ULTRA SOURCE
Commercial, Industrial, Residential
Portable Generator
Owner’s
Manual
• Safety
• Assembly
• Operation
• Maintenance
• Troubleshooting
• Electrical Data
• Parts
• Warranty
MODELS:
004451 (12,500 Watt)
004582 (15,000 Watt)
FOR YOUR NEAREST AUTHORIZED SERVICE CENTER 1-800-333-1322
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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.
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.
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.
READ THIS MANUAL THOROUGHLY
•
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.
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:
•
•
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.
-------------
-------------
ƽ
DANGER
ƽ
After this heading, you can read instructions that, if
not strictly complied with, will result in personal injury
or property damage.
•
•
•
•
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.
-------------
-------------
ƽ
WARNING
ƽ
After this heading, you can read instructions that, if
not strictly complied with, may result in personal
injury or property damage.
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.
-------------
-------------
ƽ
CAUTION
ƽ
After this heading, you can read instructions that, if
not strictly complied with, could result in damage to
equipment and/or property.
•
•
Never add fuel while unit is running.
Do not overfill the fuel tank. Always allow room for fuel expansion. If
tank is overfilled, fuel can overflow onto a hot engine and cause
FIRE or an EXPLOSION.
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.
•
•
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.
Four commonly used safety symbols accompany the DANGER,
WARNING and CAUTION blocks. The type of information each
indicates follows:
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.
ƽ This symbol points out important safety
information that, if not followed, could endanger
personal safety and/or property of you and others.
•
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.
Ʒ This symbol points out potential explosion hazard.
Ƹ This symbol points out potential fire hazard.
Ꮨ This symbol points out potential electrical shock
hazard.
The operator is responsible for proper and safe use of
the equipment. We strongly recommend that the
operator read this Owner’s Manual and thoroughly
1
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IMPORTANT SAFETY INSTRUCTIONS
Commercial-Industrial-Residential Portable Generator System
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted
ƽnear 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.
-------------
-------------
ƽ
DANGER
ƽ
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.
•
•
Do not insert objects through unit's cooling slots.
Never operate generator: in rain; in any enclosed
compartment; if connected electrical devices overheat; if electrical
output is lost; if engine or generator sparks; if flames or smoke are
observed while unit is running; if unit vibrates excessively.
Ꮨ 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.
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.
ƽ Parts of the generator are rotating and/or hot during
operation. Exercise care near running generators.
ƽ GENERAL HAZARDS ƽ
•
•
For safety reasons, GENERAC® recommends that the installation,
initial start-up and maintenance of this equipment is carried out by
a GENERAC®/GUARDIAN® Authorized Dealer.
The engine exhaust fumes contain carbon monoxide, which can be
DEADLY. This dangerous gas, if breathed in sufficient
concentrations, can cause unconsciousness or even death. This
exhaust system must be installed properly, in strict compliance with
applicable codes and standards. Following installation, you must do
nothing that might render the system unsafe or in noncompliance
with such codes and standards.
Keep hands, feet, clothing, etc., away from drive belts, fans, and
other moving or hot parts. Never remove any drive belt or fan guard
while the unit is operating.
Adequate, unobstructed flow of cooling and ventilating air is critical
to correct generator operation. Do not alter the installation or permit
even partial blockage of ventilation provisions, as this can seriously
affect safe operation of the generator. The generator MUST be
operated outdoors.
When working on this equipment, remain alert at all times. Never
work on the equipment when you are physically or mentally fatigued.
Inspect the generator regularly, and contact your nearest
GENERAC®/GUARDIAN® Authorized Dealer for parts needing repair
or replacement.
Before performing any maintenance on the generator, disconnect its
battery cables to prevent accidental start up. Disconnect the cable
from the battery post indicated by a NEGATIVE, NEG or (–) first.
Reconnect that cable last.
Never use the generator or any of its parts as a step. Stepping on
the unit can stress and break parts, and may result in dangerous
operating conditions from leaking exhaust gases, fuel leakage, oil
leakage, etc.
Study these SAFETY RULES carefully before installing, operating or
servicing this equipment. Become familiar with this Owner’s Manual and
with the unit. The generator can operate safely, efficiently and reliably
only if it is properly installed, operated and maintained. Many accidents
are caused by failing to follow simple and fundamental rules or
precautions.
GENERAC®
cannot
possibly
anticipate
every
possible
circumstance that might involve a hazard. The warnings in this
WARNING:
•
•
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
WARNING:
This product contains or emits chemicals
known to the state of California to cause
•
•
cancer, birth defects or other reproductive harm.
manual, and on tags and decals affixed to the unit are, therefore,
not all-inclusive. If you use a procedure, work method or operating
technique GENERAC® does not specifically recommend, you must
satisfy yourself that it is safe for you and others. You also must make
sure the procedure, work method or operating technique that you
choose does not render the generator unsafe.
•
•
2
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IMPORTANT SAFETY INSTRUCTIONS
Commercial-Industrial-Residential Portable Generator System
Ꮨ ELECTRICAL HAZARDSᏘ
Ʒ EXPLOSION HAZARDS Ʒ
•
All generators covered by this manual produce dangerous
electrical voltages and can cause fatal electrical shock. Utility
•
•
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.
power delivers extremely high and dangerous voltages as
does the generator when it is in operation. Avoid contact with
bare
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.
wires, terminals, connections, etc., while the unit is
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.
•
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.
1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
CODE.
ELECTRIC
•
The National Electrical Code (NEC) requires the frame and external
electrically conductive parts of the generator to be connected to an
approved earth ground. Local electrical codes also may require
proper grounding of the generator electrical system.
2. Article X, NATIONAL BUILDING CODE, available from the American
Insurance Association, 85 John Street, New York, N.Y. 10038.
•
In case of accident caused by electric shock, immediately shut down
the source of electrical power. If this is not possible, attempt to free
the victim from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a non-conducting implement, such as
a rope or board, to free the victim from the live conductor. If the victim
is unconscious, apply first aid and get immediate medical help.
3. AGRICULTURAL WIRING HANDBOOK, available from the Food
and Energy Council, 909 University Avenue, Columbia, MO 65201.
4. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM
STANDBY ELECTRICAL SYSTEMS, available from the American
Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI
49085.
•
•
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.
5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE.
Ƹ FIRE HAZARDS Ƹ
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.
