
NUT, HEX M8-1.25 G8
GUARD,FAN
HOUSING, BLOWER GASOLINE
COOLER
NUT, GROMMET 1/4 PLUG
NUT,HEX M24
WASHER, M24
PLATE, FAN
WASHER SHAKEPROOF INT M8 SS
SCREW HHC M8-1.25 X 12 G8.8
FAN, NYLON
ASSY,GROUND WIRE CONNECTOR
SCREW TAPTITE M6-1X10 YELLOW
CHROME
FLYWHEEL ASSEMBLY
PLATE, BACKING GT990 WITH OIL
COOL
KEY, WOODRFF 4 X 19D
GASKET, MANIFOLD / PORT
PLASTITE,1/4-15 X 3/4
COOLER, OIL
CLAMP HOSE .38-.87
HOSE, 3/8" I.D. X 6" LONG
BARBED STR 1/4NPT X 3/8 WITH
VIBRA SEAL
OIL FILTER
NIPPLE, 3/4"-16 UNF
ASSEMBLY, OIL DRAIN HOSE
SWITCH, OIL PRESS
BRACKET, AIRBOX SUPPORT
WRAPPER, UPPER CYLINDER 1
WRAPPER, LOWER CYLINDER 1
BRASS ST ELBOW 1/4 NPT
ASSY, ROD, GOV. STEPPER
MOTOR
SCREW HHHC M6-1.0 X12
NUT, LOCK HEX M3-0.5 (GT-990)
NUT, HEX W/TOOTH WASHER M30.5 (GT-760)
WASHER FLAT #4 (GT-990)
WASHER FLAT #4 (GT-760)
SPACER, ROD (GT-760 ONLY)
SCREW HHFC M6-1.0 X 10mm
ASSY, IGN COIL W/DIODE NO ADV
159
160
161
27
Section 7 — Exploded Views and Parts Lists
Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589E
Figure 15 - Fuel Shut-off Valve
2.6.2 ADDING GASOLINE
------------- WARNING ------------ WARNING: 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.
Caution:
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.
• Install fuel cap and wipe up any spilled gasoline.
Figure 14 - Fuel Tank
• Locate the Idle Control ON/OFF switch on the control panel and
set it to the “OFF” position.
Figure 16 - Idle Control Switch
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 "Storage" on page 18. Never use
engine or carburetor cleaner products in the fuel tank as
permanent damage may occur.
2.7 TO START THE ENGINE
WARNING!
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.
26
11
Section 7 — Exploded Views and Parts Lists
Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589E
• Move engine CHOKE knob to “Full Choke” position.
Figure 17 - Full Choke Position
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
• 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 to “Run” position. If engine falters,
move choke knob 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.
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.
2.8 STOPPING THE ENGINE
2.11.1 INITIAL START-UP
• 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.
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.
• 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.
2.11.2 SENSING LOW OIL PRESSURE
If the system senses low oil pressure during operation, the engine
shuts down.
• Close fuel valve.
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” on page 9 carefully.
12
2.11.3 RESTARTING
ITEM
PART NO. QTY.
1
0C5729
1
2
3
4
5
6
7
8
9
10
11
0E9843
090388
0C5372
0C3005
0E3372B
0D8067A
071983
0D5269
043790A
0E2950
0E2985
021533
0E1466
0D4041
0D4788
093064
0C2977
0C5943
0E4357E
1
3
1
1
1
1
4
1
1
2
2
2
2
1
2
1
1
1
1
0E4356E
1
0E3223
2
0E3222
2
21
22
23
24
25
26
27
28
29
30
31
0D2157
0E6098
0D4123A
078699E
0C3011
0C3009
0C3010
093873
0C5315
0C5998
0D4497
2
1
1
2
2
2
2
2
1
1
1
32
0C3971E
1
33
34
35
0D3745
0C3027
0E9842
1
3
1
12
13
14
15
16
17
18
19
20
DESCRIPTION
ASSEMBLY, CRANKCASE HOUSING
WITH SLEEVE
SEAL, 38 I.D. CRANKSHAFT
SCREW, TAPTITE M6-1.0 X 12 BP
ASSEMBLY, BREATHER
GASKET, BREATHER COVER
SEPARATOR, OIL BREATHER
ASSEMBLY, HEAD #1
RETAINER, PISTON PIN 20
ROCKER, COVER
BARBED EL 90 3/8NPT X 3/8
PISTON, LC (GT-990)
PISTON, HC (GT-760)
SET, PISTON RING 90MM
PIN PISTON
ASSEMBLY, CAMSHAFT & GEAR
PLUG STD PIPE 3/8 STEEL SQ HD
ASSEMBLY, OIL FILL CAP
GASKET, CRANK CASE
SEAL, OIL PASSAGE
ASSEMBLY, CRANKSHAFT
HORIZONTAL DIRECT DRIVE
(GT-990)
ASSEMBLY, CRANKSHAFT
HORIZONTAL DIRECT DRIVE
(GT-760)
ASSEMBLY, CONNECTING ROD
(GT-990)
ASSEMBLY, CONNECTING ROD
(GT-760)
SCREW SHC M6-1.0 X 50 G8.8
SCREEN, OIL PICKUP
ASSEMBLY, OIL PUMP
SLEEVE, SEAMED DOWEL 10 DIA.
COVER, OIL RELIEF
SPRING, OIL RELIEF
BALL, 1/2D OIL RELIEF
WASHER, LOCK RIB M6
GEROTOR, OUTER
CLAMP, OIL TUBE
PLUG-CRANKCASE GOVERNOR
BORE
ASSEMBLY, DIPSTICK WITH
HANDLE
TUBE, DIPSTICK
O-RING, OIL CLR
SEAL, 42 I.D. CRANKSHAFT
ITEM
PART NO. QTY.
36
0C5731
1
37
38
39
40
41
42
43
44
45
46
47
48
49
50
0C3006
080318
0C8808
0C2981C
0C2979
086515
0D2274
0D3867
078672
0C5371
072694
0C3027
0D5313
0D3998
10
8
2
1
2
8
4
4
2
4
4
2
4
4
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
0D6024
0C2976
086516
0C2229
083897
0D8067B
0D9853D
0C2978
0D6008
0D4010
0D6007
0D4012
0D8675A
0D8675B
0D4015
2
12
2
2
4
1
4
2
1
1
1
1
1
1
1
DESCRIPTION
ASSEMBLY, HOUSING COVER
WITH SLEEVE
SCREW, HHFC M10-1.5 X 55
SCREW HHFC M6-1.0 X 25
HOOK, LIFTING
ROCKER, COVER
GASKET, VALVE COVER
KEEPER, VALVE SPRING
RETAINER, VALVE SPRING
SPRING, VALVE
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
STUD, ROCKER ARM PIVOT
O-RING, 3/8" X 1/2"
ROCKER ARM
NUT, HEX M8-1.0 GB YELLOW
CHROME
PLATE, PUSH ROD GUIDE
SCREW HHFC M8-1.25 X 65
VALVE, EXHAUST
VALVE, INTAKE
TAPPET, SOLID
ASSEMBLY, HEAD #2
PUSHROD 147
GASKET, HEAD
KIT GEAR COVER
KIT GASKET
KIT PISTON & RINGS
KIT BREATHER ASSEMBLY
KIT HEAD ASSEMBLY CYLINDER 1
KIT HEAD ASSEMBLY CYLINDER 2
KIT OIL RELIEF
3, 30, 35, 65
2, 5, 17, 18, 34, 35, 40, 57, 139, 153.
8, 11, 12, 13
4, 5, 6
7, 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52,
53, 54, 57, 58
Item 64 (Kit) includes items 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, 53,
54, 56, 57, 58
Item 65 (Kit) includes items 25, 26, 27
Item
Item
Item
Item
Item
59
60
61
62
63
(Kit)
(Kit)
(Kit)
(Kit)
(Kit)
includes
includes
includes
includes
includes
items
items
items
items
items
If you try 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 you do restart the engine after such a shutdown and have not
corrected the low oil pressure, the engine runs for about 10
seconds as described above and then stops.
25
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589E
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.
Your 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.
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.
