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Generac Centurion 12500 0049860 Portable Generator Manual
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Centurion Centurion 12500 0049860 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. Especially useful as an emergency backup source for essential equipment like power tools, refrigerators, pumps and lights.
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CE SOS EC COMMERCIAL * INDUSTRIAL * RESIDENTIAL Assembly о 2 VER: LIMITED WARRANTY $ Operation Maintenance Troubleshooting Electrical Data FOR YOUR NEAREST MODELS: www .centuriongenerators.com НЕ Table of Contents CONTENTS Commercial-Industrial-Residential Portable Generator System Safety Rules cerita, 1-3 Section 3 — Maintenance..............e=.. ==. eee... 14 Section 1 — General Information ................ 4 3.1 Maintenance Schedule es 14 1.1 UNPACKING coercive sees 4 3.2 Product Specifications... 14 1.1.1 Accessory BOX....…...…..…….…eeenmenenenten 4 3.2.1 Generator Specifications …………………………….……. 14 2.2 Engine Specifications es 14 1.2 АвветМ nur crever 4 3 name speerications 1.2.1 Assembling the Wheel Kit 4 3.3 General Recommendations 15 1.22 Assembling the Handle 5 3.3.1 General Maintenance as 15 1.2.3 Battery Connection …………………………………………s 5 3.3.2 To Clean The Generator ……………………….….….….…. 15 3.3.3 Engine Maintenance res 15 Section 2 — Operation Areas ee eee eee eee aaneees 6 3.3.4 Ghecking Oil Level... 15 3.3.5 Changing The Oil a Oil Filter ..................... 15 2.1 Know The Generator ........................eeeeeeeee ee 6 3.3.6 Replacing The Spark Plug ........................ 15-16 2.2 Cord Sets and Connector Plugs...................—————....... / 3.4 Service Air Cleaner…………………….….….emnes 16 2.2.1 120V AC, 20 A, Duplex Receptacle .................. 7 2.2.2 120V AC, 20, GFCI Receptacie .................—... 7 3.5 Clean Spark Arrestor Screen ...............ee. eee 16 2.2.3 120\ АС, 30 А Receptacie ........................... 7-8 3.6 Adjusting Valve Clearance ..........................m.... 17 2.2.4 120/240V AC, 30 A, Receptacle........................ 8 225 12 VDC, 10 Amp Receptacle ..................... 8 3.7 General .....................eceee menear. 18 2.2.6 120/240V AC, 50 A, Receptacie..................... 8 3.8 Long Term Storage ....................e.ememnenee 18 23 How To Use The Generator reee. 9 3.9 Other Storage TiPS see veers eee 18 2.3.1 Grounding The Generator …………………….………………… 9 2.3.2 Connecting Electric Loads.............................. 9 Section 4 — Troubleshooting o nrarerooraneomadaa 19 2.4 Dont Overload The Generator .......................—....—.—....... 9 4.1 Troubleshooting Guide................................. 19 25 1Wattage Reference Chart ...................e........ 0 10 2.6 Before Starting The Generator 10 Section 5 — Notes .......... reassess 20-21 2.0.1 Adding Engine Oil ........................—— 10 | 2.6.2 Adding Gasoline es 11 Section 6 — Electrical Data ass 22-23 2.7 To Start The Engine …….….……...….…….………rrerrrescarrsrnensres 11 98 Stopping The Engine wooo 12 Section 7 — Exploded Views and 2.9 Automatic [die Control... 12 Parts LISS--oremnmennennns 24-33 2.10 Cold Weather Operation/De-Icer ‚u 12 Section 8 - Warranty ...............—..—.e.... 34-36 2.11 Low Oil Pressure Shutdown..................e.e.emie 12 2.11.1 Initial Start-up cc... eevee 12 2.11.2 Sensing Low Oil Pressure ...............——.=....... 12 2.11.3 Restarting .....................e_ereeneni e 12 2.12 Charging a Battery .......................eeeeee e 13 e” > ng AN ® + Pet Tran «” ъ e. INTRODUCTION 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. READ THIS MANUAL THOROUGHLY 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: After this heading, you can read instructions that, if not strictly complied with, will result in personal injury or property damage. After this heading, you can read instructions that, if not strictly complied with, may result in personal injury or property damage. 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: A This symbol points out important safety 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. À 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 Owners 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 over filled, fuel can overflow onto a hot engine and cause FIRE or an EXPLOSION. Never store generator with fuel in tank where gasoline vapors might reach an open flame, spark or pilot light (as on a furnace, water heater or clothes dryer). FIRE or EXPLOSION may result. Generator exhaust gases contain DEADLY carbon monoxide gas.This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Operate this equipment only in the open air where adequate ventilation is available. Allow at least 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. SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS 7\ Commercial-Industrial-Residential Portable Generator System SAVE THESE INSTRUCTIONS — The manufacturer suggests that these rules for safe operation be copied and posted near the unit's installation site. Safety should be stressed to all operators and potential operators of this equipment. * Never start or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON. Start the engine and let it stabilize before connecting electrical loads. Disconnect all electrical loads before shutting down the generator. * Do not insert objects through unit's cooling slots. e 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 Owners 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: IN The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. A WARNING: A 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. NY VT оненнн A 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. A Potentially lethal voltages are generated by these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator. /\ Parts of the generator are rotating and/or hot during operation. Exercise care near running generators. A GENERAL HAZARDS A » For safety reasons, GENERAC® recommends that the installation, initial start-up and maintenance of this equipment is carried out by a GENERAC*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. e 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. e Inspect the generator regularly, and contact your nearest GENERAC* 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. IMPORTANT SAFETY INSTRUCTIONS SAFETY RULES Commercial-Industrial-Residential Portable Generator System ZA ELECTRICAL HAZARDSA 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 handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT. The National Electrical Gode (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electrical system. In case of accident caused by electric shock, immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a non- conducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medica! help. Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving components causing injury. 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. AN A EXPLOSION HAZARDS A Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no combustible materials are left on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris. Gasoline is extremely EXPLOSIVE. STANDARDS INDEX In the absence of pertinent standards, codes, regulations and laws, the published information listed below may be used as a guideline for operation of this equipment. 1. МЕРА No. 70, ELECTRIC CODE. Article X, NATIONAL BUILDING CODE, available from the American Insurance Association, 85 John Street, New York, N.Y. 10038. AGRICULTURAL WIRING HANDBOOK, available from the Food and Energy Council, 909 University Avenue, Columbia, MO 65201. 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. NFPA HANDBOOK OF NATIONAL . NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE. Section 1 — General Information GENERAL 1.1 UNPACKING * Set the palleted carton on a rigid flat surface. Remove staples along bottom of carton that fasten carton to pallet. Open carton from top. * Remove all packaging material. * Remove separate accessory box. e Lift carton off the generator. Remove generator from shipping pallet by removing bolts through the shipping brackets. Figure 1 - Bracket Removal » Shipping . “Bracket 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: * Owners Manual e Bolt-on tubular handle * Wheel Axle o 2 — Pneumatic Wheels е 2 — Axle Bracket Assemblies о 2 — Washers o 2— Wheel Spacers e 2 — Cotter Pins e Bolt-on Foot e © — Carriage Bolts, Washers, Nuts * Battery Charge Cable e Spark Plug Wrench * 2 Spark Plugs. * Air Filter * Pre-cleaner Commercial-Industrial-Residential Portable Generator System 1.2 ASSEMBLY The generator requires some assembly prior to using it. 1.2.1 ASSEMBLING THE WHEEL KIT_ The wheel kit is designed to greatly improve the portability of the generator. A socket wrench with a 9/16” socket, a 1/2” socket, a 1/2” wrench and a pair of pliers are the tools that will be needed for assembly of the wheel Kit. Note: The wheel kit is not intended for over-the-road use. * Referto Figure 2 shown on opposite page and install the wheel kit as follows: | * Place the generator on a hard flat surface. * Stand at the engine end of the unit and gently tilt the generator forward, high enough to place wooden blocks beneath the cradle. This will allow space to install the wheel assemblies. e 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. e |nsert 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 e 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. | Commercial-Industrial-Residential Portable Generator System Section 1 - General Information GENERAL Figure 2 - Handle Assembly CAPSCREW, 5/16 X 2-1/2 FLAT WASHER _— — / © | ~~ FLAT WASHER— > A \) LOCKWASHER — 7 L ho LOCKNUT “SPACER (= | ; — Ss 7 WASHER SIO 7 RETAINING PIN ON < Y AXLE ng О y д, HANDLE a FRONT FOOT PA | CARRIAGE BOLT, 3/8 X 1 ASSEMBLY UNT CAPSCREW, 5/16 X 4 / ^^ LOCK WASHER LOCK NUT © FLAT WASHER 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. 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. Figure 3 - Battery Connections Positive Cable Negative Cable OPERATION Section 2 — Operation OD OPERATION 2.1 KNOW THE GENERATOR Read the Owners 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 Commercial-Industrial-Residential Portable Generator System Figure 6 - Engine Control Panel ha pga da ad O | CONTI К AM 1) 12 Volt DC, 10 Amp Receptacle — This receptacle allows the capability to recharge a 12 volt DC storage battery with provided battery charge cables. 2) 120 Volt AC, 20 Amp, Duplex Receptacle — Supplies electrical power for the operation of 120 Volt AC, 20 Amp, single-phase, 60 Hz electrical lighting, appliance, tool and motor loads. 3) 120 Volt AC, 20A Duplex GFCI Receptacle — Supplies ground fault protected electrical power for operation of 120 volt AC 20 amp, single-phase, 60 Hz electric lighting, appliances, tools and motor loads. 4) 120 Volt AC, 30 Amp Locking Receptacle — Supplies electrical power for the operation of 120 Volt AC, 30 Amp, single-phase, 60 Hz electrical lighting, appliance, tool and motor loads. 5) 120/240 Volt AC, 30 Amp Locking Receptacle — Supplies electrical power for the operation of 120 and/or 240 Volt AC, 30 Amp, single-phase, 60 Hz, electrical lighting, appliance, tool and motor loads. 6) 120/240 Volt AC, 50 Amp Receptacle — Supplies electrical power for the operation of 120/240 Volt AC, 50 Amp, single-phase, 60 Hz, welder or motor loads. 7) Air Cleaner — Filters intake air as it is drawn into the engine. 8) Choke Knob — Used when starting a cold engine. 9) Winter/ Summer Valve — See “Cold Weather Operation.” (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) 11) Fuel Tank — Tank hoids 16 U.S. gallons of fuel. 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. OPERATION Section 2 — Operation Commercial-Industrial-Residential Portable Generator System 2.2 CORD SETS AND CONNECTION PLUGS 2.2.1 AC, 20 AMP DUPLEX RECEPTACLE 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, well- insulated, 3-wire grounded cord sets rated for 125 Volts at 20 Amps (or greater). Keep extension cords as short as possible, preferably less than 15 feet long, to prevent voltage drop and possible overheating of wires. Figure 7 - 120 Volt AC, 20 Amp, Duplex Receptacle 120V 20A 2.2.2 120V AC, 20 AME, GFCI RECEPTACLE This unit is equipped with a ground fault circuit interrupter (GFCI). This device meets applicable federal, state and local codes. A GFC! receptacle is different from conventional receptacles. In the event of a ground fault, a GFCI will trip and quickly stop the flow of electricity to prevent serious injury. Definition: Instead of following its normal safe path, electricity passes through a persons body to reach the ground. For example, a defective appliance can cause a ground fault. A GFCI receptacle does NOT protect against circuit overloads, short circuits, or shocks. For example, electric shock can still occur if a person touches charged electrical wires while standing on a non-conducting surface, such as a wood floor. OD Figure 8 - 120 VAG, 20 Amp GFCI Receptacle Receptacle ———— N Outlet — и — _ | Correct wiring/ i ; Trip Indicator JA © | д a Fa Ee се. TEST button: TI Pp Ге TEST RESET и RESET button: — | = 5 2 E zZ < X E - J Outlet -...