3
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Section 1 – General Information
Commercial-Industrial-Residential Portable Generator System
1.1 UNPACKING
1.2 ASSEMBLY
•
Set the palleted carton on a rigid flat surface.
The generator requires some assembly prior to using it. If problems
arise when assembling the generator, please call the Generator
Helpline at 1-800-333-1322.
•
Remove staples along bottom of carton that fasten carton to pallet.
Open carton from top.
•
•
•
•
Remove all packaging material.
Remove separate accessory box.
Lift carton off the generator.
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.
Remove generator from shipping pallet by removing bolts through
the shipping brackets.
Note:The wheel kit is not intended for over-the-road use.
Figure 1 - Bracket Removal
•
Refer to 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.
Shipping
Bracket
(x4)
•
Attach an axle bracket assembly with attached sleeve to either side
of the frame. Ensure the sleeve faces outward.
•
•
Slide the axle through the sleeves on the axle brackets.
Slide one wheel with flat washer to the outside and a spacer to the
inside onto each end of the axle. Make sure the air inflation valve
on the wheel is facing outward.
•
Insert retaining pins and using pliers, bend out the ends to prevent
the pins from falling out of the axle. Remove the wooden blocks.
1.1.1 ACCESSORY BOX
Check all contents. If any parts are missing or damaged locate an
authorized dealer at 1-800-333-1322.
1.2.2 ASSEMBLING THE HANDLE
Contents include:
•
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.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Owner’s Manual
Bolt-on tubular handle
Wheel Axle
•
•
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.
2 – Pneumatic Wheels
2 – Axle Bracket Assemblies
2 – Washers
Remove the shipping brackets from the cradle, if not already done
so.
2 – Wheel Spacers
2 – Cotter Pins
Bolt-on Foot
6 – Carriage Bolts, Washers, Nuts
Battery Charge Cable
Spark Plug Wrench
2 Spark Plugs.
Air Filter
•
Pre-cleaner
4
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Section 1 - General Information
Commercial-Industrial-Residential Portable Generator System
Figure 2 - Handle Assembly
CAPSCREW,
5/16 X 2-1/2
FLAT WASHER
FLAT WASHER
LOCK WASHER
LOCK NUT
SPACER
WHEEL
FLAT WASHER
RETAINING PIN
AXLE
LOCK
NUT
HANDLE
CARRIAGE BOLT, 3/8 X 1
CAPSCREW, 5/16 X 1
FRONT FOOT
ASSEMBLY
LOCK WASHER
FLAT WASHER
LOCK NUT
Figure 3 - Battery Connections
1.2.3 BATTERY CONNECTION
•
•
•
The battery shipped with the generator has been provided fully
charged. Caution must be taken when connecting the battery.
Negative
Cable
Positive
Cable
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.
5
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Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
1) 12 Volt DC, 10 Amp Receptacle – This receptacle allows
OPERATION
the capability to recharge a 12 volt DC storage battery with
provided battery charge cables.
2.1 KNOW THE GENERATOR
Read the Owner’s Manual and Safety Rules before
operating this generator.
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.
Compare the generator to this illustration to become familiarized with
the locations of various controls and adjustments. Save this manual for
future reference.
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.
Figure 4 - Control Panel
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.
2
3
13
1
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.
20A
GFCI
T E S T
R E S E T
TEST
RESET
12Vdc
IDLE
CONTROL
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.
50A
20A
ON
OFF
120V
20A
120V
20A
GFCI
10A
120V
30A
CIRCUIT BREAKERS - PUSH TO RESET
7) Air Cleaner – Filters intake air as it is drawn into the engine.
8) Choke Knob – Used when starting a cold engine.
30A
30A
5
30A
4
9) Winter / Summer Valve – See “Cold Weather Operation.”
120V/240V
30A
120V/240V
50A
(Section 2, page 12.)
30A
120V
30A
10) Circuit Breakers (AC) – Each receptacle is provided with a
push-to-reset circuit breaker to protect the generator against
electrical overload.
6
10
11) Fuel Tank – Tank holds 16 U.S. gallons of fuel.
12) Grounding Lug – Ground the generator to an approved earth
Figure 5 - Generator Controls
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.
11
7
14) Start/Run/Stop Switch – Controls the operation of the
generator.
15) Oil Fill – Use this point to add oil to engine.
Figure 6 - Engine Control Panel
15
12
14
8
9
6
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Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
Figure 8 - 120 VAC, 20 Amp GFCI Receptacle
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
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.
2.2.2 120V AC, 20 AMP, GFCI RECEPTACLE
This unit is equipped with a ground fault circuit interrupter (GFCI). This
device meets applicable federal, state and local codes.
2.2.3 120V AC, 30 AMP RECEPTACLE
A GFCI receptacle is different from conventional receptacles. In the
event of a ground fault, a GFCI will trip and quickly stop the flow of
electricity to prevent serious injury.
Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire cord set
rated for 125 Volts AC at 30 Amps (or greater) to the plug.
Definition: Instead of following its normal safe path, electricity passes
through a persons body to reach the ground. For example, a defective
appliance can cause a ground fault.
A GFCI receptacle does NOT protect against circuit overloads, short
circuits, or shocks. For example, electric shock can still occur if a person
touches charged electrical wires while standing on a non-conducting
surface, such as a wood floor.
Figure 9 - 120 VAC, 30 Amp Receptacle
7
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Section 2 – Operation
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 DC, 10 Amp Receptacle
120V
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. The outlet is
protected by a 30 Amp push-to-reset circuit breaker.
2.2.4 120/240V AC, 30 AMP RECEPTACLE
2.2.6 120/240 VOLT AC, 50 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).
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
Figure 10 - 120/240 VAC, 30 Amp Receptacle
120V/240V
50A
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.
Use this receptacle to operate 120/240 Volt AC, 60 Hz electrical loads
requiring up to 12,000 watts (12.0 kW) of power. This receptacle is
protected by a 50 Amp 2-pole circuit breaker.
8
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Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
2.3.2 CONNECTING ELECTRICAL LOADS
2.3 HOW TO USE THE GENERATOR
If you have any problems operating your generator, please call the
generator helpline at 1-800-333-1322.
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.
2.3.1 GROUNDING THE GENERATOR
Plug in and turn on the desired 120 or 240 Volt AC, single phase, 60
Hz electrical loads.
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.
•
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
Figure 13 - Grounding 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.