24
13
Section 3 — Maintenance
Section 6 — Electrical Data
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Schematic – Drawing No. 0E0229-A
3.1 MAINTENANCE SCHEDULE
Follow the calendar intervals. More frequent service is required when operating in adverse conditions noted below.
Operation Maintenance
Check Oil Level
Daily
Every Season
Every Season
Every Season
✓
✓**
Service Air Pre-Cleaner
✓*
Change Oil and Oil Filter‡
✓
✓
Clean Spark Arrestor Screen
Adjust 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..
PRODUCT SPECIFICATIONS
3.2.1 GENERATOR SPECIFICATIONS
MODEL
Model #
Rated Max. Power
Surge Power
Rated AC Voltage
Rated Max AC Load
Current @ 240V
Current @ 120V
Rated Frequency
Phase
Rated DC Voltage
Rated Max DC Load
Current @ 12 Volts
GPS 12500
004451-1
12.5 kW
18.75 kW
120/240
GPS 15000
004582-1
15.0 kW
22.5 kW
120/240
52.0 Amps
104.0 Amps
62.5 Amps
125.0 Amps
60 Hz @ 3600 RPM
Single Phase
12 Volts
10 Amperes
3.2.2 ENGINE SPECIFICATIONS
Rated Horsepower
@ 3600 RPM
Displacement
Spark Plug Type
Spark Plug Gap
Gasoline Capacity
Oil Type
Oil Capacity
Run Time/Fuel
Consumption-1/2 Load
14
27
763cc
30
992cc
Champion RC14YC or Equivalent
0.030 inch or (0.76 mm)
16 U.S. gallons
Summer – SAE 30 or 10W-30 Winter – Synthetic 5W-20 or 5W-30
w/ Filter Change = 1.5 Qts. w/o Filter Change = 1.2 Qts.
10 Hours / 1.6 gallons per hour
23
Section 6 — Electrical Data
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
BATTERY
CHARGE
RECTIFI ER
BATTERY
CHARGE
RECTIFI ER
D2
R1
6
44S
4
162
11S
7
77A
77A
0
13A
15
14
15
14
0
162
55
55
55A
10A AUTO
RESET BKR
B.
15A
14
14
12Vdc OUTLET
J1
3.3.1 GENERATOR MAINTENANCE
86
0
86
14
0
167
14
0
0
15B
15
0
Check the cleanliness of the generator frequently and clean when
dust, dirt, oil, moisture or other foreign substances are visible on
its exterior surface.
0 0
0
11
0
CAUTION! Never insert any object or tool through the air
0
cooling slots, even if the engine is not running.
0
SCR
30
85
13
11
12
PIN #
10
9
7
6
8
4
5
16
SC
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.
Change the oil and filter after the first eight hours of operation.
Change the oil every 100 hours thereafter. If you are running this
unit 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:
• 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” on page 10 for oil recommendations).
• Wipe up any spilled oil.
SM
RED
FSS
LOP
12V
BATTERY
+
BLACK
-
IM2
SP2
30A
C.B.
IM1
SP1
22
0
44D
22
22
ENGIN E WIRING
44
D
D
22
0
G
WHITE
See the “BEFORE STARTING THE GENERATOR” section on page
10 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.
3.3.2 TO CLEAN THE GENERATOR
0
30A
C.B.
11D
WHITE
TWISTLOK
120V/30 A
22
3.3.4 CHECKING OIL LEVEL
0
14
86
RUN
STOP
0
(START)
IC
GOVERNOR
ACTUATOR
11
G
0
0
TWISTLOK
120V/30 A
0
0
17
22
15
13
13
11C
0
0
15
167
3
1
2
11
20A
C.B.
3
5
1
0
15
15
16
14
17
13
15
167
0
15
0
86
87a
44C
87
18
86
22
22
20A
C.B.
11
5
44
0
F1
44
0
0
0
11B
0
0
0
44B
0
0
30A
C.B.
GND
15
15
0
11
14
15
5
9
44
1
13
0
6
10
2
SSR
14
44
55
8
14
4
12
11A
18
55A
0
0
50A
C.B.
11
11
11
44
30A
C.B.
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.
0
14
83
44A
OFF
ON
229
ON/OFF
IDLE
CONTROL
SWITCH
44
11
44
44
0
22
0
22
NOTE: Once a year you should replace the spark plug
and replace the air filter. A new spark plug and clean
air filter assure proper fuel-air mixture and help your
engine run better and last longer.
0
55A
11S
44S
/
1
2
3
4
5
GOVERNOR
ENGINE SHUTDOWN P.C.
6
7
J2
8
9
ELECTRONIC
12 11 10
0
15B
83
167
229
44A
11A
22
22
0
Y
22
4
LINE
3
22
4
HOT
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.
3.3.5 CHANGING THE OIL AND OIL FILTER
TB2
TB1
BLK
BLK
RED
11
X
0
G
X
WHITE
22
2
LOAD
1
22
120V/20 A
DUPLEX
22
2
WHITE
WHITE
HOT
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.
All adjustments in the Maintenance section (3) of this manual
should be made at least once each season. Follow the
requirements in the "Maintenance Schedule" chart on page 14.
4
66A
2
55
44
11
IDLE CONTROL
TRANSFORMERS
22
Y
WHITE
GREEN
120/240 V
50A OUTLET
0
120/240 V
30A TWISTLOK
120V/20 A
GFCI
22
WHITE
WHITE
HOT
3.3.3 ENGINE MAINTENANCE
66A
66
66
77
77
6
77
66
4
14
4
4
5
4
3
2
1
11
22
CB1
HOT
3.3 GENERAL RECOMMENDATIONS
Some adjustments will need to be made periodically to properly
maintain the generator.
6
66A
55A
44S
11S
22
44
LEGEND
BA - BRUSH ASS
EMBLY
CB1 - 5AMP AUT O RESE T BREAKER
D - ENGINE SHU TDOWN DIODE
D2 - 600 V 12A DIODE
F1 - 10A FUSE
FSS - F UEL SHU T OFF SOLENOID
GND - G ROUND BAR
IM1 - I GNITION MODULE, CYL. 1
IM2 - I GNITION MODULE, CYL. 2
LOP - L OW OIL PRESSU
RE
R1 - 25 OHM, 2 5W RESISTOR
SC - STARTER CONTACT
OR
SCR - S TARTER CONTAC
TOR RELAY
SM - STARTER MOTOR
SP1 - S PARK PLUG, CYL. 1
SP2 - S PARK PLUG, CYL. 2
SSR - S TART / STOP RELAY
TB1, TB 2 - TERMINAL
BLOCK
VOLTAGE
REGULATOR
PIN
PIN
PIN
PIN
PIN
PIN
0
PIN #
10
8
2
77A
9
6
55
66
77
1
2
3
4
5
6
0
BA
4
11
12
STATOR
CLOSES T TO BEARING
Wiring Diagram – Drawing No. 0E0228
•
•
•
•
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.
15
Section 5 - Notes
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
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 0.76 mm (0.030 in.). Replace the plug once each
year. This will help your 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.
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:
3. Set the spark plug's gap to 0.76 mm (0.030 in.). Install the
correctly gapped spark plug into the cylinder head.
• Remove air cleaner cover; then remove foam pre-filter (service
if necessary) and remove paper filter.
Figure 18 - Spark Plug Gap
• 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. Reinstall 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
3.4 SERVICE AIR CLEANER
The engine exhaust muffler has a spark arrestor screen. Inspect
and clean the screen at least once each year. If unit is used
regularly, inspect and clean more often.
Your engine will not run properly and may be damaged if you run
it using a dirty air cleaner. Clean or replace the air cleaner paper
filter once a year. Clean or replace more often if operating under
dusty conditions. Clean foam pre-cleaner every month or more
often under dusty conditions.
NOTE: If you use your generator on any forestcovered, 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.
Figure 20 - Air Cleaner
Clean and inspect the spark arrestor as follows:
Cover
• 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.
Pre-Cleaner
• Replace the screen and the retaining bracket.
Base
Filter
16
21
Section 5 — Notes
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Figure 21 - Spark Arrestor
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 22 - Valve Clearance Adjustment
3.6 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, you should adjust
the valve clearance in the engine.
