Guardian GTH-760 Series, GTH-990 Series Owner's Manual

Owner’s

Manual

• SAFETY

• ASSEMBLY

• OPERATION

• TROUBLESHOOTING

• PARTS

• WARRANTY

GTV/GTH-990/760

SERIES ENGINES

AUTHORIZED DEALER SUPPORT:

1-800-333-1322

GTV/GTH - 990/760 OHVI SERIES ENGINES

2

TABLE OF CONTENTS

GENERAL INFORMATION

Service Information ..................................................................2

Engine Identification Decal Location ........................................2

Oil and Fuel Information............................................................3

Engine Emission Compliance Period ........................................3

SAFETY

Rules for Safe Operation ..........................................................4

Before Operating ......................................................................4

While Operating ........................................................................5

OPERATION & MAINTENANCE

Before Starting the Engine ........................................................6

Starting the Engine ................................................................6-7

Stopping the Engine..................................................................7

Low Pressure Shutdown System ..............................................7

Restarting the Engine................................................................7

Maintenance Schedule..............................................................7

MAINTENANCE

General Maintenance Recommendations ................................8

Service and Adjustments ........................................................10

Carburetor Adjustments ..........................................................10

Adjusting Valve to Rocker Arm Clearance..............................11

Storage Instructions ................................................................11

Product Specifications ............................................................11

Oil Capacities ..........................................................................11

Service Parts ..........................................................................12

Troubleshooting ......................................................................12

Notes ......................................................................................13

WARRANTY

California Emission Control Warranty Statement....................15

Emission Control System Warranty ........................................16

Generac Engine Warranty ......................................................17

MAINTENANCE RECORD ..................................18

This engine meets the U.S. EPA and California emissions regulations. To ensure that your engine continues to meet these regulations, refer to the following information and instructions in this owner’s manual.

SERVICE INFORMATION

Service on this engine within and after the warranty period can be performed by any authorized service dealer. Service technicians are factory trained and capable of handling all service needs.

When contacting an authorized service dealer about parts and service , always supply the complete model number and serial number of your unit as given on its data plate decal. See the illustration below for the location of the decal.

The warranty for this engine is included in the owner’s manual.

THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS, WHICH, IF NOT FOLLOWED,

COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOU AND OTHERS. READ AND

FOLLOW ALL INSTRUCTIONS IN THE MANUAL BEFORE ATTEMPTING TO OPERATE THIS UNIT.


OIL AND FUEL INFORMATION

NOTE:

Be sure to read these instructions carefully before attempting to start or operate this equipment. Using old or improper oil or fuel can cause engine damage.

CAUTION:

Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in engine damage.

CAUTION: This engine is shipped from Generac Power

Systems without oil.

Check oil level before starting Engine. If you start the engine without oil, the engine will be damaged beyond repair and will not be covered under warranty.

RECOMMENDED OIL TYPE

Using the proper type and weight of oil in the crankcase is extremely important. Check the oil before each use and change the oil regularly. Failure to use the correct oil, or using dirty oil, can cause premature engine wear and failure.

Use only high quality detergent oil rated with API service classification SF, SG or SH. The recommended oil weights include the following:

• During summer months: SAE 30. An acceptable substitute is

SAE 10W-30. After first oil change, synthetic oil is acceptable.

• During winter months: SAE 5W-30, Synthetic 5W-20 or 5W-

10W-30, SAE 30

Synthetic 5W-20, 5W-30

F -20 0 20 40 60 80

C -30 -20 -10 10 20

Temperature Range of Expected Use

30.

DO NOT USE SAE 10W-40.

30

100

40

See Oil Capacities chart (Page 11) for oil capacities. Use no special additives. Make sure that the unit is level when filling with oil. DO NOT OVERFILL.

RECOMMENDED BATTERY

Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personal away from batteries.

Use only 12 volt negative (-) ground batteries with a minimum rating of 675 cold-cranking amps at -17.8C (0 F).

WARNING:

Damage will result to the engine starter if a

Battery

Positive(+)

Starter

Contactor

Typical Battery

Ground

BATTERY CABLES

Using battery cables that are too long or too small in diameter may cause a decrease in voltage which leads to a starting problem due to voltage drop . Use a cable size “2” for length 0” to 10 feet. See Figure A for battery cable connections.