Generator Ground Lug
•
The rated wattage of lights can be taken from light bulbs. The rated
wattage of tools, appliances and motors can usually be found on a
data plate or decal affixed to the device.
•
•
If the appliance, tool or motor does not give wattage, multiply volts
times ampere rating to determine watts (volts x amps = watts).
Some electric motors, such as induction types, require about three
times more watts of power for starting than for running.This surge of
power lasts only a few seconds when starting such motors. Make
sure you allow for this high starting wattage when selecting electrical
devices to connect to your generator:
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.
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.)
9
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Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System
2.5 WATTAGE REFERENCE GUIDE
Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Running Watts
Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450
Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800
Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Microwave Oven . . . . . . . . . . . . . . . . . . . . . . . . .700 to 1000
*Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1100
Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . .300
Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . . . .400
Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . . . . . .225
Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . . . .150
*Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . . . . . .600
Paint Sprayer, Airless (handheld) . . . . . . . . . . . . . . . . . . .150
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 200
*Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
*Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . . . . . .2800
*Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . . . . . .2000
*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . . . . . .1500
*Sump Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 to 1050
*Table Saw (10") . . . . . . . . . . . . . . . . . . . . . . . .1750 to 2000
Television . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500
Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650
Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500
*Allow 3 times the listed watts for starting these devices.
Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Running Watts
*Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . . . . . .1700
*Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . . . . . .3800
*Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . . . . . .6000
Battery Charger (20 Amp) . . . . . . . . . . . . . . . . . . . . . . . .500
Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000
Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Circular Saw (6-1/2") . . . . . . . . . . . . . . . . . . . . . .800 to 1000
*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . . . . .5750
*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1150
Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750
*Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000
*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . . . . . .1800
*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . . .1400
Curling Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
*Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650
Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500
Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Electric Range (per element) . . . . . . . . . . . . . . . . . . . . .1500
Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250
*Freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . .875
*Garage Door Opener . . . . . . . . . . . . . . . . . . . . . .500 to 750
Hair Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100
• Above 40°F, use SAE 10W-30 or SAE 30.
• Below 40°F, use synthetic 5W-20 or 5W-30.
2.6 BEFORE STARTING THE
GENERATOR
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.
Prior to operating the generator, engine oil and gasoline will need to be
added, as follows:
•
•
•
•
Place generator on a level surface.
2.6.1 ADDING ENGINE OIL
Clean area around oil fill and remove oil fill cap and dipstick.
Wipe dipstick clean.
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.
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.
Select the oil’s viscosity grade according to the expected operating
temperature. Do not use SAE 10W-40.
•
•
Install dipstick. Install oil fill cap and finger tighten securely.
Check engine oil level before starting each time thereafter.
10W-30, SSAE 30
Syntthheettic 5WW-20, 55W-30
ºF -20
ºC -30
0
20
32
0
40
60
80
100
40
-20
-10
10
20
30
Temperature Range of Expected Use
10
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Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System
Figure 15 - Fuel Shut-off Valve
2.6.2 ADDING GASOLINE
-------------
-------------
ƽ
WARNING
ƽ
ON
OFF
Ʒ 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.
FUEL SHUTOFF
ƽ Caution: Do not overfill the fuel tank. Always leave
room for fuel expansion.
•
Use regular UNLEADED gasoline with the generator engine. Do not
use premium gasoline. Do not mix oil with gasoline.
•
•
Clean area around fuel fill cap, remove cap.
Slowly add unleaded regular gasoline to fuel tank. Be careful not
to overfill. Allow about 1/2" of tank space for fuel expansion, as
shown here.
• Locate the Idle Control ON/OFF switch on the control panel and set it
to the “OFF” position.
•
Install fuel cap and wipe up any spilled gasoline.
Figure 16 - Idle Control Switch
Figure 14 - Fuel Tank
IDLE
CONTROL
Fuel Tank
Fuel
1/2 inch
MPORTANT: 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.
ON
OFF
2.7 TO START THE ENGINE
Ꮨ 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.
11
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Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System
• Move engine CHOKE knob to “Full Choke” position.
2.9 AUTOMATIC IDLE CONTROL
17 - Full Choke Position
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. 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.
•
•
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.
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.
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
2.11.1 INITIAL START-UP
•
Shut off all loads, then unplug the electrical loads from generator
panel receptacles. Never start or stop the engine with electrical
devices plugged in and turned on.
A delay built into the low oil shutdown system allows oil pressure to
build during starting. The delay allows the engine to run for about 10
seconds before sensing oil pressure.
•
•
Turn “Off” the Idle Control switch (if on).
Let engine run at no-load for several minutes to stabilize the internal
temperatures of engine and generator.
2.11.2 SENSING LOW OIL PRESSURE
If the system senses low oil pressure during operation, the engine shuts
down.
•
•
Move Start/Run/Stop switch to “Off” position.
Close fuel valve.
2.11.3 RESTARTING
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.
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.
12
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Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System
2.12 CHARGING A BATTERY
Ʒ 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.
ƽ DANGER! Do not permit smoking, open flame, sparks or any
other source of heat around a battery. Wear protective goggles,
rubber apron and rubber gloves when working around a battery.
Battery electrolyte fluid is an extremely caustic sulfuric acid
solution that can cause severe burns. If spill occurs flush area with
clear water immediately.
Your generator has the capability of recharging a discharged 12 Volt
automotive or utility style storage battery. Do not use the unit to
charge any 6 Volt batteries. Do not use the unit to
crank an engine having a discharged battery.
To recharge 12 Volt batteries, proceed as follows:
•
•
Check fluid level in all battery cells. If necessary, add ONLY distilled
water to cover separators in battery cells. Do not use tap
water.
If the battery is equipped with vent caps, make sure they are
installed and are tight.
•
•
If necessary, clean battery terminals.
Connect battery charge cable connector plug to panel receptacle
identified by the words "12-VOLT D.C."
•
•
•
•
Connect battery charge cable clamp with red handle to the positive
(+) battery terminal.
Connect battery charge cable clamp with black handle to the
negative (-) battery terminal.
Start engine. Let the engine run while battery recharges. Engine idle
control switch must be in off position for battery charging.
When battery has charged, shut down engine.
Note: Use an automotive hydrometer to test battery
state of charge and condition. Follow the hydrometer
manufacturer's instructions carefully. Generally, a
battery is considered to be at 100% state of charge
when specific gravity of its fluid (as measured by
hydrometer) is 1.260 or higher.
