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Generac Power Systems 004987-2, 005396

1. 7 2 2 4 120 240 VAC 30 Amp Receptacle 8 225 12VDC 10 Amp 8 2 2 6 120 240 VAC 50 Amp Receptacle 8 2 3 How To Use The 9806 810 8 2 3 1 Grounding The 8 2 3 2 Connecting Electric 5 9 2 4 Don tOverload The 9 2 5 Wattage Reference Chart 9 2 6 Before Starting The 10 2 6 1 Adding Engine Oil sss 10 2 6 2 Adding Gasoline 10 27 Start The Engine innen 11 2 8 Stopping The Engine 11 2 9 Automatic Idle Control 12 2 10 Cold Weather 12 2 11 Low Oil Pressure Shutdown 12 2 114 Initial Startup iuo iste 12 2 11 2 Sensing Low Oil 12 2 11 3 Restarting eite 12 2 12 Charging cheer 12 Section 3 Maintenance
2. 1 12 Volt DC 10 Amp Receptacle This receptacle allows the capability to recharge a 12 volt DC storage battery with provided battery charge cables 2 120 Volt AC 20 Amp Duplex Receptacle Supplies electrical power for the operation of 120 Volt AC 20 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 3 120 Volt AC 20A Duplex GFCI Receptacle Supplies ground fault protected electrical power for operation of 120 volt AC 20 amp single phase 60 Hz electric lighting appliances tools and motor loads 4 120 Volt AC 30 Amp Locking Receptacle Supplies electrical power for the operation of 120 Volt AC 30 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 5 120 240 Volt AC 30 Amp Locking Receptacle Supplies electrical power for the operation of 120 and or 240 Volt AC 30 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 6 120 240 Volt AC 50 Amp Receptacle Located on underside of control panel Supplies electrical power for the operation of 120 240 Volt AC 50 Amp single phase 60 Hz welder or motor loads 7 Air Cleaner Filters intake air as it is drawn into the engine 8 Choke Knob Used when starting a cold engine 9 Winter Summer Valve See Cold Weather Operation De icer section Figure 5 Generator Controls 10 Circuit Breakers AC Each receptacle is provided with a push to reset circuit break
3. 13 3 1 Maintenance Schedule 13 3 2 Product Specifications 13 3 2 1 Generator Specifications 13 3 2 2 Engine Specifications 13 3 3 General Recommendations sss 13 3 3 1 Generator 13 3 3 2 Clean the 14 3 8 3 Engine 14 3 3 4 Checking Oil 8 14 3 8 5 Changing the Oil and Oil Filter 14 3 3 6 Replacing the Spark 14 3 4 Service Air Cleaner sssssssseees 14 3 5 Clean Spark Arrestor 15 3 6 X Adjusting Valve 15 97 General 16 3 8 Long Term Storage 16 3 9 Other Storage Tips etm tetas 16 Section 4 Troubleshooting 17 4 1 Troubleshooting 3 40 17 Section 5 Notes ticicsan thui rand bc i cns 18 Section 6 Electrical Data 19 Section 7 Exploded Views and Parts
4. 800 Lawn MOWER ere ten D REX REDE pe 1200 Eight BUD 100 Microwave 700 to 1000 1100 Oil Burner on Furnace 300 Oil Fired Space Heater 140 000 400 Oil Fired Space Heater 85 000 Btu 225 Oil Fired Space Heater 30 000 Btu 150 Paint Sprayer Airless 1 3 600 Paint Sprayer Airless 150 RAM Med 50 to 200 700 SIOW COOKGE ROO b MS SER patens 200 Submersible Pump 1 1 2 2800 Submersible Pump 1 2000 Submersible Pump 1 2 1500 SUMP Pump e Rn Rea ERU Ry 800 to 1050 Table Saw 107 i esser e eR REED eis 1750 to 2000 200 to 500 pies Gian 1000 to 1650 Weed Trimmer aute RE ERES 500 Allow 3 times the listed watts for starting these devices QD 2 6 BEFORE STARTING THE GENERATOR Prior to operating the generator engine oil and gasoline will need to be added as follows Section 2 Operation 26 1 ADDING ENGINE OIL NOTE When a
5. BLU Je 05 ELECTRONIC GOVERNOR 158 803 6 ENGINE SHUTDOWN P C B 11 11 55 162 4 77A 77 229 BLU RED lt RED lt BLK ee lt BLU VID lt C YEL 14 BLU m 22s ees 55 664 66 6 QCBLK C BLK lt BLK lt BLK CBLK lt VID YEL 167C BLU 14C BLU OC BLK 86 BLU tap 0 BLK I 14 40 BLUD BLU 15 ORG REGULATOR F o 4 lt BLU 15 0RG J 6PNIO MEE BLU MHD I OC BLK 14 BLU 554 BLK SSAC BLK 556 BLK 55 BLK 15 ORG 15 ORG LEGEND 15 ORG 15 0 6 gt BA E BRUSH ASSEMBLY C BCR1 BATTERY CHARGE RECTIFIER OC BLK OC BLK BCR2 BATTERY CHARGE RECTIFIER 10 2 6AMP AUTO RESET BREAKER CB2 10 AUTO RESET BREAKER 130 RED 130 RED gt OSBCR1 pi 600V 12A DIODE c32 77 YEL D2 D3 ENGINE SHUTDOWN DIODE F1 10 FUSE FSS FUEL SHUT OFF SOLENOID 4 GND GROUND STUD IDLE CURRENT TRANSFORMER 1 DUTLET IGNITION MODULE CYL 1 0 15 15 IMe IGNITION MODULE CYL GLO RO RO 0 LOP LOW DIL PRESSURE RI 25 25 RESISTUR SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SP1 SPARK PLUG CYL 1 SPe SPARK PLUG CYL 2 SSR START STOP RELAY SW1 START RUN STOP SWITCH SWe IDLE
6. 153 ORG 9 10 1e 18 41 18 BRND 13 SSR 22X BLU sP1 lt 16 15 42 15 DRO L14 BLU n OC BLK OC BLIO r SME ig 167 BLU START 0 43 lt 0 BLK OC BLK ji 1674 167 BLU I sPe lt 4 23 a 15 186 n 86 86 45 lt 86 BLU 86 BLU 13 46 13 RED EN lt LJ Lop 0 14 14 47 17 48 17 BRN FSS 16 49 C16 BLU 777 17 4 15 04 156086 0 13 41 1 S k kBLo 0 0 2 lt 0 BLK OCBLIO 14 BLU BLACK lev BATTERY eo RED SM 13 1 SC PIN amp Section 6 Electrical Data Wiring Diagram Drawing No 0G2892 A ELECTRICAL DATA 22 22 11 22 11 73 11 11 44 44 5 H 44 LC T 11SCRED RED Tak 283 BLK SSAC BLK af CLOSEST TO BEARING de BLU WHD 10 15BC ORG gt 1 4 89 BLU 0 OC BLK q 167 BLU PIN 6C BLU 83 SE See 229 86 491817 6 5 5 1 lt BLU
7. 25 PARTS STS Section 7 Exploded Views and Parts Lists Generator Drawing No 002964 28 31 39 32 LISTS Section 7 Exploded Views and Parts Lists ey ot Generator Drawing No 002964 9 066849 092921 092923 0G29220SRV 0G29240SRV 0C6043B 0D2492 0D2726 0C4138 0D3547 031971 0C3168 0D1838 0D3549 0C7038E 032712 0D4662 0C7038D 0C7758 0388050AF0 0C2417A 082121C 066386 0C2824 0A2038 022237 0D6214 045764 051731 022145 049820 043116 022129 022259 059637 0D5100 005823 0 8565 005833 005834 090388 022473 022097 005133 0D5133A 0G2387 Nea gain pin piw A SCREW HHTT M5 0 8 X 16 STATOR 15KW STATOR 17 5KW ASSEMBLY ROTOR WITH FAN 15KW ASSEMBLY ROTOR WITH FAN 17 5KW CARRIER REAR BEARING EXHAUST MANIFOLD MUFFLER GASKET EXHAUST COVER ALTERNATOR AIR IN BEARING 5 16 SPECIAL LOCK WASHER SCREW IHHC 3 8 24 X 15 50 G5 SCREW IHHC 8 1 25 400 G8 8 BRACKET ALT MOUNTING SCREW HHTT 10 32 X 1 75 SCREW HHTT 8 1 2 X 20 ENGINE MOUNTING PLATE RUBBER MOUNT BATTERY CABLE BLACK EARTH STRAP 3 8X 3 8 CLIP J VINYL COAT 625 ID ASSEMBLY BRUSH HOLDER SCREW TAP R 10 32 X 9 16 WASHER FLAT 3 8 ZINC WASHER LOCK 3 8 SHIELD RUBBER MOUNT SCREW M4 0 7 X 8 SCREW 8 1 25 X 50 G8 8 WASHER FLAT 5 16 ZINC NUT LOCK
8. 25 OHM 25W RESISTOR SC STARTER CONTACTOR SP2 SPARK PLUG CYL 2 SSR START STOP RELAY SW1 START RUN STOP SWITCH SWe IDLE CONTROL SWITCH 19 ELECTRICAL DATA Section 6 Electrical Data Wiring Diagram Drawing No 0G2892 A 120 240V 50A OUTLET OULLO 120 240V r 1e0v eoA r 1801 808 SDA TWISTLOK 180V 30A 180V 30A DUPLEX GFCI TWISTLOK TWISTLOK 0 ee 0 18 z 22 18 LOAD ze 2 0 0 z ee LINE z ee E 5 44D 0 11D 116 446 agpo 5 RUNG ii 0 44 0 22 44 4 1 44 11 M 44 44 30 11p 30 116 204 446 20A 11 C B C B 6 3 11 1 40 140 HH inl 30 11 C B 1 44 11 11 44 lt LA 44 11 j 11 44 ENGINE WIRING 14 BLU 18 BRN Sono CY 1
9. COMMERCIAL 181 17 14 RESIDENTIAL CENTURION PORTABLE GENERATORS Owner s Safety Assembly 2 YENA 5 LIMITED Operation WARRANTY Maintenance Troubleshooting Electrical Data Parts Warranty eS FOR THE NEAREST MODELS AUTHORIZED SERVICE 004987 2 15 000 Watt CENTER 1 800 333 1322 005396 0 17 500 Watt www centuriongenerators com TABLE Table of Contents OF CONTENTS 1 Read This Manual Thoroughly 1 Safety RULES dco 2 Standards Index sett nn eite 3 Section 1 General Information 4 Upa 4 1247 Accessory BOX cssc mem terne 4 1 2 ASSON teen 4 1 2 1 Assembling the Wheel 4 1 22 Assembling the 4 1 23 Battery 5 Section 2 Operation 6 2 1 Know The Generator 6 22 Sets and Connector 095 7 2 21 120 VAC 20 Amp Duplex Receptacle 7 2 2 2 120 VAC 20 Amp GFCI Receptacle 7 2 23 120 VAC 30 Amp
10. ELECTRICAL DATA POWER WINDING DPE WINDING BA BATTERY CHARGE WINDING FIELD 77 550 66A 1 5 1 4 11 11 22 44 2 6 4 0 T 4 AC1i 1 C1 8 1 6 1 7 1 11 C1 18 AN 77 m 10 BATTERY CHARGE WINDING RED EON e OY YN 22 C BLK 15 55 T is 1 6 7 5 4 5 E C1 8 x CRED CBLU C BLU BLK 774 T 668 BLK WHT VID VID 11 77 777 66 11 1 1 44 22 0 4 11 664 VIO 15 ORG 77 lt 66 YEL 13ACRED O_0 15A ORG 01 90 77 YEL gt 11S RED FRI ELEETRENIC RED BLK 0 22S BLK VOLTAGE adi EN REGULATOR PESCBLO 4 BLU 4 BLU 0 BLK OC BLIO 9 6 PNK 6 PNK 162 BLU WHT 6 0 2 BLU WHT gt 631 2 5 LOP 86681 86 BLU 5 86 gt OC BLK OCBLIO 9 0 15B ORG 1 22X BLU m 167 BLU 12 83 BLU OC BLK OC BLIO 0 BLK
