Generac 190/220 Portable Generator User Manual
Contents
1. CHECKING ENGINE OIL 1 Check the engine oil level before starting the engine each time after the initial start If the oil level is below the point of overflowing fill to the proper level M ADDING FUEL 1 Fil the fuel tank using clean fresh UNLEADED gasoline OPERATION GI STARTING THE ENGINE 1 Open the fuel shut off valve if so equipped 2 If your unit is equipped with the IDLE CONTROL feature locate the IDLE CONTROL ON OFF SWITCH on the control panel and set it to the OFF O position 3 Locate the RUN STOP SWITCH Figure 2 next to the engine cylinder head and push it to RUN Figure 2 RUN STOP SWITCH If your engine is equipped with a choke use the following instructions 1 Place the choke lever in the FULL CHOKE POSITION Figure 3 by sliding it to the left towards the valve cover in the direction indicated by the arrow Figure 3 Choke Positions 2 Grasp the recoil handle Figure 4 and pull it slowly until you feel slight resistance then PULL QUICKLY Generac GN 190 200 Engine OPERATION OD A Ifthe engine FAILS TO START go to Step 3 2 Grasp the recoil handle see Figure 4 and pull it slowly until B Ifthe engine STARTS go to Step 4 you feel slight resistance then PULL QUICKLY Repeat pulling the recoil handle three 3 times if necessary 3 If the engine FAILS TO START repeat Steps 1 and 2 4 Allow the engine to warm up for two 2 mi2. 21 oz Use no special additives RECOMMENDED FUEL Use clean fresh regular UNLEADED gasoline with this engine CAUTION Do not overfill the fuel tank Always allow room for fuel expansion WHEN THE ENGINE IS RUNNING OR HOT DO NOT LIGHT A CIGARETTE OR SMOKE WHEN FILLING THE FUEL TANK WARNING NEVER FILL THE FUEL TANK INDOORS OR Generac GN 190 220 Engine OPERATION AND MAINTENANCE It is the owner s operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the engine checked by an authorized dealer periodically Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your engine assures a minimum number of problems and keeps your operating expenses at a minimum See your authorized dealer distributor for service aids and accessories BEFORE STARTING THE ENGINE Perform the following tasks before trying to start the engine ADDING ENGINE OIL 1 Remove the yellow oil fill cap from the crankcase Figure 1 2 Add engine oil until the oil level is to the point of overflowing Figure 1 Oil Fill Cap Cil Fill Cap
3. a Breather connection tube 33 Generac GN 190 220 Engine GENERAC POWER SYSTEMS INC TWO YEAR LIMITED WARRANTY FOR GN ENGINES Generac Power Systems Inc warrants to the original purchaser that the engine will be trouble free from defects in material or workmanship for the items and period set forth below from the date of original purchase This warranty is not transferable This warranty pertains to GN engines utilized to power equipment within the lawn and garden industry Examples are but not limited to generators pressure washers air compressors welders lawn tractors snow blowers mowers edgers and pumps ENGINE COVERAGE CONSUMER COMMERCIAL 2 YEARS 2 YEAR PARTS ONLY 1 YEAR With the exception of European Community Countries all engines bound for export shall be warranted for one 1 year in consumer applications and 90 days in commercial applications as defined below NOTE For the purpose of this warranty consumer use means personal residential household use by original purchaser This does not apply to engines used in generators used for prime power in place of utility Commercial use means all other uses including rental construction and income producing purposes Once an engine has experienced commercial use it shall thereafter be considered a commercial use for the purpose of this warranty DURING SAID WARRANTY PERIOD GENERAC POWER SYSTEMS INC WILL AT ITS OPTION REPAIR OR REPLACE ANY P