————— и Testing the GFCI: Test the GFCI outlet every month as follows: * Plug a test lamp into the receptacle. * Start the generator, the test lamp should be on. * Press the “Test” button located on the front of the receptacle to trip the device. * This should stop the flow of electricity making the lamp shut off. The yellow trip indicator should now be on. * To restore the flow of electricity, press the “Reset” button on the front of the receptacle. If the GFCI does not perform in this manner, do not use the receptacle. Contact a local service dealer. * This outlet is protected against overload by a 20A push-to- reset circuit breaker. Use the outlet to power 120V AC, single- phase, 60 Hz, electrical loads requiring up to a combined 2400 watts (2.4 kW) or 20 amps of current. 2.2.3 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. OPERATION Section 2 — Operation OD Figure 9 - 120 VAC, 30 Amp Receptacle Use this receptacle to operate 120 Volt AC, 60 Hz, single phase loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps. 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). Figure 10 - 120/240 VAC, 30 Amp Receptacle 120V/240V 30A 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. Commercial-Industrial-Residential Portable Generator System 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. Figure 11 - 12 Volt DG, 10 Amp Receptacle 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 12 - 120/240 VAC, 50 Amp Receptacle Zu U N и 120V/240V 50A 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. OPERATION Section 2 — Operation Commercial-Industrial-Residential Portable Generator System 2.3 HOW TO USE THE GENERATOR If you have any problems operating your generator, please call the generator help line 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 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. | OD 2.3.2 CONNECTING ELECTRICAL LOADS DO NOT connect 240 Volt loads to 120 Volt receptacles. DO NOT connect 3-phase loads to the generator. DO NOT connect 50 Hz loads to the generator. | * Let engine stabilize and warm up for a few minutes after starting. * Plug in and turn on the desired 120 or 240 Volt AC, single phase, 60 Hz electrical loads. * Add up the rated watts (or amps) of all loads to be connected at one time. This total should not be greater than (a) the rated wattage/amperage capacity of the generator or (b) circuit breaker rating of the receptacle supplying the power. See ‘Don't Overload the Generator below. 2.4 DON'T OVERLOAD THE GENERATOR Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and to connected electrical devices. Observe the following to prevent overloading the unit: * Add up the total wattage of all electrical devices to be connected at one time. This total should NOT be greater than the generator s wattage capacity. * The rated wattage of lights can be taken from light bulbs. The rated wattage of tools, appliances and motors can usually be found on a data plate or decal affixed to the device. e |f the appliance, tool or motor does not give wattage, multiply volts times ampere rating to determine watts (volts x amps = watts). * Some electric motors, such as induction types, require about three times more watts of power for starting than for running. This surge of power lasts only a few seconds when starting such motors. Make sure 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.) OPERATION Section 2 — Operation 1X Commercial-Industrial-Residential Portable Generator System 2.5 WATTAGE REFERENCE GUIDE Device .....oce.e.emanaoenana Running Watts . . *Air Conditioner (12,000 Btu) ................. 1700 Device .....................en Running Watts * Air Conditioner (24,000 Btu) 3800 Hedge THMMer «oe ввели нонея 450 *Air Conditioner (40,000 Btu) nene, 6000 Impact Wrench ............ 2... naaa 500 Battery Charger (20 Amp) ra, 500 Iron Ce eee eee areas nea 1200 Belt Sander (3) .............. ккувеекоо, 1000 Jet PUMp ee. 800 Chain Saw ......... ee errores 1200 Lawn Mower... 1200 Circular Saw (6-1/2)................... 800 to 1000 Light BUIb erre 100 “Clothes Dryer (Electric) ..................... 5750 Microwave Oven .......... ee 700 to 1000 *Clothes Dryer (Gas) ......................... 700 Milk Cooler ............_._.recrerrereneen a. 1100 *Clothes Washer . ...... 1150 Oil Burner on Furnace ........................ 300 Coffee Maker .............. es 1750 Oil Fired Space Heater (140,000 Btu) ............. 400 "Compressor (1 HP) ...................... 2000 Oil Fired Space Heater (85,000 Btu) .............. 225 *Compressor (3/4 HP) rs 1800 Oil Fired Space Heater (30,000 Btu) aaa 150 *Compressor (1/2 HP) ....................... 1400 *Paint Sprayer, Airless (13HP) ................. 600 Curling Iron ............ as 700 Paint Sprayer, Airless (handheld) ................ 150 “Dehumidifier 11111100 eee 650 ir 50 to 200 Disc Sander (9") ................. 0... 1200 Refrigerator ................ cc ii... 700 Edge Trimmer .............. 2... a. 500 Slow Cooker... esse ee. 200 Electric Blanket ............... 0000 400 “submersible Pump (1-1/2 HP) ................ 2800 Electric Nail Gun... Len 1200 ,oubmersible Pump (1 HP) ................... 2000 Electric Range (per element) .................. 1500 “Submersible Pump (1/2 HP) ................. 1500 Electric Skillet ................... 000 ane 1250 Sump Pump =... 800 to 1050 Freezer ....... aan as 700 “Table Saw (10) ......... 0... 0... 1/50 to 2000 “Furnace Fan (3/5 HP) 11111111 1000 875 Television ........................... 200 to 500 *Garage Door Opener ................... 500 to 750 Toaster ae es eee es 1000 to 1650 Haïr Dryer LL eee 1200 Weed Trimmer ........ eee 500 Hand Drill ............ ee... 250 to 1100 2.6 BEFORE STARTING THE GENERATOR Prior to operating the generator, engine oil and gasoline will need °F -20 о 20 32 40 60 80 100 to be added, as follows: °С -30 20 0 0 10 20 30 40 Temperature Range of Expected Use 2.6.1 ADDING ENGINE OIL NOTE: When adding oil to the engine crankcase in Lu o nn the future, use only high quality detergent oil rated * Clean area around oil fill and remove oil fill cap and dipstick. with API service classification SF or SG SAE 30 e Wipe dipstick clean. weight. Use no special additives. * Place generator on a level surface. e Slowly fill engine with oil through the oil fill opening until it Select the oil's viscosity grade according to the expected reaches the full mark on the dipstick. Stop filling occasionally operating temperature. Do not use SAE 10W-40. to check oil level. DO NOT OVERFILL. * Above 40°F, use SAE 10W-30 or SAE 30. Install dipstick. Install oil fill cap and finger tighten securely. Below 40°F, use synthetic 5W-20 or 5W-30. * Check engine oil level before starting each time thereafter. 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. 