RECOMMENDED FUEL TYPE

Use clean, fresh, regular

UNLEADED gasoline with this engine.

CAUTION:

Do not overfill the fuel tank. Always allow room for fuel expansion.

WARNING:

Never fill the fuel tank indoors. or when the engine is running or hot. Do not light a cigarette or smoke when filling the fuel tank.

ENGINE EMISSION COMPLIANCE PERIOD

For non-hand held engines: The Emissions Compliance Period referred to on the Emissions Compliance label indicates the number of operating hours for which the engine has been shown to meet Federal emission requirements.

For engines less than 225 cc displacement, Category

C = 125 hours, B = 250 hours, and A = 500 hours.

For engines 225 cc or more, Category C = 250 hours,

B = 500 hours, and A = 1000 hours.

3

4


If you do not understand any portion of this manual, contact

Generac or your nearest Generac Authorized Service Dealer for starting, operating and servicing procedures.

Throughout this publication and on tags and decals affixed to the engine, DANGER, WARNING and CAUTION blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.

These safety warnings cannot eliminate the hazards that they indicate. Strict compliance with the special instructions while performing the service plus “common sense” are major measures to prevent accidents.

The following definitions apply to

DANGER, WARNING,

CAUTION and

NOTE blocks found throughout the manual.

These safety symbols indicate the following:

DANGER:

After this heading you can read handling, installing, operating or servicing instructions that, if not strictly complied with, will result in personal injury.

WARNING:

After this heading you can read handling, installing, operating or servicing instructions that, if not strictly complied with, may result in personal injury.

CAUTION:

After this heading you can read instructions for handling, installing, operating or servicing the engine that, if not strictly complied with, may result in damage to equipment and/or property.

NOTE:

After this heading you can read explanatory statements that require special emphasis.

These symbols indicate the following:

Points out important safety information that, if not followed, could endanger personal safety and/or property of yourself and others.



Potential explosion hazard.



Potential fire hazard.

Ꮨ

Potential electrical shock hazard.

RULES FOR SAFE OPERATION

Study these RULES FOR SAFE OPERATION carefully before operating or servicing this equipment. Become familiar with the

OWNER’S MANUAL and with the engine. The engine can operate safely, efficiently and reliably only if it is properly operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual and on tags and decals affixed to the equipment, are therefore, not allinclusive. If you use a procedure, work method or operating technique Generac does not specifically recommend, you must satisfy yourself that it is safe for you and others. You must also make sure the procedure, work method or operating technique that you choose does not render the engine to be unsafe.

DANGER: Do not tamper with the engine governed speed. High operating speeds are dangerous and increase the risk of personal injury or damage to the equipment. Operating at low speeds with heavy load may shorten the engine’s life.

BEFORE OPERATING

• Gasoline is highly

FLAMMABLE and its vapors are

EXPLOSIVE

. Do not permit smoking, open flames, sparks or heat in the area while handling gasoline. Avoid spilling gasoline on a hot engine. Comply with all of the laws regulating storage and handling of gasoline.

• Store gasoline and other fuels only in containers designed and approved for the storage of such materials.

• Add gasoline in a clean, well-ventilated area. Wipe up any spilled gasoline immediately.

If gasoline has been spilled, let it dry completely before starting the engine.

WARNING:

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


• Do not overfill the fuel tank. Always allow room for fuel expansion. If the tank is overfilled, the fuel can flow onto a hot engine and cause a

FIRE or an

EXPLOSION

.

• Allow at least two (2) feet of clearance on all sides of the engine, even while operating it outdoors, or you could damage the engine.

• Thoroughly inspect the engine for loose or damaged parts before each use. Do not use the engine until adjustments or repairs are made.

• Check the oil level in the engine before each use.

• Inspect the engine periodically. Repair or replace all damaged or defective parts immediately.

• Inspect fuel system frequently for leaks or damage.

Repair or replace any damaged or leaking component immediately. Never attempt to change, alter or modify the engine fuel system in any way that might affect safety or compliance with applicable codes and standards.

WHILE OPERATING

• This engine was designed and manufactured for specific applications. Do not attempt to modify the equipment or use it for any application for which it was not designed.

• Generac Power Systems does not approve or authorize the use of these engines on All Terrain Vehicles (ATV’s), go-carts, motorbikes, aircraft products, personal watercraft, or vehicles intended for use in competitive events. Use of these engines in such applications could result in property damage, serious injury (including paralysis), or even death.