11. SCREW HHC 5 16 18 X 1 31 Section 8 Warranty WARRAN CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Power Systems Inc Generac are pleased to explain the Emission Control System warranty on your new engine In California new off road Large Spark Ignition LSI engines must be designed built and equipped to meet the state s stringent anti smog standards Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition system exhaust system and crankcase ventilation system Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 2001 and later model year LSI engines are warranted for two years as hereinafter noted If during such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Dealer PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the completion of all r
12. 2 1 2 FLAT WASHER LOCK NUT WHEEL FLAT WASHER RETAINING PIN AXLE HANDLE FRONT FOOT CARRIAGE BOLT 3 8 X 1 ASSEMBLY CAPSCREW 5 16 X 1 LOCK WASHER LOCK NUT FLAT WASHER 1 2 3 BATTERY CONNECTION Figure 3 Battery Connections A battery may lose some of it s charge when not in use for prolonged periods of time The battery shipped with the generator has been provided fully charged Caution must be taken when connecting the battery NOTE Neqaive Positive 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 QD 21 KNOW THE GENERATOR Read the Owner s Manual and Safety Rules before operating this generator Section 2 Operation Compare the generator to Figures 4 through 6 to become familiarized with the locations of various controls and adjustments Save this manual for future reference Figure 4 Control Panel p 20A GFCI 12Vdc CONTROL sel ON OFF 20 10A CIRCUIT BREAKERS PUSH TO RESET
13. 22 Section 8 Warranty 32 INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc This model is a compact high performance air cooled engine driven generator designed to supply electrical power to operate electrical loads where no utility power is available or in place of utility due to a power outage READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Authorized Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows A After this heading read instructions that if not strictly complied with will result in serious personal injury including death and or property damage WARNING amp After this heading read instructions that if not strictly complied with may result in serious personal injury and or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special em
14. Always make sure the winter summer valve is in the correct location relative to the weather conditions 2 11 LOW OIL PRESSURE SHUTDOWN SYSTEM The engine is equipped with a low oil pressure sensor that shuts down the engine automatically when the oil pressure drops below 10 psi If the engine shuts down by itself and the fuel tank has enough gasoline check engine oil level Section 2 Operation 2 11 1 INITIAL START UP A delay built into the low oil shutdown system allows oil pressure to build during starting The delay allows the engine to run for about 10 seconds before sensing oil pressure 2 11 2 SENSING LOW OIL PRESSURE If the system senses low oil pressure during operation the engine shuts down 2 11 3 RESTARTING If trying to restart the engine within 10 seconds after it shuts down the engine may NOT start The system needs five 5 to 10 seconds to reset If the engine is restarted after such a shutdown and the low oil pressure has not been corrected the engine will run for about 10 seconds as described above and then stop 12 2 12 CHARGING A BATTERY DIE A 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 A
15. CONTROL SWITCH 21 Section 7 Exploded Views and Parts Lists GT 990 Engine Drawing No 0G2963 G Part 1 e T EN 92 7 7 9522 V DA D 72 A v gy 27 720 S lt SS 42 92 SZ 88 18 98 9 EG 08 LG 00 88 18 99 69 08 1S 0G 09 bh ov 1 967 EL 0 9 EGL 66 ZG 0 SE 16 BL 9 0 GQ GE 066 ITEM PARTNO DESCRIPTION 1 1 3300 400 no 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 32 0C5729 0E9843A 0G0919 005372 003005 0E3372B 0D8067A 071983 0G0693 0D4788 0G2752 0G2565 0E1466 0D4041 043790A 093064 002977 005943 0 791 0 223 002157 0E6098 0D4123B 0E8152 0C3011 003009 063010 093873 0 5458 0 5998 OF2664E lk N3 c cxx lx ck NS DO RO 5 5 26 c Section 7 Exploded Views and Parts Lists GT 990 Engine Drawing No 0G2963 G Part 1 0 ASSY CRANKCASE WITH SLEEVE SEAL 38 1 0 CRANKSHAFT GREEN SCREW HHFCS M6 1 0 X 12 08 8 ASSEMBLY BREATHER GASKET BREATHER COVER SEPARATOR OIL BREATHER ASSEMBLY HEAD 1 RETAINER PISTON PIN 20 ASSY ROCKER COVER W BARB PLUG STD PIPE 3 8 STEEL
16. 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 Section 8 Warranty WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS warranty for 2001 and later model year LSI engines a Applicability This warranty shall apply to 2001 and later model year engines The ECS Warranty period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purch
17. 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 amp SADDLE SCREW SHC 8 1 25 X 18 PANEL MUFFLER BOX BACK PANEL MUFFLER BOX END SCREW HHTT M6 1 0 X 12 WASHER FLAT M6 1 4 WASHER LOCK 6 1 4 SPARK ARRESTOR SCREEN RETAINER SPARK ARREST SCREEN PLUG GEARCOVER ADAPTOR 27 Section 7 Exploded Views and Parts Lists Ur Control Panel Drawing No 0G2965 B 0 47 59 005396 e ITEM PARTNO DESCRIPTION 1 1 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 0G28880ST03 0G28900ST03 0D4409 0 9719 0 3100 0 3101 052844 065795 032300 028578 004804 0234845 092887 005045 060923 005734 001004 087962 048505 057405 006140 049939 055444 027565 087968 090418 008740 060309 075207 075207 068868 004969 1 N Section 7 Exploded Views and Parts Lists Control Panel Drawing No 0G2965 B CONTROL PANEL BOX 15 KW amp 005396 CONTROL PANEL BOX 17 5 KW ELECTRONIC GOVERNOR IDLE CONTROLLER ASSY PCB VREG AIR COOLED RELAY 3PDT 12VDC RELAY BASE 3PDT 12VDC RELAY PNL 12VDC SPST 30A RECTIFIER BATTERY CHARGER HOLDER FUSE FUSE 10A X AGC10 TRANSFORMER IDLE CURRENT BUSHING SNAP HARNESS CONTROL PANEL BACK NOT SH
18. SQ HEAD PISTON DISH TOP DIA 90 COATED RING SET PISTON DIA 90 PIN PISTON ASSEMBLY CAMSHAFT amp GEAR BARBED ELBOW 90 DEG 3 8NPT X 3 8 VS ASSEMBLY OIL FILL CAP GASKET CRANK CASE SEAL OIL PASSAGE ASSY GTH 990 DIRECT DRIVE ASSEMBLY CONNECTING ROD GT 990 SCREW SHC M6 1 0 X 50 G8 8 SCREEN OIL PICKUP ASSY OIL PUMP GTH W O O RING O RING 0 49 ID X 0 07 THICK COVER OIL RELIEF SPRING OIL RELIEF BALL 1 2D OIL RELIEF WASHER LOCK RIB M6 SCREW PLASTITE HI LOW 10 CLAMP OIL TUBE ASSEMBLY DIPSTICK GTH 990 PORTABLE 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 49 50 51 52 53 54 55 56 57 58 60 61 62 63 64 65 66 003745 0 3027 0E9842A 0 8054 0 3006 080318 001839 0027230 0 2979 086515 002274 003867 078672 0 5371 072694 005313 003998 006024 0 2976 086516 0 2229 083897 00980678 0098530 0 2978 006008 004010 006007 004012 0D8675A 0D8675B 0D4015 l2 Sg gt FR HR OLD EB INS TUBE DIPSTICK O RING 3 8 X SEAL 42 I D CRANKSHAFT GREEN GEARCOVER ADAPTOR GTH990 760 SCREW HHFC M10 1 5 X 55 SCREW M6 1 0 X 25 LIFT HOOK GT990 760 COVER ROCKER W OIL FILL GENERAC TEXT GASKET VALVE COVER KEEPER VALVE SPRING RETAINER VALVE SPRING SPRING VALVE SEAL VALVE STEM D7 WASHER VALVE SPRING STUD ROCKER ARM PIVOT ROCKER ARM NUT HEX M8 1 0 GB YELLO
19. any other foreign material Check the cleanliness of the generator frequently and clean when dust dirt oil moisture or other foreign substances are visible on its exterior surface cauroN Never insert any object or tool through the air cooling slots even if the engine is not running 13 MAINTENANCE 28 Section 3 Maintenance NOTE DO NOT use a garden hose to clean generator Water can enter the engine fuel system and cause problems In addition if water enters the generator through cooling air slots some water will be retained in voids and crevices of the rotor and stator winding insulation Water and dirt buildup on the generator internal windings will eventually decrease the insulation resistance of these windings 3 3 2 TO CLEAN THE GENERATOR e Use damp cloth to wipe exterior surfaces clean A soft bristle brush may be used to loosen caked on dirt oil etc Avacuum cleaner may be used to pick up loose dirt and debris Low pressure air not to exceed 25 psi may be used to blow away dirt Inspect cooling air slots and openings on the generator These openings must be kept clean and unobstructed 3 3 3 ENGINE MAINTENANCE DAN A When working on the generator always disconnect negative cable from battery Also disconnect spark plug wires from spark plug and keep wire away from spark plug 3 3 4 CHECKING OIL LEVEL See the BEFORE STARTING THE GENERATOR section for in