13
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Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
3.1 MAINTENANCE SCHEDULE
Follow the calendar intervals. More frequent service is required when operating in adverse conditions noted below.
Operation Maintenance
Daily
Every Season
Every Season
Every Season
Check Oil Level
✓
Service Air Pre-Cleaner
Change Oil and Oil Filter‡
✓**
✓*
Clean Spark Arrestor Screen
Adjust Valve Clearance
Service Air Cleaner
✓
✓
✓**
Replace Spark Plugs
✓
‡
*
**
Change oil after first 8 hours of operation then every season.
Change oil and oil filter every month when operating under heavy load or in high temperatures.
Clean more often under dirty or dusty operating conditions. Replace air cleaner parts if very dirty..
PRODUCT SPECIFICATIONS
3.2.1 GENERATOR SPECIFICATIONS
MODEL
GPS 12500
004451-1
12.5 kW
GPS 15000
004582-1
15.0 kW
Model #
Rated Max. Power
Surge Power
18.75 kW
120/240
22.5 kW
Rated AC Voltage
Rated Max AC Load
Current @ 240V
Current @ 120V
Rated Frequency
Phase
120/240
52.0 Amps
62.5 Amps
104.0 Amps
125.0 Amps
60 Hz @3600 RPM
Single Phase
12 Volts
Rated DC Voltage
Rated Max DC Load
Current @ 12 Volts
10 Amperes
3.2.2 ENGINE SPECIFICATIONS
Rated Horsepower
@ 3600 RPM
Displacement
Spark Plug Type
Spark Plug Gap
Gasoline Capacity
Oil Type
27
30
760cc
992cc
Champion RC12YC or Equivalent
0.030 inch or (0.76 mm)
16 U.S. gallons
Summer – SAE 30 or 10W-30 Winter – Synthetic 5W-20 or 5W-30
w/Filter Change = 1.5 Qts. w/o Filter Change = 1.2 Qts.
10 Hours / 1.6 gallons per hour
Oil Capacity
Run Time/Fuel
Consumption-1/2 Load
14
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Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
3.3.3 ENGINE MAINTENANCE
3.3 GENERAL RECOMMENDATIONS
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.
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.
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.
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.
3.3.5 CHANGING THE OIL AND OIL FILTER
Change the oil and filter after the first eight hours of operation. Change
the oil every 100 hours thereafter. If you are running this unit under dirty
or dusty conditions, or in extremely hot weather, change the oil more
often.
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.
Use the following instructions to change the oil while
the engine is still warm:
3.3.1 GENERATOR MAINTENANCE
•
•
Clean area around oil drain hose and plug.
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.
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.
Check the cleanliness of the generator frequently and clean when dust,
dirt, oil, moisture or other foreign substances are visible on its exterior
surface.
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.
ƽ CAUTION! Never insert any object or tool through the air cooling
slots, even if the engine is not running.
•
•
Fill oil sump with recommended oil. (See “Before Starting the
Generator” on page 10 for oil recommendations).
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.
Wipe up any spilled oil.
3.3.2 TO CLEAN THE GENERATOR
•
•
•
•
Use a damp cloth to wipe exterior surfaces clean.
A soft, bristle brush may be used to loosen caked on dirt, oil, etc.
A vacuum cleaner may be used to pick up loose dirt and debris.
Low pressure air (not to exceed 25 psi) may be used to blow away
dirt. Inspect cooling air slots and openings on the generator. These
openings must be kept clean and unobstructed.
3.3.6 REPLACING THE SPARK PLUG
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Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
Use Champion RC12YC 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.
•
•
Wash pre-cleaner in soapy water. Squeeze pre-filter dry in clean
cloth (DO NOT TWIST).
Clean air cleaner cover before re-installing it.
1. Stop the engine and pull the spark plug wire off of the spark plug.
To clean or replace paper air filter:
2. Clean the area around the spark plug and remove it from the
cylinder head.
•
Remove air cleaner cover; then remove foam pre-filter (service if
necessary) and remove paper filter.
3. Set the spark plug's gap to 0.76 mm (0.030 in.). Install the correctly
gapped spark plug into the cylinder head.
•
Clean paper filter by tapping it gently on a solid surface. If the filter
is too dirty, replace it with a new one. Dispose of the old filter
properly.
Figure 18 - Spark Plug Gap
•
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.
3.4 SERVICE AIR CLEANER
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.
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.
Clean and inspect the spark arrestor as follows:
•
•
•
Remove the screen retaining bracket by removing the screw.
Slide the spark arrestor screen out from the tail pipe.
Figure 20 - Air Cleaner
Cover
Inspect screen and replace if torn, perforated or otherwise
damaged. DO NOT USE a defective screen. If screen is not
damaged, clean it with commercial solvent.
Pre-Cleaner
•
Replace the screen and the retaining bracket.
Base
Filter
To clean or replace foam pre-cleaner:
•
Remove air cleaner cover, then foam pre-filter.
16
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Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
the allen wrench and tighten the rocker arm jam nut.Tighten the jam nut
to 174 in/lbs. torque. After tightening the jam nut, recheck valve
clearance to make sure it did not change.
Figure 21 - Spark Arrestor
Figure 22 - Valve Clearance Adjustment
MUFFLER OUTLET
TUBE
Rocker
Pivot Ball
Arm
Stud
Jam Nut
RETAINER
Valve
Stem
SPARK ARRRESTOR
SCREEN
RETAINING
SCREW
3.6 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, you should adjust
the valve clearance in the engine.
•
•
Install new valve cover gasket.
Re-attach the valve cover.
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.
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.
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.
•
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.
When valve clearance is correct, hold the pivot ball stud in place with
17
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Section 3 — Maintenance
Commercial-Industrial-Residential Portable Generator System
STORAGE
3.9 OTHER STORAGE TIPS:
3.7 GENERAL
•
Do not store gasoline from one season to another.
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.
•
Replace your gasoline can if your can starts to rust. Rust and/or dirt
in your gasoline will cause problems with the carburetor and fuel
system.
•
•
If possible, store your unit indoors and cover it to give protection
from dust and dirt. BE SURETO EMPTYTHE FUELTANK.
ƷƸDANGER! NEVER store engine with fuel in tank
If it is not practical to empty the fuel tank and the unit is to be stored
for some time, use a commercially available fuel stabilizer added to
the gasoline to increase the life of the gasoline.