• Engine exhaust gases contain

DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Operate this equipment only in the open air where adequate ventilation is available.

• Do not insert any object through the cooling slots of the engine. You could damage the equipment or injure yourself.

• Do not operate the engine faster than the speed necessary to operate the equipment. Do not run the engine at high speed when not operating the equipment.

• This engine requires an adequate flow of cooling air for its continued proper operation. Never operate the equipment inside any room or enclosure where the free flow of cooling air into and out of the equipment might be obstructed.

Without sufficient cooling air flow, the engine quickly overheats, damaging the engine or nearby property.

• Do not smoke around the engine. Wipe up any fuel or oil spills immediately. Never leave oily or fuel soaked rags around the engine. Keep the area around the engine clean and free of debris.

• Keep hands, feet, clothing, etc., away from moving parts of this engine.

• Never operate the engine (a) in the rain; (b) in any enclosed compartment; (c) if the engine speed changes; (d) if the engine sparks; (e) if flame or smoke is observed while the engine is running.

• Never work on this engine or handle any electrical device while standing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRIC SHOCK will result.

5

OPERATION


OPERATION AND MAINTENANCE

It is the owner’s/operator's responsibility to perform all safety checks; to make sure that all maintenance for safe operation is performed promptly; and to have the engine checked by an authorized dealer periodically. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty.

Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of your engine assures a minimum number of problems and keeps your operating expenses at a minimum. See your authorized dealer/distributor for service aids and accessories.

BEFORE STARTING THE ENGINE

Perform the following tasks before trying to start the engine:

Figure 1 - Oil Fill Check

CHECK

DRAIN

FILL/

CHECK

FILL

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.

• Above 40°F, use SAE 10W-30 or SAE 30.

• Below 40°F, use synthetic 5W-20 or 5W-30.

Check your engine oil level frequently to avoid possible damage from running low on oil.

• Place engine on a level surface.

• Clean area around oil fill and remove oil fill cap and dipstick. (Figure 1 or figure 2)

• Wipe dipstick clean. Reinstall and check oil level on dipstick.

• 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.

ADDING FUEL

1. Fill the fuel tank using clean, fresh regular

UNLEADED gasoline.

STARTING THE ENGINE

1. Open the fuel shut-off valve, (if equipped).

2. Move choke control to CHOKE or START Position.

3. Push throttle to

FAST position (if equipped) . Operate the engine with the throttle in FAST position.

4. Turn key to

START position (hold until engine starts, but not more than 5 seconds). To prevent damage to starter, allow starter to cool for one minute between attempting to restart.

5. A) If the engine FAILS TO START , go to Step 6.

B) If the engine

STARTS

, go to Step 7.

6. Push the choke lever to the

HALF CHOKE

POSITION . Repeat step 4

• If the engine

STILL FAILS TO START

, repeat

Steps 1-5.

6

OPERATION


7. Move the choke lever to the

OFF POSITION by pushing it in or move choke control to RUN position.

Allow engine to warm up for two minutes..

NOTE: for cold weather starting: make sure the proper engine oil is being used (see page 3).

STOPPING THE ENGINE

1. Remove load from engine.

2. Move throttle to

SLOW position.

3. While still running, allow engine to cool for two minutes.

4. Turn key to OFF position.

5. Close fuel shut-off valve (if equipped).

LOW PRESSURE SHUTDOWN SYSTEM (OPTIONAL)

The engine is equipped with a low oil pressure sensor that shuts down the engine automatically when the oil pressure drops below 8 psi. If the engine shuts down by itself and the fuel tank has enough gasoline, check the engine oil level.

INITIAL STARTUP

A delay built in the shutdown system allows oil pressure to build during starting. The delay allows the engine to run for about 10 seconds before sensing oil pressure.

SENSING LOW PRESSURE

If the system senses low oil pressure during operation, the engine shuts down. The engine will not continue to run until 8 psi of oil pressure is reached.

RESTARTING THE ENGINE

If you try to restart the engine within (five) 5 seconds after it shuts down, the engine may NOT start. The system needs 10 seconds to reset.

NOTE: If you restart engine after a shutdown and have not corrected the low oil pressure, the engine will run for about 10 seconds as described above, and then it will stop.