10 OPERATION Section 2 — Operation Commercial-Industrial-Residential Portable Generator System 2.6.2 ADDING GASOLINE 2A 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. e Use regular UNLEADED gasoline with the generator engine. Do not use premium gasoline. Do not mix oil with gasoline. * (lean 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, e Install fuel cap and wipe up any spilled gasoline. Figure 14 - Fuel Tank Fuel Fuel Tank 1/2 inch ru" = 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 ZA 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. OD Figure 15 - Fuel Shut-off Valve Ni on — ( y or | FUEL SHUTOFF | * | ocate the Idle Control ON/OFF switch on the control panel and set it to the “OFF” position. Figure 16 - Idle Control Switch * Move engine CHOKE knob to “Full Choke” position. Figure 17 - Full Choke Position 11 OPERATION Section 2 — Operation OD e 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. | 2.8 STOPPING THE ENGINE * Shut off ali loads, then unplug the electrical loads from generator panel receptacies. Never start or stop the engine with electrical devices plugged in and turned on. * Turn “Off” the Idle Control switch (if on). * [et engine run at no-load for several minutes to stabilize the internal temperatures of engine and generator. * Move Start/Run/Stop switch to “Off” position. * Close fuel valve. 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. 2.9 AUTOMATIC IDLE CONTROL This feature is designed to greatly improve fuel economy. When this switch is turned “On,” the engine will only run at its normal fast governed engine speed when electrical load is connected. When the load is removed, the engine will run at a reduced speed of 2100 RPM. With the switch “Off,” the engine runs at the normal fast engine speed all the time. Always have the switch OFF when starting and stopping the engine. 2.10 COLD WEATHER OPERATION/ DE-ICER Under certain weather conditions (temperatures below 40° F (4° C) and a high dew point), the engine may experience icing of the carburetor and/or the crankcase breather system. To eliminate this problem, this generator engine is fitted with a winter/summer valve. this directs hot air into the carburetor during cold weather operation. Always make sure the winter/summer valve is in the correct location relative to the weather conditions. 12 Commercial-Industrial-Residential Portable Generator System 2.11 LOW OIL PRESSURE SHUTDOWN SYSTEM The engine is equipped with a low oil pressure sensor that shuts down the engine automatically when the oil pressure drops below 10 psi. If the engine shuts down by itself and the fuel tank has enough gasoline, check engine oil level. 2.11.1 INITIAL START-UP A delay built into the low oil shutdown system allows oil pressure to build during starting. The delay allows the engine to run for about 10 seconds before sensing oil pressure. 2.11.2 SENSING LOW OIL PRESSURE If the system senses low oil pressure during operation, the engine shuts down. 2.11.3 RESTARTING If 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. 2.12 CHARGING A BATTERY A 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. ZA 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. Section 2 — Operation Commercial-Industrial-Residential Portable Generator System To recharge 12 Volt batteries, proceed as follows: Check fluid level in all battery cells. If necessary, add ONLY distilled water to cover separators in battery cells. Do not use tap water. If the battery is equipped with vent caps, make sure they are installed and are tight. If necessary, clean battery terminals. Connect battery charge cable connector plug to panel receptacle identified by the words "12-VOLT D.C." Connect battery charge cable clamp with red handle to the positive (+) battery terminal. Connect battery charge cable clamp with black handle to the negative (-) battery terminal. Start engine. Let the engine run while battery recharges. Engine idle control switch must be in off position for battery charging. When battery has charged, shut down engine. Note: Use an automotive hydrometer to test battery state of charge and condition. Follow the hydrometer manufacturer's instructions carefully. Generally, a battery is considered to be at 100% state of charge when specific gravity of its fluid (as measured by hydrometer) is 1.260 or higher. OPERATION QD 13 = Section 3 — Maintenance MAINTENANCE Commercial-Industrial-Residential Portable Generator System — 3.1 MAINTENANCE SCHEDULE Follow the calendar intervals. More frequent service is required when operating in adverse conditions noted below. Every Season Every Season Every Season Operation Maintenance Check Oil Level / Service Air Pre-Cleaner q Change Oil and Oil Filtert Clean Spark Arrestor Screen Adjust Valve Clearance Service Air Cleaner Replace Spark Plugs й * NS t 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 GENERA CI 10 Hours / 1.6 gallons per hour Run Time/Fuel Consumption-1/2 Load 14 ed Fu a" === Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System 3.3 GENERAL RECOMMENDATIONS The warranty of the generator does not cover items that have been subjected to operator abuse or negligence. To receive full value from the warranty, the operator must maintain the generator as instructed in this manual. Some adjustments will need to be made periodically to properly maintain the generator. All adjustments in the Maintenance section (3) of this manual should be made at least once each season. Follow the requirements in the "Maintenance Schedule" chart on page 14. 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. 3.3.1 GENERATOR MAINTENANCE Generator maintenance consists of keeping the unit clean and dry. Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust, dirt, moisture or any corrosive vapors. Cooling air slots in the generator must not become clogged with snow, leaves, or any other foreign material. Check the cleanliness of the generator frequently and clean when dust, dirt, oil, moisture or other foreign substances are visible on its exterior surface. ACAUTION! Never insert any object or tool through the air cooling slots, even if the engine is not running. Note: DO NOT use a garden hose to clean generator. Water can enter the engine fuel system and cause problems. In addition, if water enters the generator through cooling air slots, some water will be retained in voids and crevices of the rotor and stator winding insulation. Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings. 3.3.2 TO CLEAN THE GENERATOR MAINTENANCE 2 3.3.3 ENGINE MAINTENANCE DANGER! When working on the generator, always disconnect negative cable from battery. Also disconnect spark plug wires from spark plug and keep wire away from spark plug. 3.3.4 CHECKING OIL LEVEL See the “BEFORE STARTING THE GENERATOR” section 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. 3.3.5 CHANGING THE OIL AND OIL FILTER * Use a damp cloth to wipe exterior surfaces clean. e À soft, bristle brush may be used to loosen caked on dirt, oil, etc. ® Avacuum 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. 