20. nearest authorized service center at 1 800 333 1322 3 5 CLEAN SPARK ARRESTOR SCREEN The engine exhaust muffler has a spark arrestor screen Inspect and clean the screen at least once each year Figure 20 If unit is used regularly inspect and clean more often NOTE If using the generator on any forest covered brush covered or grass covered unimproved land it must equipped with a spark arrestor The spark arrestor must be maintained in good condition by the owner operator Clean and inspect the spark arrestor as follows Remove the screen retaining bracket by removing the screw Slide the spark arrestor screen out from the tail pipe nspect screen and replace if torn perforated or otherwise damaged DO NOT USE a defective screen If screen is not damaged clean it with commercial solvent Replace the screen and the retaining bracket Figure 20 Spark Arrestor MUFFLER OUTLET TUBE x RETAINER SPARK ARRRESTOR SCREEN RETAINING amp SCREW MAINTENANCE 2 0 Section 3 Maintenance 3 6 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation check the valve clearance in the engine and adjust if necessary Important If feeling uncomfortable about doing this procedure or the proper tools are not available please take the generator to the nearest service center to have the valve clearance adjusted This is a very important step to insure longest life for the engine T
21. 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 in Figure 14 Install fuel cap and wipe up any spilled gasoline Figure 14 Fuel Tank Fuel Fuel Tank lt IMPORTANT It is important to prevent gum deposits from forming in fuel system parts such as the carburetor fuel hose or tank during storage Alcohol blended fuels called gasohol ethanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer See the Storage section Never use engine or carburetor cleaner products in the fuel tank as permanent damage may occur caution AN The manufacturer does not recommend using any gasoline containing alcohol such as gasohol If using any gasoline containing alcohol it must not contain more than 10 percent ethanol and it must be removed from the generator during storage Do NOT use any gasoline containing methanol If using gasoline with alcohol inspect more frequently for fuel leaks and other abnormalities 2 7 TO START THE ENGINE warninc Never start or stop engine with ele
22. road use Refer to Figure 2 and install the wheel kit as follows Place the generator on a hard flat surface Stand at the engine end of the unit and gently tilt the generator forward high enough to place wooden blocks beneath the cradle This will allow space to install the wheel assemblies Attach an axle bracket assembly with attached sleeve to either side of the frame Ensure the sleeve faces outward Slide the axle through the sleeves on the axle brackets Slide one wheel with flat washer to the outside and a spacer to the inside onto each end of the axle Make sure the air inflation valve on the wheel is facing outward Insert retaining pins and using pliers bend out the ends to prevent the pins from falling out of the axle Remove the wooden blocks 1 2 2 ASSEMBLING THE HANDLE Attach the handle by aligning one side of the handle on the cradle then spread the handle around the cradle and let it spring into place Secure the handle to the frame using the 5 16 hex head bolts provided Check each fastener to ensure that it is secure Using the handle lift the unit high enough to place wooden blocks under the unit Attach the front support foot to the underside of the cradle using the 3 8 carriage bolts provided Remove the shipping brackets from the cradle if it has not already been done Section 1 General Information GENERAL INFORMATION Figure 2 Handle Assembly CAPSCREW 5 16 X
23. swe RED 5 154 ORG 154 ORG 62 6 158 15 IX REDD 13 C ORG C ORG 13 DA 229 1eito s CBLUD aa 5 18 14 14 C8 11 C BRN BLU R1 13 RED 13 16 BLU gt 16 141 14 gt H gp BLU 8 8 777 Ce 1 sa 17 BRV 17 15B ORG 1 0 4 1 838 7 1 1 42 CONTROL 3 2 3 1 41 13 CIRCUIT DH me 0C BLK 0 179 ES E Te C2 4 SW1 TRAC BLK 5 167 BLUX 167 86 BLU 7 c2 10 15 eer LU Tos 18 15 ORG gt 15 POT GOVERNOR Sud db a ANS 15 ORG gt 15 fae 7 120V 20A 120 0 14 BLU gt 14 0 6561 DUPLEX FSS 5 5 2 0 0 22 22 120 240 118 120 240 0 180V 30A 120V 30A 30A 50 TWISTLOK TWISTLOK TWISTLOK T 44C 0 22 11C 0 44D 0 11B 44A 11A Q s 2 i 2 JE E oC 2 97 20 20A 30A 30A 30A 30A 50A 11 11 4 11 22 6 22 0 i 0 0 d 44 4 44 44 LEGEND BA BRUSH ASSEMBLY FSS FUEL SHUT OFF SOLENOID SCR STARTER CONTACTOR RELAY BCR1 BATTERY CHARGE RECTIFIER GND GROUND STUD SM STARTER MOTOR BCR2 BATTERY CHARGE RECTIFIER 104 LC T IDLE CONTROL TRANSFORMER SP1 SPARK PLUG CYL 1 1 6AMP AUTO RESET BREAKER CB2 10AMP AUTO RESET BREAKER 600V 12A DIODE D2 D3 ENGINE SHUTDOWN DIODE F1 10A FUSE IGNITION MODULE CYL 1 IM2 IGNITION MODULE CYL 2 LOP LOW OIL PRESSURE R1
24. 0 watts 7 2 kW of power at 30 Amps The outlet is protected by two 30 Amp push to reset circuit breakers 22 5 12 VOLT DC 10 RECEPTACLE This receptacle permits recharging a 12 Volt automotive or utility style storage battery with the battery charge cables provided Figure 11 This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery See the section Charging a Battery before attempting to recharge a battery Figure 11 12 Volt DC 10 Amp Receptacle 2 2 6 120 240 VAC 50 AMP RECEPTACLE Use a NEMA 14 50 plug with this receptacle Connect a 4 wire cord set rated for 250 Volts AC at 50 Amps to the plug Figure 12 8 Figure 12 120 240 VAC 50 Amp Receptacle 120V 240V 50A Use this receptacle to operate 120 240 Volt AC 60 Hz electrical loads requiring up to 12 000 watts 12 0 kW of power This receptacle is protected by a 50 Amp 2 pole circuit breaker 23 HOWTO USE THE GENERATOR If there are any problems operating the generator please call the generator helpline at 1 800 333 1322 2 3 1 GROUNDING THE GENERATOR The National Electrical Code requires that the frame and external electrically conductive parts of this generator be properly connected to an approved earth ground Figure 13 Local electrical codes may also require proper grounding of the unit For that purpose generally connecting a No 10 AWG American
25. 2 OG WINGNUT AIRBOX PRECLEANER AIR ELEMENT AIR CLEANER STUD M6 1 0 X 73 ADAPTOR SPIT BACK GASKET SPITBACK BASE AIRBOX SPRING WINTER SUMMER VALVE VALVE SUMMER WINTER SNORKEL AIR INTAKE TUBE HEAT RISER 50 8 1 0 COVER AIRBOX KNOB AIRBOX 17mm KNOB AIRBOX 95MM SCREW HHC M6 1 0 X 35 WASHER LOCK 6 1 4 WASHER FLAT 1 4 NUT HEX FLANGE WHIZ M6 1 0 STUD METRIC HOSE BREATHER CONTROLLER ASSEMBLY SCREW M5 0 8 X 10 NUT HEX LOCK M5 0 8 ZINC ASSEMBLY WIRE CARBURETOR H990 W BALL STUD GASKET CARB TO SPACER GT 990 CLAMP HOSE BAND 1 4 HOSE ID SAE 30R7 SETIFLEX II 9 PRE CUT GASKET MANIFOLD TO CARBURETOR SLEEVING FLEXO HW 3 FILTER FUEL SCREW 6 1 x 10 LONG NUT HEX LOCK M5 0 8 ZINC SCREW SHC 8 1 25 x 30LG SEMS MANIFOLD INTAKE NUT HEX M3 0 5 ROD SUMMER WINTER VALVE BUSHING MINI CONTROL PANEL KNOB CONTROL SUMMER WINTER CHOKE ASSEMBLY SCREW M5 0 8 X 8 7 PANEL CONTROL FACE PLATE SCREW TAPTITE M6 1 0X 12 CLEAR ZINC SWITCH ROCKER WRAPPER LOWER CYLINDER 2 WRAPPER UPPER CYLINDER 2 ASSEMBLY GROUND WIRE 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 181 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 149 150 151 152 153 154 155 157 160 161 162 163 003110 0G3224B OF 6263 0G0290 0G0926 0G0832 0 7585 0 9323 022129 061906 022145 0 5