MAINTENANCE SCHEDULE

The owner/operator is responsible for making sure that all periodic maintenance tasks are completed on a timely basis; that all discrepancies are corrected; and that the equipment is kept clean and properly stored. Never operate a damaged or defective engine.

CAUTION:

Disconnect the spark plug wires from the spark plugs, and place the wires where they cannot come in contact with the spark plugs before working on this engine.

MAINTENANCE SCHEDULE

Check Oil Level

Every Every Every Every

8 Hours 25 Hours 50 Hours 100 Hours or Daily Season Season Season

•

Change Oil Note 1

Change Oil Filter

Note 1

Service Air Filter

Foam

Pre-Filter if equipped

Filter

(Note 2)

Replace or Clean

Spark Plug

Clean Spark

Arrestor Screen

Adjust Valve

Clearance

•

•

•

NOTE 1:

Change oil and filter after first 8 hours of operation and then every 100 hours thereafter. Change sooner when operating under a heavy load or in a dusty or dirty environment or in high ambient temperature.

NOTE 2:

Service more often when operating in dirty or dusty conditions.

Replace standard filter element (Figure 7) every 50 hours. Replace canister style filter (Figure 8) every 500 hours.

7


GENERAL MAINTENANCE

RECOMMENDATIONS

CHECKING THE OIL LEVEL

See the

BEFORE STARTING THE ENGINE section on page 6 for information on checking the oil level. The oil level should be checked before each use, or at least every eight

(8) hours of operation. Keep the oil level maintained.

Figure 3 & 4 - Drain Plug and Oil Filter

DRAIN

Figure 5 - Oil Filter

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

3.

When changing the oil filter, use the following instructions:

A) Locate filter (Figure 4 or figure 5).

B) Place a suitable container beneath the oil filter and turn the filter counterclockwise to remove the filter.

C) Coat the gasket of a new filter with engine oil. Turn the new filter clockwise until the gasket contacts the filter adapter, then tighten an additional

3/4 turn

.

4. Remove the oil fill cap and insert a clean funnel into the oil fill opening. Fill the crankcase with the recommended oil until the oil level is at the full point on the dipstick.

Approximately 2366ml (2.5 qt.) are required when changing an oil filter.

POUR SLOWLY

.

5. When the crankcase is filled to the proper level, install and tighten the oil fill cap. Start engine to fill oil filter, recheck/correct oil level.

CLEANING INTAKE SCREEN

Clean intake screen and oil cooler fins after each use or as needed.

Figure 6 - Clean Intake Screen & Oil Cooler Fins

INTAKE SCREEN

FILTER

OIL

COOLER

FINS

CHANGING THE OIL AND OIL FILTER

Your engine is equipped with an oil filter. Change the oil and filter after the first eight (8) hours of operation. Change the oil and oil filter every 100 hours thereafter. If you are using this engine under dirty or dusty conditions, or in extremely hot weather, change the oil more often.

Use the following instructions to change the oil while the engine is still warm:

1. Clean the area around the oil drain plug, remove the plug and drain the oil completely into a suitable container

(Figure 1 or figure 3).

8

SERVICING THE AIR CLEANER

Your equipment’s air cleaner system is one of the most important items to maintain. The engine will not run properly and may be damaged if it is run with a dirty air cleaner system.

Service or replace the paper air filter per schedule on page 7.

Service or replace the filter more often if the engine is operated under dusty or dirty conditions. Clean the foam pre-filter (if equipped) every 25 hours of operation

, or sooner under dusty or dirty conditions.


Use the following instructions to clean or replace the air cleaner components. Locate your engine configuration (Figure 7 or figure 8) and follow the instruction.

CAUTION:

Never run this equipment without the complete air cleaner system installed on the engine.

This could result in premature wear to the engine.

OPTION 1

Figure 7 - Air Cleaner

OPTION 2

Figure 8 - Canister Style Air Cleaner Components

AIR FILTER

ELEMENT,

SAFETY

COVER

AIR FILTER

ELEMENT,

PRIMARY

HOUSING

1. Remove air cleaner cover.

2. Empty dust out of cover.

3. Gently pull filter out of air cleaner housing.

4. Clean inside of housing with damp cloth.

5. Push new air cleaner into housing.

6. Reinstall the air cleaner cover.

NOTE

: To order a new air filter, please contact the nearest authorized service center at 1-800-333-1322.