4. Adjust Valve Clearance D X O Retorque Head Bolts 0 21 See Note 3 NOTE 1 Change oil and filter after first 8 hours of operation and then every 50 hours thereafter Change sooner when operating under heavy load or in dusty or dirty environment or in high ambient temperature NOTE 2 Clean more often when operating under dirty or dusty conditions NOTE 3 Perform this task ONLY after first 50 hours of operation Head bolts will NOT need further retorquing 49 Generac GN 190 220 Engine STORAGE INSTRUCTIONS This engine should be started at least once a week and run for at least 30 minutes If this cannot be done and the equipment must be stored for more than 30 days use the following guidelines to prepare it for storage indoors or in an enclosed poorly ventilated areas where fumes can reach an open flame spark or pilot light as on a furnace water heater or clothes dryer A WARNING Never store the engine with the fuel in the tank 1 Run the engine for about five 5 minutes to warm it NOTE Alcohol blended fuel or gasohol attracts moisture which can lead to the separation and formation of acids during storage This acidic gas can damage internal engine parts Methanol ethanol and grain alcohol all are forms of gasohol If you did use gasohol drain the fuel tank then run the engine until it stops from lack of fuel WARNING Drain the fuel into approved container A outdoors away from open fl
5. complied with will result in personal injury WARNING After this heading you can read handling installing operating or servicing instructions that if not strictly complied with may result in personal injury CAUTION After this heading you can read instructions for handling installing operating or servicing the generator that if not strictly complied with may result in damage to equipment and or property NOTE After this heading you can read explanatory statements that require special emphasis These symbols indicate the following Points out important safety information and if not followed could endanger personal safety and or property of yourself and others Potential explosion hazard Potential fire hazard Potential electrical shock hazard SAFETY RULES RULES FOR SAFE OPERATION Study these RULES FOR SAFE OPERATION carefully before operating or servicing this equipment Become familiar with the OWNER S MANUAL and with the engine The engine can operate safely efficiently and reliably only if it is properly operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions Generac cannot possibly anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the equipment are therefore not all inclusive If you use a procedure work method
6. engine at high engine speeds is dangerous and increases the risk of personal injury or damage to the equipment Operating the engine at low engine speeds with heavy loads may shorten the engine s life 10 CARBURETOR ADJUSTMENTS The carburetor of your engine is pre set at the factory The carburetor should not be tampered with because this will VOID THE EMISSION CONTROL SYSTEM WARRANTY If you experience problems and your engine is used at an altitude in excess of 5000 feet contact the nearest authorized dealer regarding high altitude setting changes CHECKING ADJUSTING VALVE TO ROCKER ARM CLEARANCE Every 50 hours of operation remove the rocker cover and check the valve to rocker arm clearance When adjusting the clearance the engine should be at room temperature and the piston should be at Top Dead Center TDC of its compression stroke both valves are closed The correct clearance is 0 05 0 1mm 0 002 0 004 in Check and adjust the valve to rocker arm clearance as follows 1 Remove the four 4 screws from the rocker cover Figure 10 2 Remove the rocker cover and rocker cover gasket Figure 10 Removing the Valve Cover zz Generac GN 190 220 Engine MAINTENANCE gt 3 Loosen the rocker arm jam nut Using an allen wrench to turn the pivot ball stud check the clearance between the rocker arm and the valve stem with a flat feeler gauge Figure 11 Figure 11 Adjusting Valve