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.
•
Cover your unit with a suitable protective cover that does not retain
moisture.
3.8 LONG TERM STORAGE
ƽDANGER! NEVER cover your generator while
engine and exhaust area are warm.
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
storage.
of
an
engine
while
in
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.
ƷƸDANGER! 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.
ƽCAUTION! Avoid spray from spark plug holes
when cranking engine.
•
•
Install and tighten spark plugs. Do not connect spark plug wires.
Clean the generator outer surfaces. Check that cooling air slots
and openings on generator are open and unobstructed.
•
Store the unit in a clean, dry place.
18
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Section 4 — Troubleshooting
Commercial-Industrial-Residential Portable Generator System
4.1 TROUBLESHOOTING
PROBLEM
CAUSE
SOLUTION
Engine is running, but no AC
output is available.
1. Circuit breaker is open.
2. Poor connection or defective cord set.
3. Connected device is bad.
1. Reset circuit breaker.
2. Check and repair.
3. Connect another device that is in
good condition.
4. Fault in generator.
4. Contact Authorized Service Facility.
Engine runs good but bogs
down when loads are connected.
1. Short circuit in a connected load.
2. Generator is overloaded.
3. Engine speed is too slow.
4. Shorted generator circuit.
1. Disconnect shorted electrical load.
2. See “Don’t Overload the Generator” on page 9.
3. Contact Authorized Service Facility.
4. Contact Authorized Service Facility.
Engine will not start; or starts
and runs rough.
1. Dirty air cleaner.
2. Out of gasoline.
1. Clean or replace air cleaner.
2. Fill fuel tank.
3. Stale gasoline.
4. Spark plug wire not connected to
spark plug.
3. Drain fuel tank and fill with fresh fuel.
4. Connect wire to spark plug.
5. Bad spark plug.
5. Replace spark plug.
6. Water in gasoline.
7. Overchoking.
8. Low oil level.
9. Excessive rich fuel mixture.
10. Intake valve stuck open or closed.
11. Engine has lost compression.
6. Drain fuel tank; fill with fresh fuel.
7. Put choke knob to No Choke position.
8. Fill crankcase to proper level.
9. Contact Authorized Service Facility.
10. Contact Authorized Service Facility.
11. Contact Authorized Service Facility.
Engine shuts down during
operation.
1. Out of gasoline.
2. Low oil level.
3. Fault in engine.
1. Fill fuel tank.
2. Fill crankcase to proper level.
3. Contact Authorized Service Facility.
Engine lacks power.
1. Load is too high.
2. Dirty air filter.
1. See “Don’t Overload the Generator” on page 9.
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
lean.
2. Contact Authorized Service Facility.
No Battery Charge DC output.
1. Battery posts are corroded.
2. Battery cable is bad.
3. Battery is defective.
1. Clean battery posts.
2. Replace cable.
3. Check battery condition; replace if
defective.
4. Receptacle is bad.
4. Contact Authorized Service Facility.
19
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Section 5 — Notes
Commercial-Industrial-Residential Portable Generator System
20
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Section 5 - Notes
Commercial-Industrial-Residential Portable Generator System
21
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Section 6 — Electrical Data
Commercial-Industrial-Residential Portable Generator System
Wiring Diagram – Drawing No. 0E0228
C B 1
W H I T E
W H I T E
HOT
HOT
W H I T E
W H I T E
HOT
HOT
22
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Section 6 — Electrical Data
Commercial-Industrial-Residential Portable Generator System
Schematic – Drawing No. 0E0229
23
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E0034
24
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E0034
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
1
0C5729
1
ASSEMBLY, CRANKCASE HOUSING
WITH SLEEVE
37
38
39
40
41
42
43
44
45
46
47
49
50
0C3006
0C8566
0C8808
0C2981
0C2979
086515
0D2274
0D3867
078672
0C5371
072694
0D5313
0D3998
11
8
2
1
2
8
4
4
2
4
4
4
4
SCREW, HHFC M10-1.5 X 55
SCREW HHFC M6-1.0 X 20
HOOK, LIFTING
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
0C3008
090388
0C5372
0C3005
0C3003
0D8067A
071983
0D5269
043790A
0C2967
021533
071980
0D4041
0D4788
093064
0C2977
0C5943
0D4040E
1
8
1
1
3
1
4
1
1
2
2
2
1
2
1
1
1
1
SEAL, 38 I.D. CRANKSHAFT
SCREW, TAPTITE M6-1.0 X 12 BP
ASSEMBLY, BREATHER
GASKET, BREATHER COVER
SEPARATOR, OIL BREATHER
ASSEMBLY, HEAD #1
RETAINER, PISTON PIN 20
ROCKER, COVER
BARBED EL 90 3/8NPT X 3/8
PISTON, LC
SET, PISTON RING 90MM
PIN PISTON D20
ASSEMBLY, CAMSHAFT & GEAR
PLUG STD PIPE 3/8 STEEL SQ HD
ASSEMBLY, OIL FILL CAP
GASKET, CRANK CASE
SEAL, OIL PASSAGE
ASSEMBLY, CRANKSHAFT
HORIZONTAL DIRECT DRIVE
(GT-990)
ASSEMBLY, CRANKSHAFT
HORIZONTAL DIRECT DRIVE
(GT-760)
ASSEMBLY, CONNECTING ROD
(GT-990)
ROCKER, COVER
GASKET, VALVE COVER
KEEPER, VALVE SPRING
RETAINER, VALVE SPRING
SPRING, VALVE
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
STUD, D20 PIVOT BALL
ROCKER ARM
NUT, HEX M8-1.0 GB YELLOW
CHROME
PLATE, PUSH ROD GUIDE
SCREW HHFC M8-1.25 X 65
VALVE, EXHAUST
51
52
53
54
55
56
57
58
0D6024
0C2976
086516
0C2229
083897
0D8067B
0D9853D
0C2978
0D9000
0D6008
0D4010
0D6007
0D4012
0D8675A
0D8675B
0D4015
2
12
2
2
4
1
4
2
2
1
1
1
1
1
1
1
VALVE, INTAKE
TAPPET, SOLID
ASSEMBLY, HEAD #2
PUSHROD 144.6
GASKET, HEAD (GT-990)
GASKET, HEAD (GT-760)
KIT GEAR COVER
19
0D4122E
1
59
60
61
62
63
64
65
KIT GASKET
20
20
0C2969
0D3961
2
2
KIT PISTON & RINGS
KIT BREATHER ASSEMBLY
KIT HEAD ASSEMBLY CYLINDER 1
KIT HEAD ASSEMBLY CYLINDER 2
KIT OIL RELIEF
ASSEMBLY, CONNECTING ROD
(GT-760)
21
22
23
24
25
26
27
28
29
30
31
0D2157
0C5313
0D4123
078699E
0C3011
0C3009
0C3010
093873
0C5315
0C5998
0D4497
2
1
1
2
2
2
2
2
1
1
1
SCREW SHC M6-1.0 X 50 G8.8
SCREEN, OIL PICKUP
ASSEMBLY, OIL PUMP
SLEEVE, SEAMED DOWEL 10 DIA.