Figure 9 - Setting Spark Plug Gap

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 service or replace paper air filter:

• Remove air cleaner cover; then remove foam pre-filter

(service if necessary) and remove paper filter.

• 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.

REPLACING THE SPARK PLUG

Use Champion RC14YC, NGK BKR4E or equivalent spark plugs.

The correct air gap is 0.76 mm (0.030 in.). Replace the plugs every 100 hours of operation or once each year, whichever comes first. This will help your engine to start easier and run better.

1. Stop the engine and pull the spark plug wire off of the spark plug.

2. Clean around the spark plug and remove it from the cylinder head.

3. Set the spark plug gap (Figure 9) to 0.76mm (0.030 in.).

Install a correctly gapped spark plug into the cylinder head.

9


CLEANING SPARK ARRESTOR SCREEN

If the engine exhaust muffler has a spark arrestor screen, inspect and clean the screen every 100 hours of operation or once each year, whichever comes first.

NOTE:

If you use your engine on any forest-covered, brushcovered or grass-covered unimproved land, it must have a spark arrestor. The spark arrestor must be maintained in good condition by the owner/operator.

Clean and inspect the spark arrestor screen as follows:

Inspect the screen and replace if it is torn, perforated or otherwise damaged.

DO NOT USE a defective screen. If the screen is not damaged, clean it with a commercial solvent.

If the spark arrestor is found to be damaged or defective, replace it.

SERVICE AND ADJUSTMENTS

ENGINE SPEED

CAUTION: The engine speed was properly adjusted at the factory and should require no additional adjustment. Do not attempt to change engine speed. If you believe the engine is running too fast or too slow, take your engine to an authorized service center for repair and adjustment.

CHANGING THE ENGINE GOVERNED SPEED

WILL VOID THE ENGINE WARRANTY.

The operating speed of this engine is maintained by either a mechanical, flyweight type or an electronic stepper motor controlled governor. DO NOT try to adjust the governed speed setting for the following reasons:

• Operating the engine at high engine speeds is dangerous and increases the risk of personal injury or damage to the equipment.

• Operating the engine at low engine speeds with heavy loads may shorten the engine’s life.

CARBURETOR ADJUSTMENTS

The carburetor of your engine is pre-set at the factory. The carburetor should not be tampered with because this will

VOID THE EMISSION CONTROL SYSTEM

WARRANTY

. If you experience problems and your engine is used at an altitude in excess of 5000 feet, contact the nearest authorized dealer regarding high altitude setting changes.

10

ADJUSTING VALVE CLEARANCE

After the first 100 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 engine 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.

Figure 10 - Valve Clearance Adjustment

To adjust valve clearance:

• Make sure the engine is at room temperature.

• Make sure that the spark plug wires are removed from the spark plugs and out of the way.

• Remove the four screws attaching the valve cover with a 10 mm wrench or socket.

• 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

(0.05-0.1mm).

NOTE:

You must hold the rocker arm jam nut in place as you turn the pivot ball stud.


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.

• Install new valve cover gasket (Part number 0C2979).

• Re-attach the valve cover and torque to 4.8 to 5.5 ft. - lbs.

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.

STORAGE INSTRUCTIONS

This engine should be started at least once a month and run for at least 10 minutes

. If this cannot be done and the equipment must be stored for more than 30 days, use the following guidelines to prepare it for storage.

WARNING:

Never store the engine with the fuel in the tank indoors or in an enclosed or poorly ventilated area. Fumes can reach an open flame, spark, or pilot light as on a furnace, water heater, or clothes dryer and ignite.

1. Run the engine for about five (5) minutes to warm it.

NOTE:

Alcohol-blended fuel, or “gasohol”, attracts moisture which can lead to the separation and formation of acids during storage. This acidic gas can damage internal engine parts.

Methanol, ethanol and grain alcohol all are forms of gasohol. If you did use “gasohol,” drain the fuel tank, then run the engine until it stops from lack of fuel.

WARNING: Drain the fuel into approved container, outdoors, away from open flame. Be sure the engine is cool.

NOTE: Using a fuel additive such as STA-BIL ® fuel stabilizer, or an equivalent, will prevent gum deposits from forming in the engine’s fuel system.