26. 467 001131 0F1169B 0C9763 0C3034 0C3033 0C3032 045992 051754 0 3031 0 4997 045756 0 3725 0G4928A 082774 003043 009764 0C3026 003662 090286 035461 0701852 003083 0 3025 002363 063018 063019 0 9176 0 0409 0 8563 009784 006147 0G3224A 048031G 0D6342 SCREW TAPTITE M6 1 0 X 20 ZINC ASSY IGN COIL W DIODE NO ADV PUMP IMPULSE HOSE 3 8 ID x 6 1 2 SAE J30R9 SCREW HHFCS 6 1 0 X 16 G8 8 ELBOW RUBBER 90 DEG GASOLINE SPARKPLUG CHAMPION RC14YC STARTER MOTOR GEAR REDUCED WASHER LOCK 8 5 16 SCREW HHC 8 1 25 X 85 G8 8 WASHER FLAT M8 NUT HEX M8 1 25 YELLOW ZINC GUARD FAN HOUSING BLOWER GAS COOLER NUT GROMMET 1 4 PLUG NUT HEX M24 WASHER M24 PLATE FAN WASHER SHAKEPROOF INT M8 SS SCREW 8 1 25 X 12 G8 8 FAN NYLON ASSY GROUND WIRE CONNECTOR SCREW TAPTITE M6 1X10 YELLOW CHROME FLYWHEEL ASSEMBLY PLATE BACKING GT990 W OIL COOL ZINC KEY WOODRFF 4 X 19D GASKET MANIFOLD PORT PLASTITE 1 4 15 X 3 4 COOLER OIL CLAMP HOSE OETIKER STEPLESS 17mm HOSE 3 8 D X 6 SAE J30R9 BARBED STR 1 4 X 3 8 OIL FILTER 90mm w LOGO ASSEMBLY OIL DRAIN HOSE SWITCH OIL PRESS BRACKET AIRBOX SUPPORT WRAPPER UPPER CYLINDER 1 WRAPPER LOWER CYLINDER 1 HOSE 4 SAE 30R7 SETIFLEX II ASSY ROD GOV STEPPER MOTOR SCREW 6 1 0 X12 NUT LOCK HEX M3 0 5 GT 990 SCREW HHFC M6 1 0 X 10mm ASSY IGN COIL W DIODE NO ADV CLAMP HOSE BAND GREEN BALL STUD 10mm
27. 9176 075763 075763 0 0318 030795 ROSA gt E 2 2 RO RO 4 amp DO G9 OR ROM ol lol on SCREW M6 1 0 X 55 RUBBER TANK MOUNT FUEL WITH GAUGE amp VENT KIT FUEL TANK NUT HEX 8 1 25 WASHER LOCK 8 5 16 WASHER FLAT 5 16 BRACKET BATTERY BOLT BATTERY J BOLT SCREW HHC 1 4 20 X 3 4 G5 WASHER FLAT 1 4 WASHER LOCK M6 1 4 NUT HEX 1 4 20 BATTERY CABLE RED BATTERY U1 NUT WING 5 16 18 BRASS WASHER FLAT 5 16 BRASS NUT HEX 5 16 18 BRASS 5 16 SPECIAL LWASH SCREW HHC 5 16 18 X 1 5 BRASS BRACKET FRONT FOOT 15 kW BRACKET FRONT FOOT 12 5 kW VIB MOUNT WASHER FLAT 2510 X SCREW 8 1 25 X 30 SCREW HHTT M6 1 0 X 12 NUT LOCK FL 3 8 16 BOLT CARR 3 8 16 X 1 AXLE 3 A DIA X 30 15 kW AXLE 3 4 DIA X 27 25 12 5 kW WASHER FLAT 3 4 15 kW WASHER FLAT 3 4 12 5 kW 12 3 PNEUM WHEEL 3 4 AXLE 15 kW 10 PNEUM WHEEL 3 4 AXLE 12 5 kW PIN COTTER 1 8 X 1 1 4 BRACKET WHEEL SPACER NUT FLANGE M6 1 0 NYLOK HANDLE SCREW HHC 5 16 18 X 2 1 2 G5 NUT LOCK HEX 5 16 18 NYLON INSERT FRAME SCREW HHC M5 0 8 X 45 G8 8 WASHER FLAT M5 WASHER LOCK M5 NUT HEX M5 0 8 WASHER FLAT 1 BUSHING TANK DEXTOR VALVE PLASTIC TANK AIR DEFLECTOR GROMMET 75 X 06 X 50 CLAMP HOSE BAND HOSE ID BOOT BATTERY CABLE BOOT STARTER CABLE SPACER AXLE 15 kW
28. AC Voltage Rated Max AC Load Current 240V Current 120V Rated Frequency Phase Single Phase Rated DC Voltage Rated Max DC Load Current 12 Volts MAINTENANCE 2 0 Section 3 Maintenance 3 22 ENGINE SPECIFICATIONS Oil Type Summer SAE 30 Winter 5W 30 Synthetic or 10W 30 Oil Capacity w Filter Change 1 7 Qts w o Filter Change 1 4 Qts Run Time Fuel Consumption 1 2 10 Hours 1 6 gallons per hour Load 3 3 GENERAL RECOMMENDATIONS The warranty of the generator does not cover items that have been subjected to operator abuse or negligence To receive full value from the warranty the operator must maintain the generator as instructed in this manual Some adjustments will need to be made periodically to properly maintain the generator All adjustments in the Maintenance section of this manual should be made at least once each season Follow the requirements in the Maintenance Schedule chart NOTE Once a year replace the spark plug and replace the air filter A new spark plug and clean air filter assure proper fuel air mixture and help the engine run better and last longer 3 3 11 GENERATOR MAINTENANCE Generator maintenance consists of keeping the unit clean and dry Operate and store the unit in a clean dry environment where it will not be exposed to excessive dust dirt moisture or any corrosive vapors Cooling air slots in the generator must not become clogged with snow leaves or
29. AN Do not permit smoking open flame sparks or any other source of heat around a battery Wear protective goggles rubber apron and rubber gloves when working around a battery Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns If spill occurs flush area with clear water immediately This generator has the capability of recharging a discharged 12 Volt automotive or utility style storage battery Do not use the unit to charge any 6 Volt batteries Do not use the unit to crank an engine having a discharged battery This battery charger is a pulse type designed to provide a quality charge current into the battery The voltage measured at the outlet should be 8 12 VDC This is normal and does not indicate a faulty charging system To recharge 12 Volt batteries proceed as follows Check fluid level in all battery cells If necessary add ONLY distilled water to cover separators in battery cells Do not use tap water f the battery is equipped with vent caps make sure they are installed and are tight f 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 recharge
30. Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts nay not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 3 Ignition System including 1 2 LPG Natural Gas carburetion assembly and its internal components Spark plug b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including Intake pipe manifold Air cleaner b Mixer and its gaskets if so equipped c Carburetor and its gaskets if so equipped D 4 4 d Primary gas regulator if so equipped LP liquid vaporizer if so equipped 5 Crankcase Breather Assembly including 2 Air Induction System including Generac engine types covered by this warranty statement include the following 1 Prepackaged Standby Generator 2 Auxiliary Power Unit APU Generator 3 Portable Generator 4 Standby Generator Part 2 Section 8 Warranty WARRAN GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR CENTURION 15 000 AND 17 500 WATT PORTAB
31. If amperage rating of any circuit breaker is exceeded that breaker opens and electrical output to that receptacle is lost Read Don t Overload the Generator carefully 2 8 STOPPING THE ENGINE Shut off all loads then unplug the electrical loads from generator panel receptacles Never start or stop the engine with electrical devices plugged in and turned on Turn Off the Idle Control switch if on Let engine run at no load for several minutes to stabilize the internal temperatures of engine and generator Move Start Run Stop switch to Off position Close fuel valve 11 QD 2 9 AUTOMATIC IDLE CONTROL This feature is designed to greatly improve fuel economy When this switch is turned the engine will only run at its normal fast governed engine speed when electrical load is connected When the load is removed the engine will run at a reduced speed of 2100 RPM With the switch Off the engine runs at the normal fast engine speed all the time Always have the switch OFF when starting and stopping the engine 2 10 COLD WEATHER OPERATION DE ICER Under certain weather conditions temperatures below 40 F 4 C and a high dew point the engine may experience icing of the carburetor and or the crankcase breather system To eliminate this problem this generator engine is fitted with a winter summer valve This directs hot air into the carburetor during cold weather operation
32. LE GENERATORS For a period of two years from the date of original sale Generac Power Systems Inc Generac warrants its Centurion generator will be free from defects in materials and workmanship for the items and period set forth below Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Dealer is found to be defective Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Centurion portable generators and is not transferable WARRANTY SCHEDULE Consumer applications are warranted for 2 two years Commercial applications are warranted for 1 one year Rental applications are warranted for 90 ninety days CONSUMER APPLICATION YEARS ONE and TWO 100 one hundred percent coverage on Labor and Part s listed proof of purchase and maintenance is required Engine All Components Alternator All Components NOTE For the purpose of this warranty consumer use means personal residential household use by original purchaser This does not apply to units used for Prime Power in place of utility where utility power service normally exists Once a generator has experienced comme