7. it with a new one Dispose of the old filter properly Clean the air cleaner cover Insert the pre filter into the cover then the paper air filter see Figure 8 7 Reinstall the air cleaner cover and tighten the two 2 screws see Figure 7 2 Remove the paper air filter and the foam pre filter from the air cleaner cover Figure 8 EM REPLACING THE SPARK PLUG Pre Filter Use a Champion RC12YC spark plug or equivalent The correct air gap is 0 76mm 0 030 in Remove the plug every 100 hours of operation or once each year whichever comes first This will help your engine to start easier and run better 1 Stop the engine and pull the spark plug wire off of the spark plug 2 Clean around the spark plug and remove it from the cylinder head Filter Generac GN 190 220 Engine 3 Set the spark plug gap Figure 8 to 0 76mm 0 030 in Install a correctly gapped spark plug into the cylinder head Figure 8 Setting Spark Plug Gap SET PLUG GAP AT 0 76 mm 0 030 inch i CLEANING THE SPARK ARRESTOR SCREEN The engine exhaust muffler has a spark arrestor screen Inspect and clean the screen every 100 hours of operation or once each year whichever comes first NOTE f you use your engine on any forest covered brush covered or grass covered unimproved land it must have a spark arrestor The spark arrestor must be maintained in good condition by the owner operator Clean and inspect the spark arre
8. or operating technique Generac does not specifically recommend you must satisfy yourself that it is safe for you and others You must also make sure the procedure work method or operating technique that you choose does not render the engine to be unsafe DANGER Do not tamper with the engine governed speed A High operating speeds are dangerous and increase the risk of personal injury or damage to the equipment Operating at low speeds with heavy load may shorten the engine s life M BEFORE OPERATING Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flames sparks or heat in the area while handling gasoline Avoid spilling gasoline on a hot engine Comply with all of the laws regulating storage and handling of gasoline Store gasoline and other fuels only in containers designed and approved for the storage of such materials Pressure can build up in the fuel tank Loosen the fuel tank slowly to relieve any pressure in the tank Add gasoline and other fuels in a clean well ventilated area Wipe up any spilled gasoline immediately If gasoline has been spilled let it dry completely before starting the engine WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Generac GN 190 220 Engine Do not overfill the fuel tank Always allow room for fuel expansion If the t
9. to Rocker Arm Clearance Tighten Jam Nut to 65 85 inch pounds 4 When the valve clearance is correct hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut Torque the jam nut to 7 15 9 35 N m 65 85 in Ib After tightening the jam nut recheck the valve clearance to make sure it did not change see Figure 11 5 Reinstall the rocker cover gasket rocker cover and the four 4 screws see Figure 10 Generac GN 190 220 Engine MAINTENANCE gt o RETORQUING THE HEAD BOLTS i Figure 12 Tightening Sequence After the first 50 hours of operation retorque the head bolts NOTE Only perform this adjustment after the first 50 hours of operation The head bolts will need no further adjustment 1 Remove the four 4 screws from the rocker cover see Figure 10 2 Remove the rocker cover and rocker cover gasket Torque the bolts to 4 0 kg m 22 ft lb 4 Torque the bolts in the following sequence A B C D E star pattern See Figure 12 MAINTENANCE SCHEDULE Every 8 Hours or 25 Hours or Ever 50 Hours or Ever 100 Hours or Ever MAINTENANCE OPERATION or Daily Season eck Leve Z Change Oil 66565658 See Note 1 Change Oil Filter if so equipped See Note 1 ZAM C Service Air Filter Foam Pre Filter Paper Filter Note 2 Replace or Clean Spark Plug RE oo o Clean Spark Arrestor Screen
10. 1 1 Gasket 43B Carburetor 190cc 98469 43C Carburetor 220cc 97747 ae ech ect Sech 44B Air Cleaner Base 78607 45 M6 x 12mm Capscrew 66476 46 8 x 3 8 Plastite 59635 Screw 47 Air Filter 78601 1 48 Precleaner 78602 1 49 Choke Knob 83504 1 50 Curb Bolt 78643 2 Generac GN 190 220 Engine EXPLODED VIEW GAS TANK ITEM PART QTY DESCRIPTION 55 83512 2 M6 X 15 Taptite 57 95213 1 Tank Bracket 58 77395 2 M6 Flange Nut 59 95214 1 Tank Cradle 60 30340 12 1 4 ID Hose 61 48031C 1 Hose Clamp 18 Generac GN 190 220 Engine EXPLODED VIEW OIL FILTER AND OPTIONAL OIL FILL TUBE ITEM PART QTY DESCRIPTION ITEM PART QTY DESCRIPTION 1 94820 1 Expansion Plug 