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: « (lean 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. 15 Section 3 — Maintenance MAINTENANCE — 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. 3. Set the spark plug's gap to 0.76 mm (0.030 in.). Install the correctly gapped spark plug into the cylinder head. Figure 18 - Spark Plug Gap | i A { — \ Of J 2 3.4 SERVICE AIR CLEANER 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. Figure 20 - Air Cleaner 1, Cover Pre-Cleaner Filter 16 Commercial-Industrial-Residential Portable Generator System To clean or replace foam pre-cleaner: * Remove air cleaner cover, then foam pre-filter. * Wash pre-cleaner in soapy water. Squeeze pre-filter dry in clean cloth (DO NOT TWIST). * Clean air cleaner cover before re-installing it. To clean or replace paper air filter: * Remove air cleaner cover; then remove foam pre-filter (service If necessary) and remove paper filter. * Clean paner filter by tapping it gently on a solid surface. If the filter is too dirty, replace it with a new one. Dispose of the old filter properly. * Clean air cleaner cover then slip pre-cleaner over filter. Next insert new paper filter into the base of the air cleaner. Re- install air cleaner cover. Note: To order a new air filter, please contact the nearest authorized service center at 1-800-333-1322. 3.5 CLEAN SPARK ARRESTOR SCREEN The engine exhaust muffler has a spark arrestor screen. inspect and clean the screen at least once each year. If unit is used regularly, inspect and clean more often. NOTE: If you use your generator on any forest- covered, brush-covered or grass-covered unimproved land, it must equipped with a spark arrestor. The spark arrestor must be maintained in good condition by the owner/operator. Clean and inspect the spark arrestor as follows: * Remove the screen retaining bracket by removing the screw. e Slide the spark arrestor screen out from the tail pipe. * [Inspect screen and replace if torn, perforated or otherwise damaged. DO NOT USE a defective screen. If screen is not damaged, clean it with commercial solvent. * Replace the screen and the retaining bracket. CL ea = Section 3 — Maintenance Commercial-Industrial-Residential Portable Generator System Figure 21 - Spark Arrestor MUFFLER OUTLET TUBE RETAINER E xo ET E % E PT PARAM \ я COC 3 DOLO | ку ES Ts A RETAINING % — SCREW 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. * 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. e 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. a | 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/Ibs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change. MAINTENANCE — Figure 22 - Valve Clearance Adjustment Rocker Pivot Ball Arm Stud Jam Nut e Install new valve cover gasket. e 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. e Re-attach the spark plug wire to the spark plug. * Repeat the process for the other cylinder. 17 a a ——— 259 == Section 3 — Maintenance MAINTENANCE — STORAGE 3.7 GENERAL The generator should be started at least once every seven days and be allowed to run at least 30 minutes. If this cannot be done and you must store the unit for more than 30 days, use the following information as a guide to prepare it for storage. DANGER! Never store engine with fuel in tank indoors or in enclosed, poorly ventilated areas where fumes may reach an open flame, spark or pilot light as on a furnace, water heater, clothes dryer or other gas appliance. #, A 3.8 LONG TERM STORAGE It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor, fuel hose or tank during storage. Also, experience indicates that alcohol-blended fuels (called gasohol, ethanol or methanol) can attract moisture, which leads to separation and formation of acids during storage. Acidic gas can damage the fuel system of an engine while in storage. To avoid engine problems, the fuel system should be emptied before storage of 30 days or longer, as follows: * Remove all gasoline from the fuel tank. A 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. A CAUTION! Avoid spray from spark plug holes when cranking engine. * [Install and tighten spark plugs. Do not connect spark plug wires. * (lean 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 Commercial-Industrial-Residential Portable Generator System 3.9 OTHER STORAGE TIPS: * Do not store gasoline from one season to another. * 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. e |f possible, store your unit indoors and cover it to give protection from dust and dirt. BE SURE TO EMPTY THE FUEL TANK. e |fitis 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. /\ DANGER! Never cover your generator while engine and exhaust area are warm. Section 4 — Troubleshooting TROUBLESHOOTING Commercial-Industrial-Residential Portable Generator System 4,1 TROUBLESHOOTING SYMPTOM yr Y SOLUTION Engine is running, but no AC 1. Circuit breaker is open. 1. Reset circuit breaker. output is available. 2. Poor connection or defective cord set. {| 2. Check and repair. 3. Connected device is bad. 3. Connect another device that is in good condition. 4. Fault in generator. 4. Contact Authorized Service Facility. Engine runs good, but bogs 1. Short circuit in a connected load. 1. Disconnect shorted electrical load. down when loads are connected. 2. (Generator is overloaded. 2. See “Dont Overload the Generator” on page 9. | 3. Engine speed is too slow. 3. Contact Authorized Service Facility. 4. Shorted generator circuit. 4. Contact Authorized Service Facility. Engine will not start; or starts 1. Dirty air cleaner. 1. Clean or replace air cleaner. and runs rough. 2. Out of gasoline. 2. Fill fuel tank. 3. Stale gasoline. 3. Drain fuel tank and fill with fresh fuel. 4. Spark plug wire not connected to 4. Connect wire to spark plug. spark plug. 5. Bad spark plug. 5. Replace spark plug. 6. Water in gasoline. 6. Drain fuel tank; fill with fresh fuel. 7. Overchoking. 7. Put choke knob to No Choke position. 8. Low oil level. 8. Fill crankcase to proper level. 9. Excessive rich fuel mixture. 9. Contact Authorized Service Facility. 10. Intake valve stuck open or closed. 10. Contact Authorized Service Facility. 11. Engine has lost compression. 11. Contact Authorized Service Facility. Engine will not start; or 1. Insufficient fuel to fire the engine 1. Choke the 15kW engine starts hard. hot or cold to start. 2. Battery charge low. 2. Recharge the battery. 3. Battery charge low due to 3. Allow engine to run for longer frequent starts and stops. periods to recharge the battery. Engine shuts down during 1. Out of gasoline. 1. Fill fuel tank. operation. 2. Low oil level. 2. Fill crankcase to proper level. 3. Fault in engine. 