2. While the engine is still warm, drain the oil from the crankcase. Refill it with fresh oil. See

BEFORE

STARTING ENGINE on Page 6 for oil recommendations.

3. Remove spark plug and pour about 1/2 ounce (15ml) of engine oil into the cylinder. Crank slowly to distribute oil.

CAUTION:

Avoid spray from the spark plug hole when cranking the engine slowly.

4. Install the spark plug. Do not connect the spark plug wire.

5. Clean the dirt, oil and grease from the cylinder, cylinder head, fins, blower housing, rotating screen and muffler area.

6. Close the fuel shut-off valve.

OTHER STORAGE TIPS

1. Do not store gasoline from one season to another.

2. Replace the gasoline can if it starts to rust. Rust and/or dirt in gasoline can cause problems.

3. Store the equipment in a clean and dry area.

PRODUCT SPECIFICATIONS

MODEL

Bore

Stroke

Valve Clearance

Displacement

Maximum Tilt Angle

While Operating

Weight

GTV-GTH-990

90mm

GTV-GTH-760

90mm

78mm 60mm

0.05–0.10mm 0.05–0.10mm

(.002–.004 in) (.002–.004 in)

992cc 763cc

15° 15°

(44.5 kg.) (98 lbs.) (44.5 kg.) (98 lbs.)

OIL CAPACITIES

MODEL

Oil Capacity with Oil

Filter

Oil Capacity without

Oil Filter

GTV 990 & 760 GTH 990 & 760

2030 ml (2.1 qt.) 1750 ml (1.8 qt.)

1750 ml (1.8 qt.) 1470 ml (1.5 qt.)

11


SERVICE PARTS

MODEL GTV-GTH-990 & GTV-GTH-760

Spark Plug (Champion RC14YC)

Spark Plug (NGK BKR4E)

Oil Filter (Black)

Oil Filter (Yellow)

Air Cleaner Element

Air Pre-cleaner

Air Filter, Primary (Canister Style, large)

Air Filter, Safety (Canister Style, small)

P/N 0E7585

P/N 0E6037

P/N 070185B

P/N 070185C

P/N 0D9723

P/N 0D4511

P/N 0E3557

P/N 0E3656

TROUBLESHOOTING

Engine will not start; or starts and runs rough.

1.

Dirty air cleaner.

2.

Out of gasoline.

3.

Stale gasoline.

1.

Clean or replace air cleaner.

2.

Fill fuel tank.

3.

Drain fuel tank and & carburetor and fill with fresh fuel.

4.

Connect wire to spark plug.

4.

Spark plug wire not connected to spark plug

5.

6.

Bad spark plug.

Water in gasoline.

5.

Replace spark plug.

6.

Drain fuel tank & carburetor; fill with fresh

7.

Overchoking.

8. Low oil level.

7.

fuel.

Put choke knob to No Choke

8.

Fill crankcase to proper level.

position.

9.

Excessive rich fuel mixture.

9.

Contact Authorized Service Facility.

10.

Intake valve stuck open or closed. 10.


11.

Engine has lost compression.

11.


Engine shuts down during operation.

Engine lacks power.

Engine “hunts” or falters.

1.

Out of gasoline.

2.

Low oil level.

3.

Fault in engine.

1.

Fill fuel tank.

2.

Fill crankcase to proper level.

3.


1.

Dirty air filter.

2.

Engine needs to be serviced.

1.

Replace air filter.

2.


1.

Choke is opened too soon.

2.

Carburetor is running too rich or too lean.

1.

Move choke to halfway position until engine runs smoothly.

2.


3.

Governor or speed control system 3.

Contact Authorized Service Facility out of adjustment.

12


13

14



CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with

Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.*

New engines must be designed, built and equipped to meet stringent anti-smog standards for the state of California and the federal government. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improper maintenance of your engine.

Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 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 purchaser/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 because of 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 presenting your engine to a Generac Authorized Warranty Service 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 and federal 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. The purchaser/owner shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, WI 53190

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EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:

(a) Applicability: This warranty shall apply to 1997 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 EPA and CARB pursuant to their respective authority, and

(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted emissionsrelated part to fail to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.

(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:

(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the

ECS Warranty Period.

(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the

ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty

Period.

(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the period of time prior to the 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 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 proximately 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’s ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may 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.