64 74908 2 M5 X 12 Taptite 2 91848 1 Oil Filter Gasket 65 91475 1 Dipstick ASM 3A 88758 1 Oil Blockoff 66 90388 1 M6 X 12 Taptite 3B 84982 1 Oil Filter Adapter 67 22473 1 M6 Flat Washer 4 92978 2 M6 X 18 Taptite 68 47411 1 M6 X 16 HHCS 5 99236 1 Oil Press Switch 69 91230 1 Rubber Washer 6 70185 1 Oil Filter 70 91041 1 Fill Tube 71 95997 1 Oil Fill Brkt 72 77395 1 M6 Flange Nut 30 Generac GN 190 220 Engine EXPLODED VIEW LOW OIL SHUTDOWN AND GOVERNOR ITEM PART QTY DESCRIPTION z denos Runistop AW ITEM PART QTY DESCRIPTION 8 85272 1 LED Assembly 21 86962 1 Governor Lever 8A 86753 1 LED Assembly 22 85953 1 Wear Washer 10 85620 1 Black Sleeving 24 83512 1 M8 X 15 Taptite 11 00285271 1 Black Wire Assembly 25A 78604 1 60Hz Gov Sprin
11. 2 14 Governor Gear Assembly A8929 1 15 Governor Gear C Ring 78645 16 Governor Spool 7811 1 17 1 8 NPT Pipe Plug 72683 18 Camshaft Assembly 98752 19 Crankcase Gasket 89096 20 Valve Stem Seal 88156 21 Cylinder Head Gasket A8822 22 Oil Pressure Relief Cover 78691 23 Oil Pressure Spring 5772 24 11 32 Ball A5776 1 25 M5 Form Screw 74908 1 26 M6 1 0 x 12mm Screw 78606 4 27 Gov Gear Thrust Washer 76361 1 5 Generac GN 190 220 Engine EXPLODED VIEW AIR CLEANER AND CARBURETOR ITEM DESCRIPTION PART NO QTY 31 Breather Hose 90947 32 Manifold Head Gasket 90051 33 M6 x 55mm Capscrew 57058 34 M6 x 25mm Capscrew 80318 35 M6 x 30mm Screw 80316 N N N sch m 36A Intake Manifold 20136 37 M6 Lock Washer 22097 38 M6 Hex Nut 49813 39A Carburetor Air Box 21202 Gasket 40 10 32 x 3 4 Screw 36935 2 41 Canal Cover 80303 1 42 Carburetor Manifold 21201 1 Gasket 43A Dellorto Carburetor 21203 1 44A Air Cleaner Base 21200 1 45 M6 x 12mm Capscrew 66476 1 46 8 x 3 8 Plastite 59635 1 Screw 47 Air Filter 78601 1 48 Precleaner 78602 1 D Generac GN 190 220 Engine AIR CLEANER AND CARBURETOR vie W Q S SSJ R A y cJ ITEM DESCRIPTION PART NO QTY 31 Breather Hose 90947 1 32 Manifold Head 90051 1 Gasket 35 M6 x 30mm Screw 80316 36B Intake Manifold 90948 1 39B Carburetor AirBox 91846 1 Gasket 41 Canal Cover 80303 1 42 Carburetor Manifold 7863
12. 2 Any warranted emissions related part which 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 any remainder of the ECS Warranty Period 3 Any warranted emissions related part which 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 Corporation 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 Corporation Authorized Service Outlet 5 The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective provided that such diagnostic work is performed at a Generac Corporation Authorized Service Outlet 6 Generac Corpo
13. ART WHICH UPON EXAMINATION BY GENERAC POWER SYSTEMS INC IS FOUND TO BE DEFECTIVE UNDER NORMAL USE AND SERVICE Starting batteries are not warranted by Generac Power Systems Inc All transportation costs under warranty including return to the factory if necessary are borne by the purchaser and paid by him This warranty does not include normal maintenance and service and does not apply to engines or parts which have been subjected to improper or unauthorized installation misuse negligence accident overloading over speeding improper maintenance improper repair or improper storage so as in Generac Power Systems Inc s judgement to adversely affect its performance and reliability NORMAL WEAR As with all mechanical devices the GN Series engines requires periodic service and parts replacement example oil filter in accordance with the owner s manual schedules maintenance to insure proper performance of the engine This warranty will not cover repair when normal use has exhausted the life of a part or engine There is no other expressed warranty GENERAC POWER SYSTEMS INC HEREBY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT PERMITTED BY LAW The duration of any implied warranties which cannot be disclaimed is limited to the time period one year as specified in the expressed warranty Liability for consequential incidental or special dam