33. OSION may result Generator exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Operate this equipment only in the open air where adequate ventilation is available Allow at least two 2 feet of clearance on all sides of generator or damage could be done to the unit Never operate the unit inside any room or enclosure where the free flow of cooling air into and out of the unit might be obstructed Review the Cold Weather Operation section A NEVER operate the generator indoors in an attached garage or near an open window SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS AN SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted near the unit s installation site Safety should be stressed to all operators and potential operators of this equipment e Never start or stop the unit with electrical loads connected to receptacles AND with connected devices turned ON Start the engine and let it stabilize before connecting electrical loads Disconnect all electrical loads before shutting down the generator Do not insert objects through unit s cooling slots Neveroperate generator Indoorsorin any enclosed compartment in rain if connected electrical devices overheat if electrical output is lost if engine or generator sparks if flames or smoke are observed while un
34. OWN DIN RAIL 59 5mm LONG SPACER 25 X 50 X 2 5 17 5 KW SPACER 25 X 50 X 1 5 15 KW 8 005396 CIRCUIT BREAKER 50A 400V 2POLE CIRCUIT BREAKER 10A 1POLE CIRCUIT BREAKER 6A 1POLE RESISTOR 25R 5 25W GASKET PORTABLE CONTROL PANEL RECTIFIER 1N1206R HEATSINK TAPE ELEC UL PERMACEL SWITCH ROCKER 0 OUTLET 12VDC SNAP PANEL SHEET METAL 15 KW amp 005396 PANEL SHEET METAL 17 5 KW CIRCUIT BREAKER 30A CIRCUIT BREAKER 20A OUTLET 30A 120V RECEPT OUTLET 50A 125 250V 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 043437 0D4968 0D4966 051715 038150 022264 0742600142 049721 041658 0D3546 090615 090987 0 1085 075475 077682 080823 075235 093024 074908 045770 0A2053 022097 022478 070370 023897 030468 049813 022158 0E6480 082025 0D9784 160 xo c PARTS dab STS 00 OUTLET 30 125 250V OUTLET 20A 120V DPLX OUTLET 20A 120V GFCI NUT HEX M4 0 7 15 KW amp 005396 NUT HEX 4 0 7 17 5 KW WASHER FLAT 48 15 KW amp 005396 WASHER LOCK M4 15 KW amp 005396 WASHER LOCK M4 17 5 KW GROUND WIRE SCREW HHC M6 1 0 X 35 WASHER LOCK SPECIAL 1 4 HARNESS CONTROL PANEL FRONT NOT SHOWN SPRING RETAINER 17 5 KW SCREW PPHM M3 0 5 X 12 SCREW PPHM M3 0 5 X 8 SCREW PPHM M4 0 7 X 10 SCREW PPHM M5 0 8 X 80 17 5 KW SCREW PPHM 5 0 8 X 50 15 KW amp 005396 SCREW
35. PPHM 5 0 8 X 30 SCREW HHC M5 0 8 X 25 SCREW HHTT M5 0 8 X 10 SCREW HHC M5 0 8 X 10 SCREW HHC M6 1 0 X 65 WASHER LOCK M6 1 4 WASHER FLAT 1 4 WASHER MICA 203 WASHER FLAT 410 WASHER STEP NYLON 20 NUT HEX 6 1 0 NUT HEX 10 32 NUT HEX M4 0 5 NYINS NUT HEX M5 0 8 NYINS NUT HEX M3 0 5 NYINS Section 7 Exploded Views and Parts Lists Frame Handle amp Wheel Kit Drawing No 0E0695 B PARTS Or 00 V E 5 Detail of Battery Tray lt pp 27 30 LISTS Section 7 Exploded Views and Parts Lists ey ot Frame Handle amp Wheel Kit Drawing No 0 695 0 4 5 d Oo Oi amp 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 057058 005315 004570 0D22850SRV 045771 022129 022145 0D4565 0D3545 022287 022473 022097 022127 0388040 0 004575 005202 005199 029809 063168 005198 0 0317 002498 027007 005303 042909 090388 064101 039214 009165 002496 045900 045900 007668 002495 004999 004044 003700 002497 022532 027028 002271 052762 051713 049226 051716 050190 078299 080270 005142 096021 048031 0
36. W CHROM PLATE PUSH ROD GUIDE SCREW 8 1 25 X 65 VALVE EXHAUST VALVE INTAKE TAPPET SOLID ASSEMBLY HEAD 2 PUSHROD 147 GASKET HEAD KIT GEAR COVER KIT GASKET KIT PISTON amp RINGS KIT BREATHER ASSEMBLY KIT HEAD ASSEMBLY CYLINDER 1 KIT HEAD ASSEMBLY CYLINDER 2 KIT OIL RELIEF 23 Section 7 Exploded Views and Parts Lists 2 GT 990 Engine Drawing No 062963 G Part 2 85 4 DETAIL A EZ gt 464 112 ae 100 L 86 S 87 ead ITEM PARTNO DESCRIPTION 1 1 66 67 68 69 70 7i 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 006592 004511 009723 0 5302 004183 006327 0027748 005125 002930 004612 006143 002775 0D5014A 0D5014B 049721 022097 022473 0 8388 006021 0 909 004522 074908 082025 0E3398 0G4612 0D4026 048031C 0 9176 090510 0844090 006313 045756 082025 0G3730A 0C9911 051714 0D5411 0D5445 0D5416A 0D5398 0E6043 0D3432 090388 0D4767 0D1142A 0D1143 0F1177 e mA mA mA Com mk mA po 2 cla cla qoc qc clc cl la c Section 7 Exploded Views and Parts Lists 01 990 Engine Drawing 0G2963 F Part
37. Wire Gauge stranded copper wire to the grounding wing nut and to an earth driven copper or brass grounding rod electrode provides adequate protection against electrical shock However local codes may vary widely Consult with a local electrician for grounding requirements in the area Figure 13 Grounding the Generator Generator Ground Lug Proper grounding of the generator will help prevent electrical shock in the event of a ground fault condition in the generator or in connected electrical devices Proper grounding also helps dissipate static electricity which often builds up in ungrounded devices 2 3 2 CONNECTING ELECTRICAL LOADS DO NOT connect 240 Volt loads to 120 Volt receptacles DO NOT connect 3 phase loads to the generator DO NOT connect 50 Hz loads to the generator Let engine stabilize and warm up for a few minutes after starting Plug in and turn on the desired 120 or 240 Volt AC single phase 60 Hz electrical loads Add up the rated watts or amps of all loads to be connected at one time This total should not be greater than a the rated wattage amperage capacity of the generator or b circuit breaker rating of the receptacle supplying the power See Don t Overload the Generator below 24 DON T OVERLOAD THE GENERATOR Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and to connected electrical devices Observe the following to prevent overloading th
38. ance is correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in Ibs torque After tightening the jam nut recheck valve clearance to make sure it did not change nstall new valve cover gasket e Recattach the valve cover NOTE Start all four screws before tightening or it will not be possible to get all the screws in place Make sure the valve cover gasket is in place e Re attach the spark plug wire to the spark plug Repeat the process for the other cylinder 3 7 GENERAL The generator should be started at least once every seven days and be allowed to run at least 30 minutes If this cannot be done and the unit must be stored for more than 30 days use the following information as a guide to prepare it for storage A A NEVER store engine with fuel in tank indoors or in enclosed poorly ventilated areas where fumes may reach an open flame spark or pilot light as on a furnace water heater clothes dryer or other gas appliance 3 8 LONG TERM STORAGE It is important to prevent gum deposits from forming in essential fuel system parts such as the carburetor fuel hose or tank during storage Also experience indicates that alcohol blended fuels called gasohol ethanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in sto
39. aser owner that each of its engines are 1 Designed built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a warranted emissions related part to fail to be identical in all material respects to the part as described in the engine manufacturer s application for certification The ECS Warranty pertains only to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replaceme
40. bad 3 Battery is defective 4 Receptacle is bad CORRECTION 1 Reset circuit breaker 2 Check and repair 3 Connect another device that is in good condition 4 Contact Authorized Service Facility 1 Disconnect shorted electrical load 2 See Don t Overload the Generator 3 Contact Authorized Service Facility 4 Contact Authorized Service Facility 1 Replace fuse with only an identical 10 amp replacement fuse 2 Recharge or replace battery Clean or replace air cleaner Fill fuel tank Drain fuel tank and fill with fresh fuel Connect wire to spark plug Replace spark plug Drain fuel tank fill with fresh fuel Put choke knob to No Choke position Fill crankcase to proper level 9 Contact Authorized Service Facility 10 Contact Authorized Service Facility 11 Contact Authorized Service Facility 1 Fill fuel tank 2 Fill crankcase to proper level 3 Contact Authorized Service Facility 1 See Don t Overload the Generator 2 Replace air filter 3 Contact Authorized Service Facility 1 Move choke to halfway position until engine runs smoothly 2 Contact Authorized Service Facility 1 Clean battery posts 2 Replace cable 3 Check battery condition replace if defective 4 Contact Authorized Service Facility 17 NOTES 18 Section 5 Notes Section 6 Electrical Data Schematic Drawing No 0G2894 A