COVER, OIL RELIEF
SPRING, OIL RELIEF
BALL, 1/2D OIL RELIEF
WASHER, LOCK RIB M6
GEROTOR, OUTER
Item 59 (Kit) includes items 3, 30, 35 & Kit item 64
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, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52,
53, 54
Item 64 (Kit) includes items 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53,
54, 56
Item 65 (Kit) includes items 25, 26, 27
CLAMP, OIL TUBE
PLUG-CRANKCASE GOVERNOR
BORE
32
0C3971E
1
ASSEMBLY, DIPSTICK WITH
HANDLE
33
34
35
36
0D3745
0C3027
0C3007
0C5731
1
3
1
1
TUBE, DIPSTICK
O-RING, OIL CLR
SEAL, 42 I.D. CRANKSHAFT
ASSEMBLY, HOUSING COVER WITH
SLEEVE
25
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E0034
26
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E0034
ITEM PART NO. QTY.
DESCRIPTION
ITEM PART NO. QTY.
DESCRIPTION
66
67
68
69
70
71
72
73
087680
0D4511
0D3262
0D6020
0D4183
0D6327
0D2774B
0D5125
1
1
1
1
1
1
1
1
WINGNUT, AIRBOX
PRECLEANER, AIR
ELEMENT, AIR CLEANER
STUD M6-1.0 X 73
ADAPTOR, SPIT BACK
GASKET, SPITBACK
BASE, AIRBOX
SPRING, WINTER/SUMMER
VALVE
118
119
120
121
122
123
124
125
0D6142
0D5399
072347
0C3017
022129
061906
0C8919
079246
2
1
2
1
2
2
1
1
SCREW PPHM M4-0.7 X 40
ELBOW, RUBBER 90 DEG.
SPARKPLUG
STARTER
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 85 G8.8
BRACKET, STARTER
SCREW HHC M6-1.0 X 16mm W/
LOCKWASHER
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
0D2930
0D4612
0D6143
0D2775
0D5014A
0D5014B
049721
022097
022473
052857
0D6021
0C9093
0D4522
074908
066849B
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
VALVE, SUMMER / WINTER
SNORKEL, AIR INTAKE
TUBE, HEAT RISER 50.8 I.D.
COVER, AIRBOX
KNOB, AIRBOX 17mm
KNOB, AIRBOX 95MM
SCREW HHC M6-1.0 X 35
WASHER LOCK M6-1/4
WASHER FLAT 1/4
126
127
0D1131
0C3022B
1
1
GUARD,FAN
HOUSING, BLOWER GASOLINE
COOLER
NUT, GROMMET 1/4 PLUG
NUT,HEX M24
WASHER, M24
PLATE, FAN
WASHER SHAKEPROOF INT M8
SS
SCREW HHC M8-1.25 X 12 G8.8
FAN, NYLON
INSULATOR ASSEMBLY IGNITION
SCREW TAPTITE M6-1X10
YELLOW CHROME
FLYWHEEL ASSEMBLY
PLATE, BACKING GT990 WITH
OIL COOL
KEY, WOODRFF 4 X 19D
GASKET, MANIFOLD / PORT
PLASTITE,1/4-15 X 3/4
COOLER, OIL
CLAMP HOSE #5.5 .62 - .62
HOSE, 3/8" I.D. X 6" LONG
BARBED STR 1/4NPT X 3/8 WITH
VIBRA SEAL
FILTER, OIL D 69 X 64 LONG
NIPPLE, 3/4"-16 UNF
ASSEMBLY, OIL DRAIN HOSE
SWITCH, OIL PRESS
BRACKET, AIRBOX SUPPORT
WRAPPER, UPPER CYLINDER 1
WRAPPER, LOWER CYLINDER 1
BRASS ST ELBOW 1/4 NPT
ROD,GOV. STEP MOTOR-
CARBURETOR
128
129
130
131
132
0C9763
0C3034
0C3033
0C3032
0A5992
4
1
1
1
2
NUT LOCK FLANGE M6-1.0
STUD, METRIC
HOSE, BREATHER
133
134
135
136
051754
0C3031
085011
045756
2
1
1
4
CONTROLLER ASSEMBLY
SCREW HHTT M5-0.8 X 10
SCREW HHTT M5-0.8 X 8mm
ASSEMBLY, WIRE
CARBURETOR (GT-990)
CARBURETOR (GT-760)
GASKET,CARB TO SPACER
CLAMP HOSE BAND 1/4
HOSE ¼ ID
GASKET, MANIFOLD TO
CARBURETOR
SLEEVING 1/2" I.D.