14. Manual No A8926 GENERAC ENGINES SAFETY RULES Overhead Valve Industrial GENERAL Owners Manual Bierg OPERATION v MAINTENANCE gt TROUBLESHOOTING Model No 190 220 6 5 7 8 Horsepower THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER A THE PERSONAL SAFETY AND OR PROPERTY OF YOURSELF AND OTHERS READ AND FOLLOW ALL INSTRUCTIONS IN THE MANUAL BEFORE ATTEMPTING TO OPERATE THIS UNIT Revision 0 11 16 98 Printed in U S A Generac GN 190 220 Engine If you don t understand any portion of this manual contact Generac for a demonstration of actual starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING and CAUTION blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly Observe them carefully These safety warnings cannot eliminate the hazards that they indicate Strict compliance with the special instructions while performing the service plus common sense are major measures to prevent accidents The following definitions apply to DANGER WARNING CAUTION and NOTE blocks found throughout the manual These safety symbols indicate the following DANGER After this heading you can read handling installing operating or servicing instructions that if not strictly
15. ages under any and all warranties is excluded to the extent permitted by law Some states do not allow limitations on how long an implied warranty lasts or the exclusions or limitations of consequential or incidental damages so the limitations or exclusions do not apply This warranty provides the original purchaser specific legal rights and the original purchaser may also have other rights which vary state to state For service please see your nearest Generac Power Systems Inc Authorized Service Dealer or call 414 544 4811 Warranty service can only be performed by a Generac Power Systems Inc Authorized Service Dealer This warranty does not apply to service performed at any other facility or dealership At the time of requesting warranty service evidence of the original purchase date must be presented GENERAC CORPORATION P O BOX 8 WAUKESHA WI 53187 TELEPHONE 414 544 4811 FAX 414 544 4851
16. aintenance on your utility or lawn and garden equipment engine but Generac Corporation will not deny warranty solely due to the lack of receipts or for your failure to provide written evidence of the performance of all scheduled maintenance As the utility or lawn and garden equipment engine owner you should however be aware that Generac Corporation may deny you warranty coverage if your utility or lawn and garden equipment engine or a part thereof has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your utility or lawn and garden equipment engine to a Generac Corporation Authorized Service Outlet as soon as a problem exists 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 a Generac Corporation Authorized Service Outlet or by contacting Generac Corporation at GENERAC CORPORATION PH 414 544 4811 P O BOX 8 FAX 414 544 0179 WAUKESHA WI 53187 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 Corporation pursuant to California law See also the Generac Corporation Limited Warranties for Generac Corporation which is enclosed herewith on a separate sheet and also is provided to you by Generac Corporation The ECS Warranty applies only to the emission contro
17. ame Be sure the engine is cool NOTE Using a fuel additive such as STA BIL fuel stabilizer or an equivalent will prevent gum deposits from forming in the engine s fuel system 2 While the engine is still warm drain the oil from the crankcase Refill with it with fresh oil See BEFORE STARTING ENGINE on Page 6 for oil recommendations 3 Remove spark plug and pour about 1 2 ounce 15ml of engine oil into the cylinder Crank slowly to distribute oil CAUTION Avoid spray from the spark plug hole when cranking the engine slowly 4 Install the spark plug Do not connect the spark plug wire 5 Clean the dirt oil and grease from the cylinder cylinder head fins blower housing rotating screen and muffler area 6 Close the fuel shut off valve E s MAINTENANCE gt OTHER STORAGE TIPS 1 2 3 Do not store gasoline from one season to another Replace the gasoline can if it starts to rust Rust and or dirt in a gasoline can cause problems when you use that fuel with this equipment Store the equipment in a clean and dry area SPECIFICATIONS GN 190 GN 220 Bore Stroke Valve Clearance Displacement Maximum Tilt Angle While Operating 5 5 Oil Capacity with Oil Filter 770ml 29 oz 770ml 29 oz Oil Capacity without Oil Filter 620ml 21 oz 620ml 21 02 L RS 11A 11B 10 EXPLODED VIEW SHORT BLOCK Generac GN 190 220 Engine jd G