1) Fuel Metering System:

1.1) Gasoline carburetor assembly and its internal components (if so equipped).

a) Fuel filter (if so equipped) b) Carburetor gaskets c) Fuel pump (if so equipped)

1.2) LPG carburetion assembly and its internal components (if so equipped).

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

*Generac engine types covered by this warranty statement include the following:

1) Utility

2) Lawn and Garden Equipment

16

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

3) Recreational Vehicle (RV) Generator

4) Industrial Mobile (IM) Generator


GENERAC POWER SYSTEMS’

TWO-YEAR LIMITED WARRANTY FOR GT SERIES ENGINES

For a period of 2 (two) years of operation from the date of original sale, Generac Power Systems, Inc. (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 under normal use and service, in accordance with the warranty schedule set forth below. 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 GT engines sold and rated for GT engine applications, as Generac has defined GT engine applications.

This warranty pertains only to the GT engines utilized to power equipment within the lawn and garden industry. Examples include, but are not limited to, portable generators, pressure washers, air compressors, welders, lawn tractors and mowers, snow blowers, edgers and pumps. THIS WARRANTY IS NOT TRANSFERABLE.

•

•

WARRANTY SCHEDULE

GT engines bound for export outside of North America shall be warranted for a period of 1 (one) year for consumer/personal applications and 90 (ninety) days for commercial applications.

CONSUMER/COMMERCIAL APPLICATIONS

YEAR ONE - 100% (one hundred percent) coverage on part(s) and labor as listed (proof of purchase required):

Engine - All components

YEAR TWO - 100% (one hundred percent) coverage on part(s) ONLY as listed (proof of purchase required):

Engine - All components

All warranty expense allowances are subject to the conditions defined in Generac’s Warranty Policies, Procedures and Flat Rate Manual for engines.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Generac engines that utilize non-Generac replacement parts.

• Costs of normal maintenance, adjustments, installation and start-up.

• Failures caused by any contaminated fuels, oils, or lack of proper fluid amounts.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the GT-Series 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.

• 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).

• Engines used for generators that are utilized as “Prime Power” in place of existing utility power where utility is present or in place of utility power where utility power service does not normally exist.

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.

• Expenses related to “customer instruction” or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO

OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

GENERAC’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL

GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT

RESULT OF GENERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. Purchaser/owner agrees to make no claims against Generac based on negligence.

This warranty gives you specific legal rights. You also may have other rights that vary from state to state.

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MAINTENANCE RECORD

Maintenance performed ______________________
























18

Date __/__/__ Engine hours _____

























MAINTENANCE RECORD

















































19

GENERAC POWER SYSTEMS, INC.

P.O. Box 297 • Whitewater, WI 53190

Part No. 0D8699 REV. C / PRINTED IN THE USA / 3.04

Guardian GTH-760 Series, GTH-990 Series Owner's Manual

Owner’s

Manual

• SAFETY

• ASSEMBLY

• OPERATION

• TROUBLESHOOTING

• PARTS

• WARRANTY

SERIES ENGINES

AUTHORIZED DEALER SUPPORT:

TABLE OF CONTENTS

SERVICE INFORMATION

OIL AND FUEL INFORMATION

RECOMMENDED OIL TYPE

RECOMMENDED BATTERY

RECOMMENDED FUEL TYPE

ENGINE EMISSION COMPLIANCE PERIOD

RULES FOR SAFE OPERATION

BEFORE OPERATING

WARNING:

WHILE OPERATING

OPERATION AND MAINTENANCE

BEFORE STARTING THE ENGINE

STARTING THE ENGINE

STOPPING THE ENGINE

RESTARTING THE ENGINE

MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE

GENERAL MAINTENANCE

RECOMMENDATIONS

CLEANING INTAKE SCREEN

SERVICING THE AIR CLEANER

REPLACING THE SPARK PLUG

SERVICE AND ADJUSTMENTS

CARBURETOR ADJUSTMENTS

STORAGE INSTRUCTIONS

OTHER STORAGE TIPS

PRODUCT SPECIFICATIONS

OIL CAPACITIES

SERVICE PARTS

TROUBLESHOOTING

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT

EMISSION CONTROL SYSTEM WARRANTY

GENERAC POWER SYSTEMS’

TWO-YEAR LIMITED WARRANTY FOR GT SERIES ENGINES

MAINTENANCE RECORD

MAINTENANCE RECORD

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Table of contents