3. Contact Authorized Service Facility. Engine lacks power. 1. Load is too high. 1. See “Don’t Overload the Generator” On page 9. 2. Dirty air filter. 2. Replace air filter. 3. Engine needs to be serviced. 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. Carburetor is running too rich or too 2. Contact Authorized Service Facility. lean. No Battery Charge DC output. 1. Battery posts are corroded. 1. Clean battery posts. 2. Battery cable is bad. 2. Replace cable. 3. Battery is defective. 3. Check battery condition; replace if defective. 4. Receptacle is bad. 4, Contact Authorized Service Facility. 19 NOTES Section 5 — Notes Commercial-Industrial-Residential Portable Generator System 20 Section 5 - Notes Commerciai-Industrial-Residential Portable Generator System NOTES 21 Commercial-Industrial-Residential Portable Generator System Wiring Diagram — Drawing No. 0E0228 Section 6 — Electrical Data | — = 1 Нолан мег WHO 57 - IY pA анпевана ЛЮ мет - 401 Aw | Ue" E A Es "al 4 9 A Lo | Tv и” DNIEYIE OL 1S3IS0ND + X „ 7 / LA LA | MOTLSIML vor E — AOVZ/OEL NN Sy a Juno vos ee, мкг ELECTRICAL DATA fe 22 ELECTRICAL DATA 4 Section 6 — Electrical Data Schematic — Drawing No. 0E0229A Commercial-Industrial-Residential Portable Generator System MOOTE TWNIAREL - Tal TEL HOULIMS TOBINOO TTO!- TMS ATH dOLS-NNH-LHVLS - LAS AYEH «015 / HVS - HSS AYVTAH HOLIVINOO HALHVIS - HOS HOIVINOI HAIHVIS - 35 HOLSISAU AASZ ‘iNHO SZ - LH TANSSIHd HO MOT - dO1 £ U ITNCIÓN NOLINO! - 2YUl EA “TINCION NOLLUNEA - HAN HE L TORINGD F101 - 1D HVE GNIMOUD - OND 0e MOSS 440 NHS ла - S84 Mc mu | 38TH OLNY WYSE - 289 WD Ba 13834 OLNY dWY0L - 18D HE S9HVHI AUALLYS - 2408 VOL "HAT 39HYHD AHL IVE - USE ATEWISSY HSNHA - ve NET 0. [я Le miei e Be u —— | Eo | © vœŒ |6! ao | oe ? me : zz or о о =— | | > > SIL mo | DL ner ar NEL fs J "e = | Г | 1249 KIO AOZI лог! т т LEER 23 eo = — 88 — pf — (a. POR LLE VO ES Y Cada PORT AVEO O Yi PARTS Gre 24 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 1) — Drawing No. 0E8589E Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 8: GT-760 Engine (Page 1) — Drawing No. 0E8589E ITEM PART# QTY. DESCRIPTION 1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH SLEEVE 2 0E9843 1 SEAL, 38 |.D. CRANKSHAFT 3 090388 3 SCREW, TAPTITE M6-1.0 X 12 BP 4 005372 1 ASSEMBLY, BREATHER 5 0C3005 1 GASKET, BREATHER COVER 6 0E3372B 1 SEPARATOR, OIL BREATHER 7 0D8067A 1 ASSEMBLY, HEAD #1 8 071983 4 RETAINER, PISTON PIN 20 9 0D5269 1 ROCKER, COVER 10 043790A 1 BARBED EL 90 3/8NPT X 3/8 11 0Е2950 2 PISTON, LC (GT-990) 0E2985 2 PISTON, HC (GT-760) 12 021533 2 — SET, PISTON RING 90MM 13 0E1466 2 PIN PISTON 14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR 15 0D4788 2 PLUG STD PIPE 3/8 STEEL SQ HD 16 093064 1 ASSEMBLY, OIL FILL CAP 17 0С2977 1 GASKET, CRANK CASE 18 0C5943 1 SEAL, OIL PASSAGE 19 0E4357E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL DIRECT DRIVE (GT-990) OE4356E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL DIRECT DRIVE (GT-760) 20 0Е3223 2 ASSEMBLY, CONNECTING ROD (GT-990) 0E3222 2 ASSEMBLY, CONNECTING ROD (GT-760) 21 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8 22 0E6098 1 SCREEN, OIL PICKUP 23 OD4123A 1 ASSEMBLY, OIL PUMP 24 078699E 2 + SLEEVE, SEAMED DOWEL 10 DIA. 25 0C3011 2 COVER, OIL RELIEF 26 0C3009 2 SPRING, OIL RELIEF 27 0C3010 2 BALL, 1/2D OIL RELIEF 28 093873 2 WASHER, LOCKRIB M6 29 0C5315 1 GEROTOR, OUTER 30 0C5998 1 CLAMP, OIL TUBE 31 0D4497 1 PLUG-CRANKCASE GOVERNOR BORE 32 OC3971E 1 ASSEMBLY, DIPSTICK WITH HANDLE ton ITEM PART# QTY. DESCRIPTION 33 0D3745 1 TUBE, DIPSTICK 34 0C3027 3 O-RING, OIL CLR 35 0E9842 1 SEAL, 42 |.D. CRANKSHAFT 36 0C5731 1 ASSEMBLY, HOUSING COVER WITH SLEEVE 37 0C3006 10 SCREW, HHFC M10-1.5 X 55 38 080318 8 SCREW HHFC M6-1.0 X 25 39 0C8808 2 HOOK, LIFTING 40 0C2981C 1 ROCKER, COVER 41 0C2979 2 GASKET, VALVE COVER 42 086515 8 KEEPER, VALVE SPRING 43 0D2274 4 RETAINER, VALVE SPRING 44 0D3867 4 SPRING, VALVE 45 078672 2 SEAL, VALVE STEM D7 46 005371 4 WASHER, VALVE SPRING 47 072694 4 STUD, ROCKER ARM PIVOT 48 0C3027 2 O-RING, 3/8" X 1/2" 49 0D5313 4 ROCKER ARM 50 0D3998 4 NUT, HEX M8-1.0 GB YELLOW CHROME 51 0D6024 2 PLATE, PUSH ROD GUIDE 52 0C2976 12 SCREW HHFC M8-1.25 X 65 53 086516 2 VALVE, EXHAUST 54 0C2229 2 VALVE, INTAKE 55 083897 4 TAPPET, SOLID 56 0D8067B 1 ASSEMBLY, HEAD #2 57 0D9853D 4 PUSHROD 147 58 0C2978 2 GASKET, HEAD 59 006008 1 KIT GEAR COVER 60 0D4010 1 KIT GASKET 61 0D6007 1 KIT PISTON & RINGS 62 0D4012 1 KIT BREATHER ASSEMBLY 63 OD8675A 1 KIT HEAD ASSEMBLY CYL 1 64 0D8675B 1 KIT HEAD ASSEMBLY CYL 2 65 0D4015 1 KIT OIL RELIEF item 59 (Kit) includes items 3, 30, 35 & Kit item 65 item 60 (Kit) includes items 2, 5, 17, 18, 34, 35, 40, 57, 139, 153. Item 61 (Kit) includes items 8, 11, 12, 13 Item 62 (Kit) includes items 4, 5, 6 Item 63 (Kit) includes items 7, 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, Item 64 (Kit) includes items Item 65 (Kit) includes items 53, 54, 57, 58 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, 53, 54, 56, 57, 58 25, 26, 27 25 Commercial-Industrial-Residential Portable Generator System Section 7 — Exploded Views and Parts Lists GT-990 & GT-760 Engine (Page 2) — Drawing Мо. ОЕ8589Е 921 Re 821 | y a LV a | У ; : gpl | EEL LEL Ÿ- = SSI — MINI er N Za sh ` + | - DA U S ELL NT a 14 _ > 191 SIL—— A == 2 A 3 FY 401 > | > > Da SE -98 YL Eno, ~ A 121 A RH Sp 8 » | / > vel Ос! Sel y \ LISTS % PARTS Co Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System GT-990 & GT-760 Engine (Page 2) —- Drawing No. 0E8589E ITEM PART# QTY. DESCRIPTION 66 0D6592 1 WINGNUT, AIRBOX 67 0D4511 1 PRECLEANER, AIR 68 009723 1 ELEMENT, AIR CLEANER 69 OE5302 1 STUD M6-1.0 X 73 70 004183 1 ADAPTER, SPIT BACK 71 0D6327 1 GASKET, SPITBACK 72 0D2774B 1 BASE, AIRBOX (GT-990) 0E4870 11 BASE, AIRBOX (GT-760) 73 0D5125 1 SPRING, WINTER/SUMMER VALVE 74 0D2930 1 VALVE, SUMMER / WINTER 75 004612А 1 SNORKEL, AIR INTAKE 76 0D6143 1 TUBE, HEAT RISER 50.8 I.D. 77 002775 1 COVER, AIRBOX 78 OD5014A 1 KNOB, AIRBOX 17mm 79 0D50148 1 KNOB, AIRBOX 95MM 80 049721 1 SCREWHHC M6-1.0 X 35 81 022097 1 WASHER LOCK M6-1/4 82 022473 1 WASHER FLAT 1/4 83 052857 4 NUT LOCK FLANGE M6-1.0 84 0D6021 4 STUD, METRIC 85 0C9093A 1 HOSE, BREATHER 86 0D4522 1 CONTROLLER ASSEMBLY 87 074908 2 SCREW HHTT M5-0.8 X 10 89 OE3398 1 ASSEMBLY, WIRE 90 0E2548 1 CARBURETOR (GT-990) 0E5077 1 CARBURETOR (GT-760) 91 0D4026 1 GASKET, CARB TO SPACER (GT-990) 0D4024 1 GASKET, CARB/AIRBOX (GT-760) 92 048031С 4 CLAMP HOSE BAND 1/4 93 030340 12" HOSE % ID 94 0D4023 1 GASKET, MANIFOLD TO CARB (GT-990) 0D5282 1 GASKET, MANIFOLD TO CARB (GT-760) 95 086061G 1 SLEEVING 1/2"1.D. 96 0D6313 1 FILTER, FUEL 97 070008 «4 WASHER FLAT M8 98 070006 4 WASHER LOCK M8 99 049821 4 SCREWSHCM8-1.25 X 30 100 0С9911 1 MANIFOLD, INTAKE 101 051714 1 NUT HEX M3-0.5 102 0D5411 1 ROD, SUMMER / WINTER VALVE 103 0D5445 1 BUSHING, MINI CONTROL PANEL 104 0D5416A 1 KNOB, CONTROL SUMMER / WINTER | 105 005398 1 CHOKE ASSEMBLY 106 0E6043 2 SCREW TAPTITE M5-0.8 X 8 ZP 107 0D3432 1 PANEL, CONTROL FACE PLATE 108 045756 24 SCREW TAPTITE M6-1.0X 10 | YELLOW CHROME 109 0D4767 1 SWITCH ROCKER 110 OD1142A 1 WRAPPER, LOWER CYLINDER 2 111 0D1143 1 WRAPPER, UPPER CYLINDER 2 112 0F1177 1 ASSEMBLY, GROUND WIRE 113 022097 4 WASHER LOCK M6-1/4 ITEM PARTS E “o PART#. QTY. DESCRIPTION 114 092079 4 SCREW TAPTITE M6-1.0 X 25 BP 115 0С3052 2 ASSEMBLY, IGNITION COIL 116 0С4147 1 PUMP IMPULSE 117 022264 2 WASHER LOCK M4 118 0D6142 2 SCREW PPHM M4-0.7 X 40 119 0D5399A 1 ELBOW, RUBBER 90 DEG. 120 0E7585 2 SPARKPLUG, CHAMPION RC14YC 121 0E4271 1 STARTER, DELCO REMY SD80 122 022129 3 WASHER LOCK M8-5/16 123 061906 2 SCREW HHC M8-1.25 X 85 G8.8 124 022145 1 WASHER, FLAT M8 125 045771 1 NUT, HEX M8-1.25 G8 126 0D1131 1 GUARD,FAN 127 0C3022B 1 HOUSING, BLOWER GASOLINE COOLER 128 0С9763 4 NUT, GROMMET 1/4 PLUG 129 0C3034 1 NUTHEX M24 130 0C3033 1 WASHER, M24 131 0C3032 1 PLATE, FAN 132 045992 2 WASHER SHAKEPROOF INT M8 ss 133 051754 2 SCREWHHC M8-1.25 X 12 G8.8 134 0C3031 1 FAN, NYLON 135 085011 1 INSULATOR ASSEMBLY IGNITION 136 045758 4 SCREW TAPTITE M6-1X10 YELLOW CHROME 137 0C3725A 1 FLYWHEEL ASSEMBLY 138 0C3016A 1 PLATE, BACKING GT990 WITH OIL COOL 139 082774 1 KEY, WOODRUFF 4 X 19D 140 0C3043 2 GASKET, MANIFOLD / PORT 141 0C9764 4 PLASTITE,1/4-15 X 3/4 142 0C3026 1 COOLER, OIL 143 0C7649 4 CLAMP HOSE .38-.87 144 0C9806 2 HOSE, 3/8" .D.X 6" LONG 145 035461A 2 BARBED STR 1/4NPT X 3/8 WITH VIBRA SEAL 146 070185 1 FILTER, OIL D 69 X 64 LONG 147 0C7299 1 NIPPLE, 3/4"-16 UNF 148 003083 1 ASSEMBLY, OIL DRAIN HOSE 149 0С3025 1 SWITCH, OIL PRESS 150 0D4550 1 BRACKET, AIRBOX SUPPORT 151 0С3018 1 WRAPPER, UPPER CYLINDER 1 152 0C3019 1 WRAPPER, LOWER CYLINDER 1 153 046964A 1 BRASS ST ELBOW 1/4 NPT 154 OE0409 1 ASSY, ROD, GOV. STEPPER MOTOR 155 0C8563 6 SCREW HHHC M6-1.0 X12 157 0D9784 2 NUT, LOCK HEX M3-0.5 (GT-990) 0E4869 12 NUT, HEX W/TOOTH WASHER M3-0.5 (GT-760) 158 031879 1 WASHER FLAT #4 (GT-990) 0E4868 1 WASHER FLAT #4 (GT-760) 159 0D6098 1 SPACER, ROD (GT-760 ONLY) 27 Section 7 — Exploded Views and Parts Lists Bers Generator — Drawing No. 0D4488D ‚ ©) œu — 0 16 44— & + û - X 28 Commercial-Industrial-Residential Portable Generator System 34 — 39 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Generator — Drawing No. 0D4488D PARTS Qo O ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 1 0C6934 1 ADAPTOR, ENGINE 23 0A2038 1 WASHER FLAT 3/8 ZINC 2 0D2123 1 STATOR 12.5KW 24 022237 5 WASHER LOCK 3/8 0D2134 STATOR 15KW 25 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5 0D2136 STATOR 18KW 26 022131 4 WASHER FLAT 3/8-M10 ZINC 3 0D21320SRV 1 ASSEMBLY, ROTOR WITH FAN 27 051731 4 SCREW HHC M8-1.25 X 50 G8.8 12.5KW 28 022145 21 WASHER FLAT 5/16 ZINC 0D21330SRV ASSEMBLY, ROTOR WITH FAN 29 049820 4 NUT LOCK HEX M8-1.25 NYLON 15KW INSERT 0D2135 ROTOR 18KW 30 079246 SCREW HHC M6-1.0 X 16 WITH 4 0C6043B 1 CARRIER, REAR BEARING LOCK WASHER 5 0D2492 1 EXHAUST MANIFOLD 31 022129 18 WASHER LOCK M8-5/16 6 0D2726 1 MUFFLER 32 022259 12 NUT HEX 5/16-18 STEEL 7 0C4138 2 GASKET, EXHAUST 33 059637 2 SCREW TAPTITE 3/8-16 X 3/4 BP 8 0D3547 1 COVER, ALTERNATOR AIR IN 34 0D5100 1 SHIELD, MUFFLER HEAT 9 031971 1 BEARING 35 0D5823 1 U-BOLT & SADDLE 10 0C3168 3 5/16 SPECIAL LOCK WASHER 36 0C8565 4 SCREW SHC M8-1.25 X 18 11 0D1838 1 SCREW IHHC 3/8-24 X 15.50 G5 37 0D5833 1 PANEL, MUFFLER BOX BACK 12 0D3549 4 SCREW IHHC M8-1.25 X 400 G8.8 38 0D5834 1 PANEL, MUFFLER BOX END 13 0C7038E 1 BRACKET, ALT MOUNTING 39 090388 3 SCREW HHTT M6-1.0 X 12 14 032712 4 SCREW HHTT #10-32 X 1.75 40 022473 5 WASHER FLAT 1/4 15 0D4662 1 SCREW HHTT M8-1.2 X 20 41 N/A - NOT USED 16 0C7038D 1 ENGINE MOUNTING PLATE 42 0D5133 1 SPARK ARRESTOR SCREEN 17 0C7758 6 RUBBER MOUNT 43 OD5133A 1 RETAINER, SPARK ARREST 18 0388050AF0 1 BATTERY CABLE, BLACK SCREEN 19 0C2417A 1 EARTH STRAP 3/8X 3/8 44 045764 1 SCREW HHTT M4-0.7 X 8 20 082121C 1 CLIP-J VINYL COAT .625 ID 45 0D6214 1 SHIELD, RUBBER MOUNT 21 066386 1 ASSEMBLY, BRUSH HOLDER 46 066849 2 SCREW HHTT M5-0.8 X 16 22 002824 1 SCREW TAP-R #10-32 X 9/16 < 18 30 LISTS der Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel — Drawing No. 0E0227B N A LY 7 © — co ‹ LO < Ba \ a + * wy A <} | o \ / - со = D Es \ y = RY + ñ © 7 MM EN р LO ” / 7 % € \ o о | = A / ) 5 _ TX ; со * В | j Et o с. rn o < , / Ax © > o © ERA o © o N — { И — со N o — — У Ч / Ql + q — И Ва Sw \ o © \ ) N \ / N | / à ZA Do © | + < . «© — © К TX + © 2 И © / — =} Pa — & — _ + + ~ LD \ a QI Dai \ 7 a N ip x wd -— 4 | N O O < N x; ! "He | о 0 0 Y) S— 9 LO f a : N I D Qu 5 \ с $ — < a X / Q T QA | © 2 \ а ON + = © e a 7 / © AI 09 } т oe = т { TQ ‘я + о a ; <t e € o) ” > LO E a æ / Ql e y; / __— т > % > y о — T= т . 5 ы 7 © e A Pe LO — a \ \ \ \ / / ‘ a 7 y 7 o / © > > A \ LO | T a Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Control Panel — Drawing No. 0E0227B ITEM PART NO. QTY. DESCRIPTION O ONU BON 21 22 23 24 25 26 27 28 29 30 31 087968 090418 0D6640 090987 0D2502 068868 022985 043182 051714 075207A 075207 0D4969 043437 0D4968 0D4966 0D1004E 051716 022152 0D5045 067680 0D4409 052844 OF3100 0D2691 023484L 0A1661 048766 003550 049939 070370 030468 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 ITEM PART NO. QTY. DESCRIPTION 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 022158 023897 057405 022473 022097 049813 065795 0D4804 0C1085 051715 022264 048505 087962 036261 0A2769 032300 028578 055444 075475 049815 0A2053 055440 045770 0D5734 074908 075235 080823 038150 0D6140 075476 027565 058000K OF3101 = Co — HN 2 A/R 2 1 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 38.8 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 31 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit — Drawing No. 0E0695A 6 oN 17 j 45 87 9 11 1213 - POWER м — | WIRE TO or 49 — ay ENGINE NA | | —14 lo A ” —15 \ al > > 46 OT Detail of Battery Tray _ : | ; NES A ~ A | A MS _ om ol 6 | | Ay N ; 16 e 36 | 17—. | * + 18 > | | v7 3 a — 35 _ 17 | oh, ~~ 41 | q - a | >44 6 40 og < 0 [| 19 39 32 / | 17 | fk E | | | | | - 20 $ E \ Po 34- | P= 24 \) 7. 