41. ctrical devices plugged into the receptacles AND devices turned on Unplug all electrical loads from the unit s receptacles before starting the engine Make sure the unit is in a level position Open the fuel shut off valve Figure 15 Figure 15 Fuel Shut off Valve QU TN 3 m 1 14 FUEL SHUTOFF Locate the Idle Control ON OFF switch on the control panel and set it to the OFF position Figure 16 Figure 16 Idle Control Switch IDLE CONTROL ON OFF OPERATION Ot Move engine CHOKE knob outward to Full Choke position Figure 17 Section 2 Operation Figure 17 Full Choke Position To start engine press and hold the Start Run Stop switch in the Start position The engine will crank and attempt to start When the engine starts release the switch to the run position When the engine starts move choke knob to 1 2 Choke position until the engine runs smoothly and then fully in to the Run position If engine falters move choke knob back out to 1 2 Choke position until the engine runs smoothly and then to Run position NOTE If engine fires but does not continue to run move choke lever to Full Choke and repeat starting instructions IMPORTANT Do not overload the generator Also do not overload individual panel receptacles These outlets are protected against overload with push to reset type circuit breakers
42. dding oil to the engine crankcase in the future use only high quality detergent oil rated with service classification SG SH or SL Use no special additives _ 10W 30 F 20 10 0 10 20 32 40 60 80 100 C 30 20 10 0 10 20 30 40 Temperature Range of Expected Use Although multi viscosity oils BW 30 10W 30 etc improve starting in cold weather these multi viscosity oils will result in increased oil consumption when used above 32 F Check the engine oil level more frequently to avoid possible damage from running low on oil Place generator on a level surface Clean area around oil fill and remove oil fill cap and dipstick Wipe dipstick clean Slowly fill engine with oil through the oil fill opening until it reaches the full mark on the dipstick Stop filling occasionally to check oil level DO NOT OVERFILL Install dipstick Install oil fill cap and finger tighten securely Check engine oil level before starting each time thereafter 2 6 2 ADDING GASOLINE warninc 4 Never fill fuel tank indoors Never fill fuel tank when engine is running or hot DO NOT light a cigarette or smoke when filling the fuel tank caution Do not overfill the fuel tank Always leave room for fuel expansion To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator engine Leaded REGULAR grade gasoline is an acceptable substitute Do
43. e unit 2 Add up the total wattage of all electrical devices to be connected at one time This total should NOT be greater than the generator s wattage capacity The rated wattage of lights can be taken from light bulbs The rated wattage of tools appliances and motors can usually be found on a data label or decal affixed to the device If the appliance tool or motor does not give wattage multiply volts times ampere rating to determine watts volts x amps watts Some electric motors such as induction types require about three times more watts of power for starting than for running This surge of power lasts only a few seconds when starting such motors Make sure to allow for high starting wattage when selecting electrical devices to connect to the generator Figure the watts needed to start the largest motor Add to that figure the running watts of all other connected loads The Wattage Reference Guide is provided to assist in determining how many items the generator can operate at one time NOTE All figures are approximate See data label on appliance for wattage requirements OPERATION Ot Section 2 Operation 2 5 WATTAGE REFERENCE GUIDE pl Running Watts Air Conditioner 12 000 1700 Air Conditioner 24 000 3800 Air Conditioner 40 000 6000 Batt
44. equired maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unapproved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer To locate the Generac Authorized Warranty Service Dealer nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The
45. er to protect the generator against electrical overload B0 amp uses toggle reset 11 Fuel Tank Tank holds 16 U S gallons of fuel 12 Grounding Lug Ground the generator to an approved earth ground here See Grounding the Generator for details 13 Idle Control Switch The idle control runs the engine at normal high speeds when there is an electrical load present and runs the engine at idle low speeds when a load is not present 14 Start Run Stop Switch Controls the operation of the generator 15 0il Fill Use this point to add oil to engine 16 Fuse 10 Amp Located at rear of control panel Protects the DC control circuit from overload If this fuse element has melted open the engine will not be able to crank and start Figure 6 Engine Control Panel ENGINE START UP ZONE PUSH SUMMER above 40 F 22 CORD SETS AND CONNECTION PLUGS 22 1 120 VAC 20 DUPLEX RECEPTACLE This is a 120 Volt outlet protected against overload by a 20 Amp push to reset circuit breaker Figure 7 Use each socket to power 120 Volt AC single phase 60 Hz electrical loads requiring up to a combined 2400 watts 2 4 kW or 20 Amps of current Use only high quality well insulated 3 wire grounded cord sets rated for 125 Volts at 20 Amps or greater Keep extension cords as short as possible preferably less than 15 feet long to prevent voltage drop and possible overheating of wires Figure 7 120 Volt AC 20 Am
46. ery Charger 20 500 Belt 3 2225 1000 Chain 1200 Circular Saw 6 1 2 800 to 1000 Clothes Dryer Electric 5750 Clothes Dryer Gas 2 sates cm det Rene 700 1150 00186 6 2 1750 Compressor 1 2000 Compressor 3 4 1800 Compressor 1 2 eie err eee nen 1400 CUMING 700 etr 650 Disc Sander 07 1200 Edge 500 Electric Blanket 400 Electric Nail GUN Soie Een 1200 Electric Range per 1500 Electric Skillet 1250 dicc p 700 Furnace Fan 3 5 HP te 875 Garage Door 500 to 750 Halt Dryer visp Eten Apo eb RR RA 1200 Hand nori ep eed e b 250 to 1100 Hedge Trirmimet 450 Impact 500 Ms 1200 ve had n a tre Leite ei e
47. es Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE Section 1 General Information 1 1 UNPACKING Setthe palleted carton on a rigid flat surface Remove staples along bottom of carton that fasten carton to pallet Open carton from top Remove all packaging material Remove separate accessory box Lift carton off the generator Remove generator from shipping pallet by removing bolts through the shipping brackets Figure 1 Figure 1 Bracket Removal 1 1 1 ACCESSORY BOX Check all contents If any parts are missing or damaged locate an authorized dealer at 1 800 333 1322 Contents include Wheel Axle e Bolt on tubular handle 2 Washers e 2 Pneumatic Wheels 2 Wheel Spacers 2 Axle Bracket Assemblies 2 Cotter Pins e Bolt on Foot e 2 Spark Plugs Spark Plug Wrench Air Filter OilFilter Pre cleaner Battery Charge Cable 6 Carriage Bolts Washers Nuts 1 2 ASSEMBLY The generator requires some assembly prior to using it If problems arise when assembling the generator please call the Generator Helpline at 1 800 333 1322 1 2 1 ASSEMBLING THE WHEEL KIT The wheel kit is designed to greatly improve the portability of the generator A socket wrench with a 9 16 socket a 1 2 socket a 1 2 wrench and a pair of pliers are the tools that will be needed for assembly of the wheel kit NOTE The wheel kit is not intended for over the
48. ess 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 e Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s e Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part No 0G2955 Rev B Printed in U S A 05 30 07