Important: If you feel uncomfortable about doing this procedure
or you don't have the proper tools, please take your generator in
to the nearest service center to have the valve clearance adjusted.
This is a very important step to insure longest life for your engine.
To adjust valve clearance:
• Make sure the engine is at room temperature.
• Install new valve cover gasket.
• Re-attach the valve cover.
NOTE: Start all four screws before tightening or you
will not be able 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.
• 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 with a #2 or
#3 phillips screwdriver.
• 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. 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.
• Loosen the rocker jam nut. 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: You must hold the rocker arm jam nut in place
as you turn the pivot ball stud.
20
17
Section 3 — Maintenance
Section 4 — Troubleshooting
Commercial-Industrial-Residential Portable Generator System
STORAGE
4.1 TROUBLESHOOTING
3.7 GENERAL
3.9 OTHER STORAGE TIPS:
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 you must store the unit for more than 30 days, use the
following information as a guide to prepare it for storage.
• Do not store gasoline from one season to another.
DANGER! NEVER store engine with fuel in
• If possible, store your unit indoors and cover it to give
protection from dust and dirt. BE SURE TO EMPTY THE
FUEL TANK.
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.
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.
Commercial-Industrial-Residential Portable Generator System
• Replace your gasoline can if your can starts to rust. Rust
and/or dirt in your gasoline will cause problems with the
carburetor and fuel system.
• 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 your unit with a suitable protective cover that does not
retain moisture.
SYMPTOM
CAUSE
SOLUTION
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.
1.
2.
3.
4.
Short circuit in a connected load.
Generator is overloaded.
Engine speed is too slow.
Shorted generator circuit.
1.
2.
3.
4.
Disconnect shorted electrical load.
See “Don’t Overload the Generator” on page 9.
Contact Authorized Service Facility.
Contact Authorized Service Facility.
Engine will not start; or starts
and runs rough.
1.
2.
3.
4.
Dirty air cleaner.
Out of gasoline.
Stale gasoline.
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.
2.
3.
4.
Clean or replace air cleaner.
Fill fuel tank.
Drain fuel tank and fill with fresh fuel.
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.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Authorized Service Facility.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. See “Don’t Overload the Generator” on page 9.
2. Replace air filter.
3. Contact Authorized Service Facility.
Engine “hunts” or falters.
1. Choke is opened too soon.
1. Move choke to halfway position until
engine runs smoothly.
2. Contact Authorized Service Facility.
DANGER! NEVER cover your generator while
engine and exhaust area are warm.
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.
CAUTION!
Avoid spray from spark plug holes
when cranking engine.
• Install and tighten spark plugs. Do not connect spark plug
wires.
2. Carburetor is running too rich or too
lean.
No Battery Charge DC output.
1. Battery posts are corroded.
2. Battery cable is bad.
3. Battery is defective.
4. Receptacle is bad.
1. Clean battery posts.
2. Replace cable.
3. Check battery condition; replace if
defective.
4. Contact Authorized Service Facility.
• 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.
18
19
Section 3 — Maintenance
Section 4 — Troubleshooting
Commercial-Industrial-Residential Portable Generator System
STORAGE
4.1 TROUBLESHOOTING
3.7 GENERAL
3.9 OTHER STORAGE TIPS:
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 you must store the unit for more than 30 days, use the
following information as a guide to prepare it for storage.
• Do not store gasoline from one season to another.
DANGER! NEVER store engine with fuel in
• If possible, store your unit indoors and cover it to give
protection from dust and dirt. BE SURE TO EMPTY THE
FUEL TANK.
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.
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.
Commercial-Industrial-Residential Portable Generator System
• Replace your gasoline can if your can starts to rust. Rust
and/or dirt in your gasoline will cause problems with the
carburetor and fuel system.
• 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 your unit with a suitable protective cover that does not
retain moisture.
SYMPTOM
CAUSE
SOLUTION
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.
1.
2.
3.
4.
Short circuit in a connected load.
Generator is overloaded.
Engine speed is too slow.
Shorted generator circuit.
1.
2.
3.
4.
Disconnect shorted electrical load.
See “Don’t Overload the Generator” on page 9.
Contact Authorized Service Facility.
Contact Authorized Service Facility.
Engine will not start; or starts
and runs rough.
1.
2.
3.
4.
Dirty air cleaner.
Out of gasoline.
Stale gasoline.
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.
2.
3.
4.
Clean or replace air cleaner.
Fill fuel tank.
Drain fuel tank and fill with fresh fuel.
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.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Authorized Service Facility.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. See “Don’t Overload the Generator” on page 9.
2. Replace air filter.
3. Contact Authorized Service Facility.
Engine “hunts” or falters.
1. Choke is opened too soon.
1. Move choke to halfway position until
engine runs smoothly.
2. Contact Authorized Service Facility.
DANGER! NEVER cover your generator while
engine and exhaust area are warm.
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.
CAUTION!
Avoid spray from spark plug holes
when cranking engine.
• Install and tighten spark plugs. Do not connect spark plug
wires.
2. Carburetor is running too rich or too
lean.
No Battery Charge DC output.
1. Battery posts are corroded.
2. Battery cable is bad.
3. Battery is defective.
4. Receptacle is bad.
1. Clean battery posts.
2. Replace cable.
3. Check battery condition; replace if
defective.
4. Contact Authorized Service Facility.
• 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.
18
19
Section 5 — Notes
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Figure 21 - Spark Arrestor
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 22 - Valve Clearance Adjustment
3.6 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, you should adjust
the valve clearance in the engine.
Important: If you feel uncomfortable about doing this procedure
or you don't have the proper tools, please take your generator in
to the nearest service center to have the valve clearance adjusted.
This is a very important step to insure longest life for your engine.
To adjust valve clearance:
• Make sure the engine is at room temperature.
• Install new valve cover gasket.
• Re-attach the valve cover.
NOTE: Start all four screws before tightening or you
will not be able 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.
• 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 with a #2 or
#3 phillips screwdriver.
• 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. 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.
• Loosen the rocker jam nut. 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: You must hold the rocker arm jam nut in place
as you turn the pivot ball stud.
20
17
Section 5 - Notes
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
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 0.76 mm (0.030 in.). Replace the plug once each
year. This will help your 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.
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:
3. Set the spark plug's gap to 0.76 mm (0.030 in.). Install the
correctly gapped spark plug into the cylinder head.
• Remove air cleaner cover; then remove foam pre-filter (service
if necessary) and remove paper filter.
Figure 18 - Spark Plug Gap
• 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. Reinstall 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
3.4 SERVICE AIR CLEANER
The engine exhaust muffler has a spark arrestor screen. Inspect
and clean the screen at least once each year. If unit is used
regularly, inspect and clean more often.
Your engine will not run properly and may be damaged if you run
it using a dirty air cleaner. Clean or replace the air cleaner paper
filter once a year. Clean or replace more often if operating under
dusty conditions. Clean foam pre-cleaner every month or more
often under dusty conditions.
NOTE: If you use your generator on any forestcovered, 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.
Figure 20 - Air Cleaner
Clean and inspect the spark arrestor as follows:
Cover
• 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.
Pre-Cleaner
• Replace the screen and the retaining bracket.
Base
Filter
16
21
Section 6 — Electrical Data
Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
BATTERY
CHARGE
RECTIFI ER
BATTERY
CHARGE
RECTIFI ER
D2
R1
6
44S
4
162
11S
7
77A
77A
0
13A
15
14
15
14
0
162
55
55
55A
10A AUTO
RESET BKR
B.
15A
14
14
12Vdc OUTLET
J1
3.3.1 GENERATOR MAINTENANCE
86
0
86
14
0
167
14
0
0
15B
15
0
Check the cleanliness of the generator frequently and clean when
dust, dirt, oil, moisture or other foreign substances are visible on
its exterior surface.
0 0
0
11
0
CAUTION! Never insert any object or tool through the air
0
cooling slots, even if the engine is not running.
0
SCR
30
85
13
11
12
PIN #
10
9
7
6
8
4
5
16
SC
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.
Change the oil and filter after the first eight hours of operation.