FILTER, FUEL
WASHER FLAT M8
137
138
0C3725A
0C3016A
1
1
0536210209 1
0C8526
0D8059
0D4024
048031C
030340
0D5282
1
1
1
4
12"
1
139
140
141
142
143
144
145
082774
0C3043
0C9764
0C3026
040173
0C9806
035461A
1
2
4
1
4
2
2
91
92
93
94
95
96
97
98
086061G
0D6313
070008
070006
049821
0C9911
051714
0D5411
0D5445
0D5416
1
1
4
4
4
1
3
1
1
1
146
147
148
149
150
151
152
153
154
070185
0C7292
0D3083
0C3025
0D4550
0C3018
0C3019
046964
0D5605
1
1
1
1
1
1
1
1
1
WASHER LOCK M8
SCREW SHC M8-1.25 X 30
MANIFOLD, INTAKE
99
100
101
102
103
104
NUT HEX M3-0.5
ROD, SUMMER / WINTER VALVE
BUSHING, MINI CONTROL PANEL
KNOB, CONTROL SUMMER /
WINTER
105
106
107
108
0D5398
066849
0D3432
045756
1
2
1
CHOKE ASSEMBLY
SCREW TAPTITE M5-0.8 X 8 BP
PANEL, CONTROL FACE PLATE
SCREW TAPTITE M6-1.0X 10
YELLOW CHROME
155
156
157
158
0D6341
0D6342
0D9784
031879
2
2
2
1
ROD END
BALL STUD
NUT LOCK HEX M3-0.5
WASHER FLAT #4
26
109
110
111
112
113
114
115
116
117
0D4767
0D1142A
0D1143
0C3053
022097
092079
0C3052
0C4147
022264
1
1
1
1
4
4
2
1
2
SWITCH ROCKER
WRAPPER, LOWER CYLINDER 2
WRAPPER, UPPER CYLINDER 2
ASSEMBLY, GROUND WIRE
WASHER LOCK M6-1/4
SCREW TAPTITE M6-1.0 X 25 BP
ASSEMBLY, IGNITION COIL
PUMP, IMPULSE
WASHER LOCK M4
27
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Generator – Drawing No. 0D4488
7
5
29
35
31
36
1
28
2
29
28
3
26
30
41
24
18
25
22
20
40
4
9
21
22
32
19
37
15
14
10
23
10
6
11
28
27
31
32
17
10
12
28
31
42
16
24
43
44
8
19
17
32
33
13
39
38
40
41
45
30
34
28
31
32
39
28
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Generator – Drawing No. 0D4488
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
0C6934
0D2123
0D2134
0D2132
0D2133
0C6043B
0D2492
0D2726
0C4138
0D3547
031971
0C3168
1
1
ADAPTOR, ENGINE
STATOR 12.5KW
STATOR 15KW
ROTOR 12.5KW
23
24
25
26
27
28
29
0A2038
022237
022511
022131
039288
022145
049820
1
5
4
4
4
22
4
WASHER FLAT 3/8 ZINC
WASHER LOCK 3/8
SCREW HHC 3/8-16 X 1-1/4 G5
WASHER FLAT 3/8-M10 ZINC
SCREW HHC M8-1.25 X 55 G8.8
WASHER FLAT 5/16 ZINC
NUT LOCK HEX M8-1.25
NYLON INSERT
SCREW HHC M6-1.0 X 12
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW TAPTITE 3/8-16 X 3/4 BP
SHIELD, MUFFLER HEAT
U-BOLT & SADDLE
SCREW SHC M8-1.25 X 18
PANEL, MUFFLER BOX BACK
PANEL, MUFFLER BOX END
SCREW HHTT M6-1.0 X 12
WASHER FLAT 1/4
WASHER LOCK M6-1/4
SPARK ARRESTOR SCREEN
RETAINER, SPARK
3
1
ROTOR 15KW
4
5
6
7
8
9
10
1
1
1
2
1
1
3
CARRIER, REAR BEARING
EXHAUST MANIFOLD
MUFFLER
GASKET, EXHAUST
COVER, ALTERNATOR AIR IN
BEARING
30
31
32
33
34
35
36
37
38
39
40
41
42
43
043116
022129
022259
059637
0D5100
0D5823
0C8565
0D5833
0D5834
090388
022473
022097
0D5133
0D5133A
5
18
12
2
1
1
4
1
1
3
5
5
1
1
5/16 SPECIAL LOCK
WASHER
11
12
13
14
15
16
17
18
19
20
21
22
0D1838
0D3549
0C7038E
032712
083512
0C7038D
0C7758
1
4
1
4
1
1
6
SCREW IHHC 3/8-24 X 15.50 G5
SCREW IHHC M8-1.25 X 400 G8.8
BRACKET, ALT MOUNTING
SCREW HHTT #10-32 X 1.75
SCREW TAPTITE M8-1.25 X 16 BP
ENGINE MOUNTING PLATE
RUBBER MOUNT
BATTERY CABLE, BLACK
EARTH STRAP 3/8X 3/8
CLIP-J VINYL COAT .625 ID
ASSEMBLY, BRUSH HOLDER
SCREW TAP-R #10-32 X 9/16
0388050AF0 1
0C2417A
082121C
066386
1
1
1
3
ARREST SCREEN
SCREW HHTT M4-0.7 X 8
SHIELD, RUBBER MOUNT
44
45
045764
0D6214
1
1
0C2824
29
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Control Panel – Drawing No. 0E0227
30
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Control Panel – Drawing No. 0E0227
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
32
33
34
35
36
37
38
39
40
41
42
43
44
022158
023897
057405
022473
022097
049813
065795
0D4804
0C1085
051715
022264
048512
087962
1
1
1
1
1
1
2
2
4
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
1
2
3
4
5
6
7
8
087968
090418
0D6640
090987
0D2502
068868
022985
043182
051714
075207A
075207
0D4969
043437
0D4968
0D4966
0D1004E
1
1
1
6
1
2
2
10
6
4
2
1
1
1
1
1
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
9
18
18
1
10
11
12
13
14
15
16
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
WASHER LOCK M4
CIRCUIT BREAKER 5 X 1
CIRCUIT BREAKER 10 X 1 12VDC
1/4"QC
RIVET POP .125 X .129-.133 / #30
LUG GRND 8 TABS
HOLDER FUSE
FUSE 10A X AGC10
HEATSINK
SCREW PPHM M4-0.7 X 10
SCREW HHC M5-0.8 X 16 G8.8
SCREW HHC M6-1.0 X 65 G8.8
SCREW HHC M5-0.8 X 25 G8.8
SCREW HHC M5-0.8 X 10 G8.8
SPACER .25 X .50 X 1.5
SCREW HHTT M5-0.8 X 10
SCREW PPHM M5-0.8 X 30
SCREW PPHM M5-0.8 X 50
WASHER FLAT #8
1
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
036261
0A2769
032300
028578
055444
075475
049815
0A2053
055440
045770
0D5734
074908
075235
080823
038150
0D6140
2
1
1
1
1
2
4
1
2
1
2
18
1
2
17
18
19
20
051716
022152
0D5045
067680
8
8
1
1
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 12VDC 5A 3PDT 240V
CONTROL PANEL BOX
BUSHING SNAP
RIVET POP .156 X .160-.164 / #20
BLOCK TERMINAL 20A 2 X 6 X
1100V
21
0D4409
1
22
23
24
25
26
27
052844
0D4766
0D2691
023484L
0A1661
048766
1
1
1
1
2
1
14
1
GASKET, PORTABLE CONTROL
PANEL
SCREW PPHM M4-0.7 X 16
61
62
63
075476
027565
058000K
2
28
0D3550
1
BLOCK DOUBLE ROW TERMINAL 8
POSITION
RECTIFIER MSC 12A 600V
WASHER MICA .203
A/R TAPE ELEC UL PERMACEL
NUT TRIC M5-0.8
2
29
30
31
049939
070370
030468
1
1
1
WASHER STEP NYLON .20
31
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Frame, Handle & Wheel Kit – Drawing No. 0E0695
32
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Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System
Frame, Handle & Wheel Kit – Drawing No. 0E0695
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
28
29
30
31
32
33
34
35
36
0D9165
045900
0D7668
0D4999
0D4044
0D3700
0D2497
022532
027028
1
2
2
2
2
4
1
4
6
AXLE, 3/4"DIA X 30"
WASHER FLAT 3/4
1
2
3
4
5
6
7
8
057058
0D5315
0D4570
0D22850SRV
045771
022129
022145
0D4565
0D3545
022287
022473
022097
022127
0388040AK0
0D4575
0D5202
0D5199
029809
0C3168
0D5198
0E0317
027007
0D5303
042909
090388
064101
039214
4
4
1
1
4
SCREW HHC M6-1.0 X 55
RUBBER TANK MOUNT
CAP, FUEL WITH GAUGE & VENT
KIT, FUEL TANK
12.3" PNEUM WHEEL 3/4" AXLE
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
NUT HEX M8-1.25
10 WASHER LOCK M8-5/16
14 WASHER FLAT 5/16
1
2
2
2
2
2
1
1
1
4
1
1
1
1
2
4
2
4
6
6
BRACKET BATTERY
9
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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
0D2271
052762
051713
049226
051716
050190
078299
080270
0D5142
096021
048031C
030340
075763
075763A
0E0318
030795
1
4
8
4
4
2
1
1
1
2
2
FRAME
SCREW HHC M5-0.8 X 45 G8.8
WASHER FLAT M5
WASHER LOCK M5
NUT HEX M5-0.8
WASHER FLAT 1"
BUSHING TANK DEXTOR
VALVE, PLASTIC TANK
AIR DEFLECTOR
GROMMET .75 X .06 X .50
CLAMP HOSE BAND ¼
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
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