49. formation on checking the oil level The oil level should be checked before each use or at least every eight hours of operation Keep the oil level maintained 3 3 5 CHANGING THE OIL AND OIL FILTER Change the oil and filter after the first eight hours of operation Change the oil every 200 hours thereafter If running this unit under dirty or dusty conditions or in extremely hot weather change the oil more often NOTE Whenever possible run engine for approximately 5 minutes to get the engine oil hot This will aid in draining the oil Use the following instructions to change the oil while the engine is still warm Clean area around oil drain hose and plug Remove oil drain plug from end of hose and oil fill plug to drain oil completely into a suitable container When oil has completely drained install oil drain plug and tighten securely Place a suitable container beneath the oil filter and turn filter counterclockwise to remove Discard according to local regulations Coat gasket of new filter with clean engine oil Turn filter clockwise until gasket contacts lightly with filter adapter Then tighten an additional 3 4 turn Fill oil sump with recommended oil See Before Starting the Generator for oil recommendations Wipe up any spilled oil 3 3 6 REPLACING THE SPARK PLUG Use Champion RC14YC spark plug or equivalent The correct air gap is 1 01 mm 0 040 in Replace the plug once each
50. he gasoline to increase the life of the gasoline Cover the unit with a suitable protective cover that does not retain A NEVER cover the generator while engine and exhaust area are warm Section 4 Troubleshooting TROUBLESHOOT 41 TROUBLESHOOTING GUIDE PROBLEM Engine is running but no AC output is available Engine runs good but bogs down when loads are connected Engine will not start or starts and runs rough Engine shuts down during operation No Battery Charge DC output 1 Circuit breaker is open 2 Poor connection or defective cord set 3 Connected device is bad 4 Fault in generator 1 Short circuit in a connected load 2 Generator is overloaded 3 Engine speed is too slow 4 Shorted generator circuit 1 10 amp fuse at rear of generator control panel has melted open 2 Battery weak or dead Dirty air cleaner Out of gasoline Stale gasoline Spark plug wire not connected to spark plug Bad spark plug Water in gasoline Overchoking Low oil level 9 Excessive rich fuel mixture 10 Intake valve stuck open or closed 11 Engine has lost compression 1 2 3 4 5 6 7 8 1 Out of gasoline 2 Low oil level 3 Fault in engine 1 Load is too high 2 Dirty air filter 3 Engine needs to be serviced 1 Choke is opened too soon 2 Carburetor is running too rich or too lean 1 Battery posts are corroded 2 Battery cable is
51. it is running if unit vibrates excessively NOTE This generator is equipped with a spark arrestor muffler The spark arrestor must be maintained in effective working order by the owner operator In the State of California a spark arrestor is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique the manufacturer does not specifically recommend satisfy yourself that it is safe for others Make sure the procedure work
52. lamp shut off The yellow trip indicator should now be on To restore the flow of electricity press the Reset button on the front of the receptacle If the GFCI does not perform in this manner do not use the receptacle Contact a local service dealer This outlet is protected against overload by a 20A push to reset circuit breaker Use the outlet to power 120V AC single phase 60 Hz electrical loads requiring up to a combined 2400 watts 2 4 kW or 20 amps of current 2 2 3 120 VAC 30 AMP RECEPTACLE Use a NEMA L5 30 plug with this receptacle Connect a 3 wire cord set rated for 125 Volts AC at 30 Amps or greater to the plug Figure 9 Figure 9 120 VAC 30 Amp Receptacle 120V 30A QD 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 Section 2 Operation 2 24 120 240 VAC 30 AMP RECEPTACLE Use a NEMA L14 30 plug with this receptacle Connect a suitable 4 wire grounded cord set to the plug and to the desired load The cord set should be rated for 250 Volts AC at 30 Amps or greater Figure 10 Figure 10 120 240 VAC 30 Amp Receptacle 120V 240V 30A Use this receptacle to operate 120 Volt AC 60 Hz single phase loads requiring up to 3600 watts 3 6 kW of power at 30 Amps or 240 Volt AC 60 Hz single phase loads requiring up to 720
53. method or operating technique chosen does not render the generator unsafe A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment Potentially lethal voltages generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators N GENERAL HAZARDS N Never operate in an enclosed area or indoors For safety reasons the manufacturer recommends that the maintenance of this equipment is carried out by an Authorized Dealer The engine exhaust fumes contain carbon monoxide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust system must be properly maintained Do nothing that might render the exhaust system unsafe or in noncompliance with any local codes and or standards Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical to correct generator operation Do not alter the installation
54. nt 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 b When the engine is inspected by a Generac Authorized Warranty Service Facility the purchaser owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS warranty maintenance or repairs and will be provided without charge to the purchaser owner Such use shall not reduce
55. o check valve clearance Make sure the engine is at room temperature 60 80 F Make sure that the spark plug wire is removed from the spark plug and out of the way Remove the four screws attaching the valve cover Make sure the piston is at Top Dead Center TDC of its compression stroke both valves closed To get the piston at TDC remove the intake screen at the front of the engine to gain access to the flywheel nut Use a large socket and socket wrench to rotate the nut and hence the engine in a clockwise direction while watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is up as high as it can go nsert a 0 002 0 004 inch 0 05 0 1mm feeler gauge between the rocker arm and valve stem Correct clearance is when a slight drag is felt when sliding the gauge back and forth If the clearance is either excessively loose or tight the rocker arms will need adjusting To adjust valve clearance Loosen the rocker jam nut Figure 21 Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm Figure 21 Valve Clearance Adjustment Pivot Ball Jam Nut NOTE The rocker arm jam nut must be held in place as the pivot ball stud is turned 15 MAINTENANCE 2 0 Section 3 Maintenance When valve clear
56. or Never handle any kind of electrical cord or device while standing in water while barefoot or while hands or feet are wet Dangerous electrical shock will result The National Electric Code requires the frame and external electrically conductive parts of the generator be properly connected to an approved earth ground Local electrical codes may also require proper grounding of the generator Consult with a local electrician for grounding requirements in the area Use a ground fault circuit interrupter in any damp or highly conductive area such as metal decking or steel work Do not use worn bare frayed or otherwise damaged electrical cord sets with the generator Operate generator only on level surfaces and where it will not be exposed to excessive moisture dirt dust or corrosive vapors Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flames sparks or heat in the vicinity while handling gasoline Avoid spilling gasoline on a hot engine Comply with all laws regulating storage and handling of gasoline Never add fuel while unit is running Do not overfill the fuel tank Always allow room for fuel expansion If tank is over filled fuel can overflow onto a hot engine and cause FIRE or an EXPLOSION Never store generator with fuel in tank where gasoline vapors might reach an open flame spark or pilot light as on a furnace water heater or clothes dryer FIRE or EXPL