Change the oil every 100 hours thereafter. If you are running this
unit 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:
• 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” on page 10 for oil recommendations).
• Wipe up any spilled oil.
SM
RED
FSS
LOP
12V
BATTERY
+
BLACK
-
IM2
SP2
30A
C.B.
IM1
SP1
22
0
44D
22
22
ENGIN E WIRING
44
D
D
22
0
G
WHITE
See the “BEFORE STARTING THE GENERATOR” section on page
10 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.
3.3.2 TO CLEAN THE GENERATOR
0
30A
C.B.
11D
WHITE
TWISTLOK
120V/30 A
22
3.3.4 CHECKING OIL LEVEL
0
14
86
RUN
STOP
0
(START)
IC
GOVERNOR
ACTUATOR
11
G
0
0
TWISTLOK
120V/30 A
0
0
17
22
15
13
13
11C
0
0
15
167
3
1
2
11
20A
C.B.
3
5
1
0
15
15
16
14
17
13
15
167
0
15
0
86
87a
44C
87
18
86
22
22
20A
C.B.
11
5
44
0
F1
44
0
0
0
11B
0
0
0
44B
0
0
30A
C.B.
GND
15
15
0
11
14
15
5
9
44
1
13
0
6
10
2
SSR
14
44
55
8
14
4
12
11A
18
55A
0
0
50A
C.B.
11
11
11
44
30A
C.B.
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.
0
14
83
44A
OFF
ON
229
ON/OFF
IDLE
CONTROL
SWITCH
44
11
44
44
0
22
0
22
NOTE: Once a year you should replace the spark plug
and replace the air filter. A new spark plug and clean
air filter assure proper fuel-air mixture and help your
engine run better and last longer.
0
55A
11S
44S
/
1
2
3
4
5
GOVERNOR
ENGINE SHUTDOWN P.C.
6
7
J2
8
9
ELECTRONIC
12 11 10
0
15B
83
167
229
44A
11A
22
22
0
Y
22
4
LINE
3
22
4
HOT
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.
3.3.5 CHANGING THE OIL AND OIL FILTER
TB2
TB1
BLK
BLK
RED
11
X
0
G
X
WHITE
22
2
LOAD
1
22
120V/20 A
DUPLEX
22
2
WHITE
WHITE
HOT
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.
All adjustments in the Maintenance section (3) of this manual
should be made at least once each season. Follow the
requirements in the "Maintenance Schedule" chart on page 14.
4
66A
2
55
44
11
IDLE CONTROL
TRANSFORMERS
22
Y
WHITE
GREEN
120/240 V
50A OUTLET
0
120/240 V
30A TWISTLOK
120V/20 A
GFCI
22
WHITE
WHITE
HOT
3.3.3 ENGINE MAINTENANCE
66A
66
66
77
77
6
77
66
4
14
4
4
5
4
3
2
1
11
22
CB1
HOT
3.3 GENERAL RECOMMENDATIONS
Some adjustments will need to be made periodically to properly
maintain the generator.
6
66A
55A
44S
11S
22
44
LEGEND
BA - BRUSH ASS
EMBLY
CB1 - 5AMP AUT O RESE T BREAKER
D - ENGINE SHU TDOWN DIODE
D2 - 600 V 12A DIODE
F1 - 10A FUSE
FSS - F UEL SHU T OFF SOLENOID
GND - G ROUND BAR
IM1 - I GNITION MODULE, CYL. 1
IM2 - I GNITION MODULE, CYL. 2
LOP - L OW OIL PRESSU
RE
R1 - 25 OHM, 2 5W RESISTOR
SC - STARTER CONTACT
OR
SCR - S TARTER CONTAC
TOR RELAY
SM - STARTER MOTOR
SP1 - S PARK PLUG, CYL. 1
SP2 - S PARK PLUG, CYL. 2
SSR - S TART / STOP RELAY
TB1, TB 2 - TERMINAL
BLOCK
VOLTAGE
REGULATOR
PIN
PIN
PIN
PIN
PIN
PIN
0
PIN #
10
8
2
77A
9
6
55
66
77
1
2
3
4
5
6
0
BA
4
11
12
STATOR
CLOSES T TO BEARING
Wiring Diagram – Drawing No. 0E0228
•
•
•
•
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.
15
Section 3 — Maintenance
Section 6 — Electrical Data
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Schematic – Drawing No. 0E0229-A
3.1 MAINTENANCE SCHEDULE
Follow the calendar intervals. More frequent service is required when operating in adverse conditions noted below.
Operation Maintenance
Check Oil Level
Daily
Every Season
Every Season
Every Season
✓
✓**
Service Air Pre-Cleaner
✓*
Change Oil and Oil Filter‡
✓
✓
Clean Spark Arrestor Screen
Adjust 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..
PRODUCT SPECIFICATIONS
3.2.1 GENERATOR SPECIFICATIONS
MODEL
Model #
Rated Max. Power
Surge Power
Rated AC Voltage
Rated Max AC Load
Current @ 240V
Current @ 120V
Rated Frequency
Phase
Rated DC Voltage
Rated Max DC Load
Current @ 12 Volts
GPS 12500
004451-1
12.5 kW
18.75 kW
120/240
GPS 15000
004582-1
15.0 kW
22.5 kW
120/240
52.0 Amps
104.0 Amps
62.5 Amps
125.0 Amps
60 Hz @ 3600 RPM
Single Phase
12 Volts
10 Amperes
3.2.2 ENGINE SPECIFICATIONS
Rated Horsepower
@ 3600 RPM
Displacement
Spark Plug Type
Spark Plug Gap
Gasoline Capacity
Oil Type
Oil Capacity
Run Time/Fuel
Consumption-1/2 Load
14
27
763cc
30
992cc
Champion RC14YC or Equivalent
0.030 inch or (0.76 mm)
16 U.S. gallons
Summer – SAE 30 or 10W-30 Winter – Synthetic 5W-20 or 5W-30
w/ Filter Change = 1.5 Qts. w/o Filter Change = 1.2 Qts.
10 Hours / 1.6 gallons per hour
23
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589E
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.
Your 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.
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.
24
13
Section 7 — Exploded Views and Parts Lists
Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589E
• Move engine CHOKE knob to “Full Choke” position.
Figure 17 - Full Choke Position
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
• 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 to “Run” position. If engine falters,
move choke knob 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.
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.
2.8 STOPPING THE ENGINE
2.11.1 INITIAL START-UP
• 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.
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.
• 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.
2.11.2 SENSING LOW OIL PRESSURE
If the system senses low oil pressure during operation, the engine
shuts down.
• Close fuel valve.
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” on page 9 carefully.
12
2.11.3 RESTARTING
ITEM
PART NO. QTY.
1
0C5729
1
2
3
4
5
6
7
8
9
10
11
0E9843
090388
0C5372
0C3005
0E3372B
0D8067A
071983
0D5269
043790A
0E2950
0E2985
021533
0E1466
0D4041
0D4788
093064
0C2977
0C5943
0E4357E
1
3
1
1
1
1
4
1
1
2
2
2
2
1
2
1
1
1
1
0E4356E
1
0E3223
2
0E3222
2
21
22
23
24
25
26
27
28
29
30
31
0D2157
0E6098
0D4123A
078699E
0C3011
0C3009
0C3010
093873
0C5315
0C5998
0D4497
2
1
1
2
2
2
2
2
1
1
1
32
0C3971E
1
33
34
35
0D3745
0C3027
0E9842
1
3
1
12
13
14
15
16
17
18
19
20
DESCRIPTION
ASSEMBLY, CRANKCASE HOUSING
WITH SLEEVE
SEAL, 38 I.D. CRANKSHAFT
SCREW, TAPTITE M6-1.0 X 12 BP
ASSEMBLY, BREATHER
GASKET, BREATHER COVER
SEPARATOR, OIL BREATHER
ASSEMBLY, HEAD #1
RETAINER, PISTON PIN 20
ROCKER, COVER
BARBED EL 90 3/8NPT X 3/8
PISTON, LC (GT-990)
PISTON, HC (GT-760)
SET, PISTON RING 90MM
PIN PISTON
ASSEMBLY, CAMSHAFT & GEAR
PLUG STD PIPE 3/8 STEEL SQ HD
ASSEMBLY, OIL FILL CAP
GASKET, CRANK CASE
SEAL, OIL PASSAGE
ASSEMBLY, CRANKSHAFT
HORIZONTAL DIRECT DRIVE
(GT-990)
ASSEMBLY, CRANKSHAFT
HORIZONTAL DIRECT DRIVE
(GT-760)
ASSEMBLY, CONNECTING ROD
(GT-990)
ASSEMBLY, CONNECTING ROD
(GT-760)
SCREW SHC M6-1.0 X 50 G8.8
SCREEN, OIL PICKUP
ASSEMBLY, OIL PUMP
SLEEVE, SEAMED DOWEL 10 DIA.