18" HOSE ¼ ID
1
1
2
2
BOOT BATTERY CABLE
BOOT STARTER CABLE
SPACER, AXLE
SCREW HHC 5/16"-18 X 1"
BOLT CARR 3/8-16 X 1
33
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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-Ignition (LSI) engines must be designed, built and equipped to meet the state's
stringent anti-smog standards. Generac will warrant the emission control. system on your engine one for the periods of time listed below provided
there has been no abuse, neglect, unapproved modification or improper maintenance of your engine.
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will repair your engine at no
cost to you for diagnosis, replacement parts arid labor, should a warrantable condition occur.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 2001 and later model year LSI engines are warranted for two years as hereinafter noted- If, during such warranty period,
any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be
performed by a Generac Authorized Warranty Service Facility.
PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES:
As the engine owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner's Manual. For
warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty
solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility if your
engine, or a part/component thereof, has failed due to abuse, neglect , improper maintenance or unapproved modifications, or the use of counterfeit
and/ox "grey market" parts not made, supplied or approved by Generac.
You are responsible for contacting a. Generac Authorized Warranty Facility as soon as a problem occurs. The
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac
Authorized Warranty Service Facility nearest you, call our toll free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty),
which is provided to you by Generac pursuant to California law. See also the "Generac Limited Warranties for Generac Power Systems, Inc.," which
is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your
new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS warranty shall apply except in
circumstances where the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe
important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be
presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at one of the following addresses:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Part 1
34
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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 shall be warranted for the ECS Warranty
Period. A statement in such written instructions to the effect of "repair or replace as necessary" shall not reduce the ECS Warranty Period. Any such part repaired
or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the period of time
prior to first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac
according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the ECS
Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized
Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for diagnostic costs if the
repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components 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.
b) Ignition module
a) Fuel controller (if so equipped)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
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)
5) Crankcase Breather Assembly including:
a) Breather connection tube
2) Air Induction System including:
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
35
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Section 8 – Warranty
Commercial-Industrial-Residential Portable Generator System
®
GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR GUARDIAN
“12,500 WATT AND 15,000 WATT PORTABLE GENERATORS”
For
a
period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its Guardian
generator will be free from defects in materials and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which,
upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective. Any equipment that the
purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer. All transportation costs under
the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac Guardian portable generators
and is not transferable.
WARRANTY SCHEDULE
Consumer applications are warranted for 2 (two) years. Commercial applications are warranted for 1 (one) year. Rental applications are warranted for 90 (ninety) days.
CONSUMER APPLICATION
YEARS ONE and TWO - 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):
•
•
Engine - All Components
Alternator - All Components
NOTE: For the purpose of this warranty "consumer use" means personal residential household use by original purchaser. This does not apply to units used for Prime
Power in place of utility where utility power service normally exists. Once a generator has experienced commercial or rental use, it shall thereafter be considered a
non-consumer use generator for the purpose of this warranty.
All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate Manual.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
•
•
•
•
Generac Guardian portable generators that utilize non-Generac replacement parts.
Costs of normal maintenance and adjustments.
Failures caused by any contaminated fuels, oils or lack of proper oil levels.
Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper use. As with all mechanical devices, the Generac engines
need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.
•
Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing, lightning, earthquake,
windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
•
•
•
•
•
•
•
•
•
•
•
Damage related to rodent infestation.
Products that are modified or altered in a manner not authorized by Generac in writing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).
Failure due to misapplication.
Telephone, cellular phone, facsimile, internet access or other communication expenses.
Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.
Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
Rental equipment used while warranty repairs are being performed.
Overnight freight costs for replacement part(s).
Overtime labor.
Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS
TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the
above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not
allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
®
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
36
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Part No. 0E0226
06/01/02
Printed in U.S.A.
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