52 | 22 — — | v > L > 3 CoN DS 24— 4 4 N 7 26 36 ОР y | 39 — 38 — 32 27 Section 7 — Exploded Views and Parts Lists Commercial-Industrial-Residential Portable Generator System Frame, Handle & Wheel Kit — Drawing No. 0E0695A ITEM PART NO. QTY.DESCRIPTION © 60 — ©) WN = 057058 005315 004570 0D22850SRV 045771 022129 022145 0D4565 0D3545 022287 022473 022097 022127 0388040АКО 004575 005202 005199 029809 0C3168 0D5198 OEOS17 0D2498 027007 0D5303 042909 090388 064101 039214 0D9165 0D2496 SAL OORNAN == = = = — Бо = — = о NNNNNIRSZHR IED 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) PARTS ton LISTS ITEM PART NO. QTY. DESCRIPTION 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 045900 045900 0D7668 0D2495 0D4999 0D4044 0D3700 0D2497 022532 027028 0D2271 052762 051713 049226 051716 050190 078299 080270 0D5142 096021 0480310 030340 075763 075763A 0E0318 030795 2 4 2 Го ©) + NN ГО ГО — —© со ГО ГО — + —<— DEA FER 00 + — 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 % HOSE % ID BOOT BATTERY CABLE BOOT STARTER CABLE SPACER, AXLE (15 kW) SCREW HHC 5/16"-18 X 1" 33 Section 8 — Warranty Commercial-Industrial-Residential Portable Generator System CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission Control System warranty on your new engine. In California, new off-road Large Spark-lgnition (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/or "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 Part 1 34 Section 8 — Warranty Commercial-Industrial-Residential Portable Generator System EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS warranty) for 2001 and later model year LSI engines: (a) Applicability: This warranty shall apply to 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: (1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. (2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner's Manual shail be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of "repair or replace as necessary" shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period. (3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the period of time prior to first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part. (4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility. (5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable. (6) Generac shall be liable for damages to other original engine components 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: 3) Ignition System including: a) Spark plug 1.2) LPG/Natural Gas carburetion assembly and its internal components. Ignition module ) b) a) Fuel controller (if so equipped) , . , , A. b) Mixer and its gaskets (if so equipped) ; ir qee Assembly (if so equipped) including: c) Carburetor and its gaskets (if so equipped) b) Exhaust manifold d) Primary gas regulator (if so equipped) | e) LP liquid vaporizer (if so equipped) 5) Crankcase Breather Assembly including: 2) Air Induction System including: 2) Breather connection tube a) Intake pipe/manifold b) Air cleaner * 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 as Section 8 — Warranty “Commercial-Industrial-Residential Portable Generator System GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR CENTURION “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 Centurion 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 Centurion 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): * 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 Centurion portable generators that utilize non-Generac replacement parts. + (Costs of normal maintenance and adjustments. e 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 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). e 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 Part No. 0E8082 Rev. C Printed in USA 9.03, 11.03, 9.04, 10.04 PART NO. | 0E0695 6 > 7 8 9 11 1213 \ | / WIRE TO ENGINE Detail of Battery Tray 35 E.C.O. | REV. | DATE F -9380 A 2/26/03 G-6907 В 11/18/05 H-1412 C 11/15/07 H-3135 D 9/10/08 DO NOT SCALE ITEM PART# QTY. DESCRIPTION 1 057058 4 SCREW HHC M6-1.0 X 55 2 0D5315 4 RUBBER TANK MOUNT 3 0D4570 1 CAP, FUEL WITH GAUGE & VENT 4 0D22850SRV 1 KIT, FUEL TANK 5 045771 4 NUT HEX M8-1.25 6 022129 6 WASHER LOCK M8-5/16 7 022145 14 WASHER FLAT 5/16 8 0D4565 1 BRACKET BATTERY 9 0D3545 2 BOLT,BATTERY J-BOLT 10 022287 2 SCREW HHC 1/4-20 X 3/4 G5 11 022473 2 WASHER FLAT 1/4 12 022097 2 WASHER LOCK M6-1/4 13 022127 2 NUT HEX 1/4-20 14 0388040AK0 1 BATTERY CABLE, RED 15 0D4575 1 BATTERY U1 16 0D5202 1 NUT WING 5/16-18 BRASS 17 0D5199 4 WASHER FLAT 5/16 BRASS 18 029809 1 NUT HEX 5/16-18 BRASS 19 0C3168 1 5/46 SPECIAL LWASH 20 0D5198 1 SCREW HHC 5/16-18 X 1.5 BRASS 21 0E0317 1 BRACKET FRONT FOOT (15 kW) 0D2498 1 BRACKET FRONT FOOT (12.5 kW) 22 027007 2 VIB MOUNT 23 0D5303 4 WASHER FLAT .25ID X 1"OD 24 042909 2 SCREW HHC M8-1.25 X 30 25 090388 4 SCREW HHTT M6-1.0 X 12 26 064101 6 NUT LOCK FL 3/8-16 27 039214 6 BOLT CARR 3/8-16 X 1 28 0D9165 1 AXLE, 3/4"DIA X 30" (15 kW) 0D2496 1 AXLE, 3/4"DIA X 27.25" (12.5 kW) 29 045900 2 WASHER FLAT 3/4” (15 kW) 045900 4 WASHER FLAT 3/4” (12.5 kW) 30 0D7668 2 12.3" PNEUM WHEEL 3/4" AXLE (15 kW) 0D2495 2 10" PNEUM WHEEL 3/4" AXLE (12.5 kW) 31 0D4999 2 PIN COTTER 1/8 X 1-1/4 32 0D4044 2 BRACKET, WHEEL SPACER 33 0D3700 4 NUT FLANGE M6-1.0 NYLOK 34 0D2497 1 HANDLE 35 022532 4 SCREW HHC 5/16-18 X 2-1/2 G5 36 027028 6 NUT LOCK HEX 5/16-18 NYLON INSERT 37 0D2271 1 FRAME 38 052762 4 SCREW HHC M5-0.8 X 45 G8.8 39 051713 8 WASHER FLAT M5 40 049226 4 WASHER LOCK M5 41 051716 4 NUT HEX M5-0.8 42 050190 2 WASHER FLAT 1” 43 078299 1 BUSHING TANK DEXTOR 44 080270 1 VALVE, PLASTIC TANK 45 0D5142 1 AIR DEFLECTOR 46 096021 2 GROMMET .75 X .06 X .50 47 0G3662A 2 CLAMP,HOSE OETIKR STEPLSS 14.5 48 0F9176 18” HOSE%ID 49 075763 1 BOOT BATTERY CABLE 50 075763A 1 BOOT STARTER CABLE 51 0E0318 2 SPACER, AXLE (15 kW) 52 030795 2 SCREW HHC 5/16”-18 X 1” EXPLODED VIEW: GENERAC POWER ss mE SYSTEMS BEN KIELAS 4/13/02 VAUKESHA, WIS. 63106 [CHECKED BY: DATE: [FIRST USE: Ш J. VRANAK _4/24/02 — 00451-1 _ C. TURNER _4/24/02 PART NO | REY. GROUP remera " C. TURNER 4/24/02 0E0695 D
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Key Features
- Produces dangerously high voltage, requiring caution.
- Has a special charging receptacle for charging a battery.
- Has GFCI receptacle to protect against electrical shock.
- Protected by low oil pressure shutdown to prevent damage.
- Generator is protected by automatic idle control to save fuel.
- Easy and safe electric starting with included battery
- Has convenient and compact design for easy storage and transportation.
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Frequently Answers and Questions
Where can I find the cord sets and connector plugs specifications?
See the Operation section of the manual for detailed specifications on each type of cord set and connector plug.
What is included in the accessory box?
The accessory box includes the battery, battery cables, and a funnel for adding oil.
How do I replace the spark plug?
See the Maintenance section of the manual for detailed instructions on how to replace the spark plug.
What is the recommended oil to use in the generator?
Refer to the Maintenance section of the manual for the recommended oil type and specifications.
How long should I run the generator before adding load?
Run the generator for 5 minutes before adding any electrical load.