COVER, OIL RELIEF
SPRING, OIL RELIEF
BALL, 1/2D OIL RELIEF
WASHER, LOCK RIB M6
GEROTOR, OUTER
CLAMP, OIL TUBE
PLUG-CRANKCASE GOVERNOR
BORE
ASSEMBLY, DIPSTICK WITH
HANDLE
TUBE, DIPSTICK
O-RING, OIL CLR
SEAL, 42 I.D. CRANKSHAFT
ITEM
PART NO. QTY.
36
0C5731
1
37
38
39
40
41
42
43
44
45
46
47
48
49
50
0C3006
080318
0C8808
0C2981C
0C2979
086515
0D2274
0D3867
078672
0C5371
072694
0C3027
0D5313
0D3998
10
8
2
1
2
8
4
4
2
4
4
2
4
4
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
0D6024
0C2976
086516
0C2229
083897
0D8067B
0D9853D
0C2978
0D6008
0D4010
0D6007
0D4012
0D8675A
0D8675B
0D4015
2
12
2
2
4
1
4
2
1
1
1
1
1
1
1
DESCRIPTION
ASSEMBLY, HOUSING COVER
WITH SLEEVE
SCREW, HHFC M10-1.5 X 55
SCREW HHFC M6-1.0 X 25
HOOK, LIFTING
ROCKER, COVER
GASKET, VALVE COVER
KEEPER, VALVE SPRING
RETAINER, VALVE SPRING
SPRING, VALVE
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
STUD, ROCKER ARM PIVOT
O-RING, 3/8" X 1/2"
ROCKER ARM
NUT, HEX M8-1.0 GB YELLOW
CHROME
PLATE, PUSH ROD GUIDE
SCREW HHFC M8-1.25 X 65
VALVE, EXHAUST
VALVE, INTAKE
TAPPET, SOLID
ASSEMBLY, HEAD #2
PUSHROD 147
GASKET, HEAD
KIT GEAR COVER
KIT GASKET
KIT PISTON & RINGS
KIT BREATHER ASSEMBLY
KIT HEAD ASSEMBLY CYLINDER 1
KIT HEAD ASSEMBLY CYLINDER 2
KIT OIL RELIEF
3, 30, 35, 65
2, 5, 17, 18, 34, 35, 40, 57, 139, 153.
8, 11, 12, 13
4, 5, 6
7, 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52,
53, 54, 57, 58
Item 64 (Kit) includes items 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, 53,
54, 56, 57, 58
Item 65 (Kit) includes items 25, 26, 27
Item
Item
Item
Item
Item
59
60
61
62
63
(Kit)
(Kit)
(Kit)
(Kit)
(Kit)
includes
includes
includes
includes
includes
items
items
items
items
items
If you try 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 you do restart the engine after such a shutdown and have not
corrected the low oil pressure, the engine runs for about 10
seconds as described above and then stops.
25
Section 7 — Exploded Views and Parts Lists
Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589E
Figure 15 - Fuel Shut-off Valve
2.6.2 ADDING GASOLINE
------------- WARNING ------------ WARNING: 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.
Caution:
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.
• Install fuel cap and wipe up any spilled gasoline.
Figure 14 - Fuel Tank
• Locate the Idle Control ON/OFF switch on the control panel and
set it to the “OFF” position.
Figure 16 - Idle Control Switch
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 "Storage" on page 18. Never use
engine or carburetor cleaner products in the fuel tank as
permanent damage may occur.
2.7 TO START THE ENGINE
WARNING!
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.
26
11
Section 7 — Exploded Views and Parts Lists
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589E
ITEM PART #
2.5 WATTAGE REFERENCE GUIDE
Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts
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.
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
• Above 40°F, use SAE 10W-30 or SAE 30.
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 SF or SG SAE 30
weight. Use no special additives.
Select the oil’s viscosity grade according to the expected
operating temperature. Do not use SAE 10W-40.
• Below 40°F, use synthetic 5W-20 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 your
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.
10
66
67
68
69
70
71
72
QTY.
91
0D6592
0D4511
0D9723
0E5302
0D4183
0D6327
0D2774B
0E4870
0D5125
0D2930
0D4612A
0D6143
0D2775
0D5014A
0D5014B
049721
022097
022473
052857
0D6021
0C9093A
0D4522
074908
0E3398
0E2548
0E5077
0D4026
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
2
1
1
1
1
92
93
94
0D4024
048031C
030340
0D4023
1
4
12"
1
0D5282
1
95
96
97
98
99
100
101
102
103
104
086061G
0D6313
070008
070006
049821
0C9911
051714
0D5411
0D5445
0D5416A
1
1
4
4
4
1
1
1
1
1
105
106
107
108
0D5398
0E6043
0D3432
045756
1
2
1
24
109
110
111
112
113
114
0D4767
0D1142A
0D1143
0F1177
022097
092079
1
1
1
1
4
4
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
89
90
DESCRIPTION
WINGNUT, AIRBOX
PRECLEANER, AIR
ELEMENT, AIR CLEANER
STUD M6-1.0 X 73
ADAPTOR, SPIT BACK
GASKET, SPITBACK
BASE, AIRBOX (GT-990)
BASE, AIRBOX (GT-760)
SPRING, WINTER/SUMMER VALVE
VALVE, SUMMER / WINTER
SNORKEL, AIR INTAKE
TUBE, HEAT RISER 50.8 I.D.
COVER, AIRBOX
KNOB, AIRBOX 17mm
KNOB, AIRBOX 95MM
SCREW HHC M6-1.0 X 35
WASHER LOCK M6-1/4
WASHER FLAT 1/4
NUT LOCK FLANGE M6-1.0
STUD, METRIC
HOSE, BREATHER
CONTROLLER ASSEMBLY
SCREW HHTT M5-0.8 X 10
ASSEMBLY, WIRE
CARBURETOR (GT-990)
CARBURETOR (GT-760)
GASKET, CARB TO SPACER
(GT-990)
GASKET, CARB/AIRBOX (GT-760)
CLAMP HOSE BAND 1/4
HOSE ¼ ID
GASKET, MANIFOLD TO CARB
(GT-990)
GASKET, MANIFOLD TO CARB
(GT-760)
SLEEVING 1/2" I.D.
FILTER, FUEL
WASHER FLAT M8
WASHER LOCK M8
SCREW SHC M8-1.25 X 30
MANIFOLD, INTAKE
NUT HEX M3-0.5
ROD, SUMMER / WINTER VALVE
BUSHING, MINI CONTROL PANEL
KNOB, CONTROL SUMMER /
WINTER
CHOKE ASSEMBLY
SCREW TAPTITE M5-0.8 X 8 ZP
PANEL, CONTROL FACE PLATE
SCREW TAPTITE M6-1.0X 10
YELLOW CHROME
SWITCH ROCKER
WRAPPER, LOWER CYLINDER 2
WRAPPER, UPPER CYLINDER 2
ASSEMBLY, GROUND WIRE
WASHER LOCK M6-1/4
SCREW TAPTITE M6-1.0 X 25 BP
ITEM PART NO#.QTY.