57. or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator The generator MUST be operated outdoors When working on this equipment remain alert at all times Never Work on the equipment when physically or mentally fatigued nspectthe generator regularly and contact the nearest Authorized Dealer for parts needing repair or replacement Before performing any maintenance on the generator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc A ELECTRICAL HAZARDS A All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages as does the generator when it is in operation Avoid contact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in wate
58. p Duplex Receptacle 120V 20A 22 2 120 20 RECEPTACLE This unit is equipped with a ground fault circuit interrupter GFCI This device meets applicable federal state and local codes Figure 8 A GFCI receptacle is different from conventional receptacles In the event of a ground fault a GFCI will trip and quickly stop the flow of electricity to prevent serious injury Definition Instead of following its normal safe path electricity passes through a persons body to reach the ground For example a defective appliance can cause a ground fault A GFCI receptacle does NOT protect against circuit overloads short circuits or shocks For example electric shock can still occur if a person touches charged electrical wires while standing on a non conducting surface such as a wood floor OPERATION Ep Figure 8 120 VAC 20 Amp GFCI Receptacle Section 2 Operation Receptacle Outlet WEE Correct wiring Trip Indicator N 8 1531 TEST button E TEST RESET Pd Az Y RESET button g 5 2 2 Testing the GFCI Test the GFCI outlet every month as follows Pluga 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
59. phasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety information that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment We strongly recommend that the operator read this manual and thoroughly understand all instructions before using the equipment We also strongly recommend instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency caution Always disconnect spark plug wires and place the wires where they cannot contact the spark plugs to prevent accidental starting when setting up transporting adjusting or making repairs to the generator The generator produces dangerously high voltage that can cause extremely hazardous electrical shock Avoid contact with bare wires terminals etc Never permit any unqualified person to operate or service the generat
60. r while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT The National Electrical Code NEC requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground Local electrical codes also may require proper grounding of the generator electrical system In case of accident caused by electric shock immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a non conducting implement such as a rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS For fire safety the generator must be operated and maintained properly Operation must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is operated in accordance with the manufacturer s instructions and recommendations Do not alter the construction of the generator or change controls which might create an unsafe opera
61. rage 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 16 DIE A Drain fuel into approved container outdoors away from open flame Be sure engine is cool Do not smoke Start and run engine until engine stops from lack of fuel While engine is still warm drain oil from crankcase Refill with recommended grade Remove spark plugs and pour about 1 2 ounce 15 ml of engine oil into the cylinders Cover spark plug hole with rag Press the Start button and allow engine to crank for 2 seconds Then press the Stop button caution Avoid spray from spark plug holes when cranking engine Install and tighten spark plugs Do not connect spark plug wires e 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 3 9 OTHER STORAGE TIPS Do not store gasoline from one season to another Replace the gasoline can if it starts to rust Rust and or dirt in the gasoline will cause problems with the carburetor and fuel system f possible store the unit indoors and cover it to give protection from dust and dirt BE SURE TO EMPTY THE FUEL TANK If itis 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 t
62. rcial or rental use it shall thereafter be considered a non consumer use generator for the purpose of this warranty All warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Centurion portable generators that utilize non Generac replacement parts e Costs of normal maintenance and adjustments Failures caused by any contaminated fuels oils or lack of proper oil levels Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper use As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation e Products that are modified or altered in a manner not authorized by Generac in writing 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 acc
63. s 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 3 1 MAINTENANCE SCHEDULE Follow the calendar intervals More frequent service is required when operating in adverse conditions noted below Daily Check Oil Level Service Air Pre Cleaner Change Oil and Oil Filtert Clean Spark Arrestor Screen Check Valve Clearance Every Season Service Air Cleaner Replace Spark Plugs Change oil after first 8 hours of operation then every season Change oil and oil filter every month when operating under heavy load or in high temperatures Clean more often under dirty or dusty operating conditions Replace air cleaner parts if very dirty Check valve clearance and adjust if necessary after first 50 hours of operation and every 100 hours thereafter 3 2 PRODUCT SPECIFICATIONS 321 GENERATOR SPECIFICATIONS MODEL Rated Max Power 17 5 KW 15 0 kW 17 5 kW 22 5 kW 26 25 kW 120 240 120 240 62 5 Amps 72 9 Amps 125 0 Amps 145 8 Amps 60 Hz 3600 RPM 60 Hz 3600 RPM Single Phase 12 Volts 12 Volts 10 Amperes 10 Amperes Surge Power Rated
64. ting condition Keep a fire extinguisher near the generator at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the standby electric system Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department IMPORTANT SAFETY INSTRUCTIONS SAFETY RULES EXPLOSION HAZARDS A Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Gasoline is extremely EXPLOSIVE STANDARDS INDEX In the absence of pertinent standards codes regulations and laws the published information listed below may be used as a guideline for operation of this equipment Always reference the latest revision available for the standards listed 1 2 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK available from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRICAL SYSTEMS available from the American Society of Agricultural Engineers 2950 Nil
65. year This will help the engine start easier and run better 1 Stop the engine and pull the spark plug wire off of the spark plug 2 Clean the area around the spark plug and remove it from the cylinder head 3 Setthe spark plug s gap to 1 01 mm 0 040 in Install the correctly gapped spark plug into the cylinder head Figure 18 Spark Plug Gap 3 4 SERVICE AIR CLEANER The engine will not run properly and may be damaged if using a dirty air cleaner Clean or replace the air cleaner paper filter once a year Clean or replace more often if operating under dusty conditions Clean foam pre cleaner every month or more often under dusty conditions Figure 19 Air Cleaner Pre Cleaner Filter To clean or replace foam pre cleaner Remove air cleaner cover then foam pre filter Wash pre cleaner in soapy water Squeeze pre filter dry in clean cloth DO NOT TWIST Clean air cleaner cover before re installing it To clean or replace paper air filter Remove air cleaner cover then remove foam pre filter service if necessary and remove paper filter Clean paper filter by tapping it gently on a solid surface If the filter is too dirty replace it with a new one Dispose of the old filter properly Clean air cleaner cover then slip pre cleaner over filter Next insert new paper filter into the base of the air cleaner Re install air cleaner cover NOTE To order a new air filter please contact the

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