DESCRIPTION
115
116
117
118
119
120
121
122
123
124
125
126
127
0F1338B
0C4147
022264
0D6142
0D5399A
0E7585
0E4271
022129
061906
022145
045771
0D1131
0C3022B
1
1
2
2
1
2
1
3
2
1
1
1
1
128
129
130
131
132
133
134
135
136
0C9763
0C3034
0C3033
0C3032
0A5992
051754
0C3031
0E4997
045756
4
1
1
1
2
2
1
1
4
137
138
0C3725A
0C3016A
1
1
139
140
141
142
143
144
145
082774
0C3043
0C9764
0C3026
0C7649
0C9806
035461A
1
2
4
1
4
2
2
146
147
148
149
150
151
152
153
154
070185B
0C7292
0D3083
0C3025
0D4550
0C3018
0C3019
046964A
0E0409
1
1
1
1
1
1
1
1
1
155
157
0C8563
0D9784
0E4869
6
2
2
158
031879
0E4868
0D6098
0D6147
0F1338A
1
1
1
7
1
ASSY, IGN COIL W/DIODE NO ADV
PUMP, IMPULSE
WASHER LOCK M4
SCREW PPHM M4-0.7 X 40
ELBOW, RUBBER 90 DEG.
SPARKPLUG, CHAMPION RC14YC
STARTER, DELCO REMY SD80
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 85 G8.8
WASHER, FLAT M8
NUT, HEX M8-1.25 G8
GUARD,FAN
HOUSING, BLOWER GASOLINE
COOLER
NUT, GROMMET 1/4 PLUG
NUT,HEX M24
WASHER, M24
PLATE, FAN
WASHER SHAKEPROOF INT M8 SS
SCREW HHC M8-1.25 X 12 G8.8
FAN, NYLON
ASSY,GROUND WIRE CONNECTOR
SCREW TAPTITE M6-1X10 YELLOW
CHROME
FLYWHEEL ASSEMBLY
PLATE, BACKING GT990 WITH OIL
COOL
KEY, WOODRFF 4 X 19D
GASKET, MANIFOLD / PORT
PLASTITE,1/4-15 X 3/4
COOLER, OIL
CLAMP HOSE .38-.87
HOSE, 3/8" I.D. X 6" LONG
BARBED STR 1/4NPT X 3/8 WITH
VIBRA SEAL
OIL FILTER
NIPPLE, 3/4"-16 UNF
ASSEMBLY, OIL DRAIN HOSE
SWITCH, OIL PRESS
BRACKET, AIRBOX SUPPORT
WRAPPER, UPPER CYLINDER 1
WRAPPER, LOWER CYLINDER 1
BRASS ST ELBOW 1/4 NPT
ASSY, ROD, GOV. STEPPER
MOTOR
SCREW HHHC M6-1.0 X12
NUT, LOCK HEX M3-0.5 (GT-990)
NUT, HEX W/TOOTH WASHER M30.5 (GT-760)
WASHER FLAT #4 (GT-990)
WASHER FLAT #4 (GT-760)
SPACER, ROD (GT-760 ONLY)
SCREW HHFC M6-1.0 X 10mm
ASSY, IGN COIL W/DIODE NO ADV
159
160
161
27
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
Generator – Drawing No. 0D4488-D
2.3.2 CONNECTING ELECTRICAL LOADS
2.3 HOW TO USE THE GENERATOR
If you have any problems operating your 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. 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
your area.
Figure 13 - Grounding the Generator
Generator Ground Lug
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).
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.
• 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 you allow for this high starting
wattage when selecting electrical devices to connect to your
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 on page 10 is provided to assist
you in determining how many items your generator can operate
at one time. (Note: All figures are approximate. See data plate on
appliance for wattage requirements.)
28
9
Section 2 – Operation
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Generator – Drawing No. 0D4488-D
Figure 9 - 120 VAC, 30 Amp Receptacle
2.2.5 12 VOLT DC, 10 AMP RECEPTACLE
This receptacle allows you to recharge a 12 Volt automotive or
utility style storage battery with the battery charge cables
provided. 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" (page 12) before attempting
to recharge a battery.
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
23
24
25
26
27
28
29
0A2038
022237
022511
022131
051731
022145
049820
1
5
4
4
4
21
4
30
079246
5
31
32
33
34
35
36
37
38
39
40
41
42
43
022129
022259
059637
0D5100
0D5823
0C8565
0D5833
0D5834
090388
022473
N/A
0D5133
0D5133A
18
12
2
1
1
4
1
1
3
5
1
1
44
45
46
045764
0D6214
066849
1
1
2
3
0D21330SRV
Figure 11 - 12 Volt DC, 10 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.
The outlet is protected by a 30 Amp push-to-reset circuit breaker.
2.2.4 120/240V AC, 30 AMP RECEPTACLE
Use a NEMA L14-30 plug with this receptacle. Connect a suitable
4-wire 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).
2.2.6 120/240 VOLT AC, 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 10 - 120/240 VAC, 30 Amp Receptacle
Figure 12 - 120/240 VAC, 50 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-to-reset circuit breakers.
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.
8
0C6934
1
0D2123
1
0D2134
0D2136
0D21320SRV 1
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
0D2135
0C6043B
0D2492
0D2726
0C4138
0D3547
031971
0C3168
0D1838
0D3549
0C7038E
032712
0D4662
0C7038D
0C7758
0388050AF0
0C2417A
082121C
066386
0C2824
1
1
1
2
1
1
3
1
4
1
4
1
1
6
1
1
1
1
1
ADAPTOR, ENGINE
STATOR 12.5KW
STATOR 15KW
STATOR 18KW
ASSEMBLY, ROTOR WITH FAN
12.5KW
ASSEMBLY, ROTOR WITH FAN
15KW
ROTOR 18KW
CARRIER, REAR BEARING
EXHAUST MANIFOLD
MUFFLER
GASKET, EXHAUST
COVER, ALTERNATOR AIR IN
BEARING
5/16 SPECIAL LOCK WASHER
SCREW IHHC 3/8-24 X 15.50 G5
SCREW IHHC M8-1.25 X 400 G8.8
BRACKET, ALT MOUNTING
SCREW HHTT #10-32 X 1.75
SCREW HHTT M8-1.2 X 20
ENGINE MOUNTING PLATE
RUBBER MOUNT
BATTERY CABLE, BLACK
EARTH STRAP 3/8X 3/8
CLIP-J VINYL COAT .625 ID
ASSEMBLY, BRUSH HOLDER
SCREW TAP-R #10-32 X 9/16
WASHER FLAT 3/8 ZINC
WASHER LOCK 3/8
SCREW HHC 3/8-16 X 1-1/4 G5
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M8-1.25 X 50 G8.8
WASHER FLAT 5/16 ZINC
NUT LOCK HEX M8-1.25 NYLON
INSERT
SCREW HHC M6-1.0 X 16 WITH
LOCK WASHER
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW TAPTITE 3/8-16 X 3/4 BP
SHIELD, MUFFLER HEAT
U-BOLT & SADDLE
SCREW SHC M8-1.25 X 18
PANEL, MUFFLER BOX BACK
PANEL, MUFFLER BOX END
SCREW HHTT M6-1.0 X 12
WASHER FLAT 1/4
NOT USED
SPARK ARRESTOR SCREEN
RETAINER, SPARK ARREST
SCREEN
SCREW HHTT M4-0.7 X 8
SHIELD, RUBBER MOUNT
SCREW HHTT M5-0.8 X 16
29
Section 2 – Operation
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Control Panel – Drawing No. 0E0227B
Figure 8 - 120 VAC, 20 Amp GFCI Receptacle
38
Keep extension cords as short as possible, preferably less than 15
feet long, to prevent voltage drop and possible overheating of wires.
7
42
22
41
18
50
33
29
34
37
36
25
17
45
35
54
4
53
Figure 7 - 120 Volt AC, 20 Amp, Duplex 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.
59
42
41
• 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.
15
13
41
• 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.
14
2.2.2 120V AC, 20 AMP, GFCI RECEPTACLE
This unit is equipped with a ground fault circuit interrupter (GFCI).
This device meets applicable federal, state and local codes.
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.
• This outlet is protected against overload by a 20A push-toreset circuit breaker. Use the outlet to power 120V AC, singlephase, 60 Hz, electrical loads requiring up to a combined 2400
watts (2.4 kW) or 20 amps of current.
2.2.3 120V AC, 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.
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 non-conducting surface, such as a wood floor.
2
1
5
60
43
42
41
44
9
8
3
21
56
11
9
10
8
6
64
63
20
18
17
23
12
40
39
59
42
8
26
27
46
59
16
42
28
41
9 8
18
17
55
19
30
49
52
4
51
47,48
17
18
24
58
This is a 120 Volt outlet protected against overload by a 20 Amp
push-to-reset circuit breaker. 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, wellinsulated, 3-wire grounded cord sets rated for 125 Volts at 20 Amps
(or greater).
31
32
2.2.1 AC, 20 AMP, DUPLEX RECEPTACLE
61
57
62
2.2 CORD SETS AND CONNECTION
PLUGS
30
7
Section 2 – Operation
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Control Panel – Drawing No. 0E0227B
OPERATION
7)
12 Volt DC, 10 Amp Receptacle – This receptacle
allows the capability to recharge a 12 volt DC storage battery
with provided battery charge cables.
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.
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.
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.
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.
120/240 Volt AC, 50 Amp Receptacle – Supplies
electrical power for the operation of 120/240 Volt AC, 50
Amp, single-phase, 60 Hz, welder or motor loads.
Air Cleaner – Filters intake air as it is drawn into the engine.
8)
Choke Knob – Used when starting a cold engine.
1)
2.1 KNOW THE GENERATOR
2)
Read the Owner’s Manual and Safety Rules before
operating this generator.
Compare the generator to this illustration to become familiarized
with the locations of various controls and adjustments. Save this
manual for future reference.
Figure 4 - Control Panel
3)
4)
5)
6)
Winter / Summer Valve – See “Cold Weather Operation.”
(Section 2, page 12.)
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)
9)
11) Fuel Tank – Tank holds 16 U.S. gallons of fuel.
Figure 5 - Generator Controls
7
12) Grounding Lug – Ground the generator to an approved
earth ground here. See page 9 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.
11
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
087968
090418
0D6640
090987
0D2502
068868
022985
043182
051714
075207A
075207
0D4969
043437
0D4968
0D4966
0D1004E
1
1
1
6
1
2
2
10
6
4
2
1
1
1
1
1
32
33
34
35
36
37
38
39
40
41
42
43
44
022158
023897
057405
022473
022097
049813
065795
0D4804
0C1085
051715
022264
048505
087962
1
1
1
1
1
1
2
2
4
18
18
1
1
17
18
19
20
051716
022152
0D5045
067680
8
8
1
1
21
0D4409
1
22
23
24
25
26
27
052844
0F3100
0D2691
023484L
0A1661
048766
1
1
1
1
2
1
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
036261
0A2769
032300
028578
055444
075475
049815
0A2053
055440
045770
0D5734
074908
075235
080823
038150
0D6140
2
1
1
1
1
2
4
1
2
1
2
18
1
2
14
1
28
0D3550
1
29
30
31
049939
070370
030468
1
1
1
61
62
63
64
075476
027565
058000K
0F3101
2
A/R
2
1
SWITCH, ROCKER -/0
OUTLET, 12VDC SNAP
COVER, GOVERNOR CONTROL
SCREW PPHM M3-0.5 X 12
PANEL, SHEET METAL
OUTLET 30A 120V RECEPT
WASHER FLAT #6
WASHER LOCK M3
NUT HEX M3-0.5 G8
CIRCUIT BREAKER 30A
CIRCUIT BREAKER 20A
OUTLET 50A 125/250V
OUTLET 30A 125/250V
OUTLET 20A 120V DPLX
OUTLET 20A 120V GFCI
CIRCUIT BREAKER 50A 400V
2POLE
NUT HEX M5-0.8 G8
WASHER LOCK #10
DIN RAIL 59.5mm LONG
ASSEMBLY VOLTAGE REGULATOR
60HZ
ELECTRONIC GOVERNOR / IDLE
CONTROLLER
RELAY PNL 12VDC SPST 30A
RELAY 3PDT 12VDC
CONTROL PANEL BOX
BUSHING SNAP
RIVET POP .156 X .160-.164 / #20
BLOCK TERMINAL 20A 2 X 6 X
1100V
BLOCK DOUBLE ROW TERMINAL 8
POSITION
RECTIFIER MSC 12A 600V
WASHER MICA .203
WASHER STEP NYLON .20
NUT HEX #10-32
WASHER FLAT #10
RESISTOR 25R 5% 25W
WASHER FLAT 1/4
WASHER LOCK M6-1/4
NUT HEX M6-1.0 G8
RECTIFIER-BATTERY CHARGER
TRANSFORMER, IDLE CURRENT
SCREW PPHM M3-0.5 X 8
NUT HEX M4-0.7 G8
WASHER LOCK M4
CIRCUIT BREAKER 6 X 1
CIRCUIT BREAKER 10 X 1 12VDC
1/4"QC
RIVET POP .125 X .129-.133 / #30
LUG GRND 8 TABS
HOLDER FUSE
FUSE 10A X AGC10
HEATSINK
SCREW PPHM M4-0.7 X 10
SCREW HHC M5-0.8 X 16 G8.8
SCREW HHC M6-1.0 X 65 G8.8
SCREW HHC M5-0.8 X 25 G8.8
SCREW HHC M5-0.8 X 10 G8.8
SPACER .25 X .50 X 1.5
SCREW HHTT M5-0.8 X 10
SCREW PPHM M5-0.8 X 30
SCREW PPHM M5-0.8 X 50
WASHER FLAT #8
GASKET, PORTABLE CONTROL
PANEL
SCREW PPHM M4-0.7 X 16
TAPE ELEC UL PERMACEL
NUT TRIC M5-0.8
RELAY BASE 3PDT 12VDC
Figure 6 - Engine Control Panel
15
12
14
6
8
9
31
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Section 1 - General Information
Commercial-Industrial-Residential Portable Generator System
Frame, Handle & Wheel Kit – Drawing No. 0E0695-A
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.
• Cut the tie wrap cable holding the RED and BLACK battery
cables to the stator.
Figure 3 - Battery Connections
Negative
Cable
Positive
Cable
• 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 at right.
32
5
Section 1 – General Information
Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Commercial-Industrial-Residential Portable Generator System
Frame, Handle & Wheel Kit – Drawing No. 0E0695-A
ITEM PART NO.
1.1 UNPACKING
1.2 ASSEMBLY
• Set the palleted carton on a rigid flat surface.
• Remove staples along bottom of carton that fasten carton to
pallet. Open carton from top.
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.
• Remove all packaging material.
1.2.1 ASSEMBLING THE WHEEL KIT
• Remove separate accessory box.
• Remove generator from shipping pallet by removing bolts
through the shipping brackets.
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.
Figure 1 - Bracket Removal
Note:The wheel kit is not intended for over-the-road use.
• Lift carton off the generator.
• Refer to Figure 2 shown on opposite page and install the wheel
kit as follows:
• Place the generator on a hard flat surface.
Shipping
Bracket
(x4)
• 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.
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:
• Owner’s Manual
• Bolt-on tubular handle
• Wheel Axle
• 2 – Pneumatic Wheels
• 2 – Axle Bracket Assemblies
• 2 – Washers
• 2 – Wheel Spacers
• 2 – Cotter Pins
• Bolt-on Foot
• 6 – Carriage Bolts, Washers, Nuts
• Battery Charge Cable
• Spark Plug Wrench
• 2 Spark Plugs.
• Air Filter
• Pre-cleaner
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
QTY.
057058
4
0D5315
4
0D4570
1
0D22850SRV 1
045771
4
022129
10
022145
14
0D4565
1
0D3545
2
022287
2
022473
2
022097
2
022127
2
0388040AK0 1
0D4575
1
0D5202
1
0D5199
4
029809
1
0C3168
1
0D5198
1
0E0317
1
0D2498
1
027007
2
0D5303
4
042909
2
090388
4
064101
6
039214
6
0D9165
1
0D2496
1
DESCRIPTION
SCREW HHC M6-1.0 X 55
RUBBER TANK MOUNT
CAP, FUEL WITH GAUGE & VENT
KIT, FUEL TANK
NUT HEX M8-1.25
WASHER LOCK M8-5/16
WASHER FLAT 5/16
BRACKET BATTERY
BOLT,BATTERY J-BOLT
SCREW HHC 1/4-20 X 3/4 G5
WASHER FLAT 1/4
WASHER LOCK M6-1/4
NUT HEX 1/4-20
BATTERY CABLE, RED
BATTERY U1
NUT WING 5/16-18 BRASS
WASHER FLAT 5/16 BRASS
NUT HEX 5/16-18 BRASS
5/16 SPECIAL L/WASH
SCREW HHC 5/16-18 X 1.5 BRASS
BRACKET FRONT FOOT (15 kW)
BRACKET FRONT FOOT (12.5 kW)
VIB MOUNT
WASHER FLAT .25ID X 1"OD
SCREW HHC M8-1.25 X 30
SCREW HHTT M6-1.0 X 12
NUT LOCK FL 3/8-16
BOLT CARR 3/8-16 X 1
AXLE, 3/4"DIA X 30" (15 kW)
AXLE, 3/4"DIA X 27.25" (12.5 kW)
ITEM PART NO.
29
QTY.
045900
045900
0D7668
2
4
2
0D2495
2
31
32
33
34
35
36
0D4999
0D4044
0D3700
0D2497
022532
027028
2
2
4
1
4
6
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
0D2271
052762
051713
049226
051716
050190
078299
080270
0D5142
096021
048031C
030340
075763
075763A
0E0318
030795
1
4
8
4
4
2
1
1
1
2
2
18"
1
1
2
2
30
DESCRIPTION
WASHER FLAT 3/4" (15 kW)
WASHER FLAT 3/4" (12.5 kW)
12.3" PNEUM WHEEL 3/4" AXLE
(15 kW)
10" PNEUM WHEEL 3/4" AXLE
(12.5 kW)
PIN COTTER 1/8 X 1-1/4
BRACKET, WHEEL SPACER
NUT FLANGE M6-1.0 NYLOK
HANDLE
SCREW HHC 5/16-18 X 2-1/2 G5
NUT LOCK HEX 5/16-18 NYLON
INSERT
FRAME
SCREW HHC M5-0.8 X 45 G8.8
WASHER FLAT M5
WASHER LOCK M5
NUT HEX M5-0.8
WASHER FLAT 1"
BUSHING TANK DEXTOR
VALVE, PLASTIC TANK
AIR DEFLECTOR
GROMMET .75 X .06 X .50
CLAMP HOSE BAND ¼
HOSE ¼ ID
BOOT BATTERY CABLE
BOOT STARTER CABLE
SPACER, AXLE (15 kW)
SCREW HHC 5/16"-18 X 1"
• Insert retaining pins and using pliers, bend out the ends to
prevent the pins from falling out of the axle. Remove the
wooden blocks.
1.2.2 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 you have not
already done so.
33
Section 8 – Warranty
IMPORTANT SAFETY INSTRUCTIONS
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 one 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 and exhaust system. Generac will repair your
engine at no cost to you for diagnosis, replacement parts arid 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 Facility.
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/ox "grey market" parts not made, supplied or approved by Generac.
You are responsible for contacting a. Generac Authorized Warranty Facility 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 Facility. To locate the
Generac Authorized Warranty Service Facility 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
Commercial-Industrial-Residential Portable Generator System
ELECTRICAL HAZARDS
EXPLOSION 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 you must work
around an operating unit, stand on an insulated, dry surface
to reduce shock hazard.
• 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.
• 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.
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.
• 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.
1. NFPA No. 70,
ELECTRIC CODE.
• 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 nonconducting 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.
3. AGRICULTURAL WIRING HANDBOOK, available from the Food
and Energy Council, 909 University Avenue, Columbia, MO
65201.
• 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.
• Gasoline is extremely EXPLOSIVE.
STANDARDS INDEX
NFPA
HANDBOOK
OF
NATIONAL
2. Article X, NATIONAL BUILDING CODE, available from the
American Insurance Association, 85 John Street, New York,
N.Y. 10038.
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 always must
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
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 you have any question pertaining to fire
extinguishers, consult your local fire department.
Part 1
34
3
IMPORTANT SAFETY INSTRUCTIONS
Section 8 – Warranty
Commercial-Industrial-Residential Portable Generator System
THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted
SAVE
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: in rain; in any enclosed
compartment; 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: Your 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.
Study these SAFETY RULES carefully before installing,
operating or servicing this equipment. Become familiar with this
Owner’s 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.
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
GENERAC® cannot possibly 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 you use a procedure, work method or
operating technique GENERAC® does not specifically recommend,
you must satisfy yourself that it is safe for you and others. You
also must make sure the procedure, work method or operating
technique that you choose does not render the generator unsafe.
2
------------- DANGER ------------ 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
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 1995 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 is...
(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:
machines. Ensure all steps are taken to render
the machine safe before attempting to work on
the generator.
(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.
Parts of the generator are rotating and/or hot during
(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.
operation. Exercise care near running generators.
GENERAL HAZARDS • For safety reasons, GENERAC® recommends that the
installation, initial start-up and maintenance of this equipment
is carried out by a GENERAC®/GUARDIAN® 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 installed properly, in strict
compliance with applicable codes and standards. Following
installation, you must do nothing that might render the system
unsafe or in noncompliance with such codes and 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 you are physically or
mentally fatigued.
• Inspect the generator regularly, and contact your nearest
GENERAC®/GUARDIAN® 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.
(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 or approved modifications 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 RCS 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) Standby Generator
Part 2
35
Section 8 – Warranty
INTRODUCTION
Commercial-Industrial-Residential Portable Generator System
Thank you for purchasing this model of the GUARDIAN® product
line 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.
GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR GUARDIAN®
“12,500 WATT AND 15,000 WATT PORTABLE GENERATORS”
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 2 (two) years. Commercial applications are warranted for 1 (one) year. Rental applications are warranted for
90 (ninety) 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):
If you do not understand any portion of this manual, contact your
nearest GENERAC/GUARDIAN® 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 you to special instruction about a particular operation
that may be hazardous if performed incorrectly or carelessly.
Observe them carefully. Their definitions are as follows:
------------- DANGER -------------
• 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).
After this heading, you can read instructions that, if
not strictly complied with, will result in personal injury
or property damage.
------------- WARNING ------------After this heading, you can read instructions that, if
not strictly complied with, may result in personal
injury or property damage.
------------- CAUTION ------------After this heading, you can read instructions that, if
not strictly complied with, could result in damage to
equipment and/or property.
NOTE: After this heading, you can 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 follows:
This symbol points out important safety
• 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® POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
36
READ THIS MANUAL THOROUGHLY
information that, if not followed, could endanger
personal safety and/or property of you and 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 Owner’s Manual and thoroughly
understand all instructions before using this
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.
CAUTION! Always disconnect spark plug wire and place the
wire where it cannot contact the spark plug to prevent accidental
starting when setting up, transporting, adjusting or making
repairs to your 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 your
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 overfilled, 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 2 feet of clearance on all sides of generator or
you could damage 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 “Cold Weather
Operation” on page 12.
1
ULTRA SOURCE
Portable Generator
Owner’s
Manual
• SAFETY
• ASSEMBLY
GENERAC POWER SYSTEMS, INC.
P.O. Box 297 • Whitewater, WI 53190
• OPERATION
• TROUBLESHOOTING
• ELECTRICAL DATA
• PARTS
• WARRANTY
AUTHORIZED DEALER SUPPORT:
Part No. 0E0226 Rev. F
Printed in USA
5.04, 10.04
1-800-333-1322
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODELS:
004451 (12,500 WATT)
004582 (15,000 WATT)
ULTRA SOURCE
Portable Generator
Owner’s
Manual
• SAFETY
• ASSEMBLY
• OPERATION
• TROUBLESHOOTING
• ELECTRICAL DATA
• PARTS
• WARRANTY
AUTHORIZED DEALER SUPPORT:
1-800-333-1322
COMMERCIAL • INDUSTRIAL • RESIDENTIAL
MODELS:
004451 (12,500 WATT)
004582 (15,000 WATT)