18. ank is overfilled the fuel can overflow onto a hot engine and cause a FIRE or an EXPLOSION Allow at least two 2 feet of clearance on all sides of the engine even while operating it outdoors or you could damage the engine Thoroughly inspect the engine for loose or damaged parts before each use Do not use the engine until adjustments or repairs are made Check the oil level in the engine before each use Inspect the engine periodically Repair or replace all damaged or defective parts immediately Inspect fuel system frequently for leaks or damage Repair or replace any damaged or leaking component immediately Never attempt to change alter or modify the engine fuel system in any way that might affect safety or compliance with applicable codes and standards M WHILE OPERATING This engine was designed and manufactured for specific applications Do not attempt to modify the equipment or use it for any application for which it was not designed Engine exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Operate this equipment only in the open air where adequate ventilation is available SAFETY RULES AN Do not insert any object through the cooling slots of the engine You could damage the equipment or injure yourself Do not operate the engine faster than the speed necessary to operate the equipment Do not run the en
19. e 11 Retorquing Head Bolts 12 Maintenance Schedule sss 12 Storage Instructions 13 SDEOLICZIANS UL 13 PARTS LISTS amp EXPLODED VIEWS 14 21 WARRANTIES E 22 24 California Emission Control Warranty Statement 22 Emission Control System Warranty 23 Generac Engine Warranty Back Cover Generac GN 190 220 Engine OIL AND FUEL INFORMATION NOTE BE SURE TO READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO START OR OPERATE THIS EQUIPMENT Using old or improper oil or fuel can cause engine damage CAUTION Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in engine damage EM RECOMMENDED OIL TYPE Using the proper type and weight of oil in the crankcase is extremely important Check the oil before each use and change the oil regularly Failure to use the correct oil or using dirty oil can cause premature engine wear and failure GENERAL INFORMATION The recommended oils include the following During summer months SAE 10W 30 During winter months SAE 5W 20 or 5W 30 DO NOT USE SAE 10W 40 The crankcase oil capacity is about 770 ml 29 oz with the oil filter Without the filter the oil capacity is 620ml
20. econds after it shuts down the engine may NOT start The system needs 5 to 10 seconds to reset 1 Pressthe primer bulb three 3 times waiting two 2 seconds between each push Figure 5 Figure 5 Pressing the Primer Bulb NOTE f you do restart engine after a shutdown and have not corrected the low oil pressure the engine will run for about 10 seconds as described above and then it will stop Generac GN 190 220 Engine GENERAL MAINTENANCE RECOMMENDATIONS The owner operator is responsible for making sure that all periodic maintenance tasks are completed on a timely basis that all discrepancies are corrected and that the equipment is kept clean and properly stored Never operate a damaged or defective engine CAUTION Disconnect the spark plug wire from the spark plug and place the wire where it cannot come in contact with the spark plug before working on this engine M CHECKING THE OIL LEVEL See the BEFORE STARTING THE ENGINE section on page 6 for information on checking the oil level The oil level should be checked before each use or at least every eight 8 hours of operation Keep the oil level maintained EM CHANGING THE OIL AND OIL FILTER Your engine may be equipped with an oil filter Change the oil and filter after the first eight 8 hours of operation Change the oil and oil filter if so equipped every 50 hours thereafter If you are using this engine under dirty or dust
21. enerac GN 190 220 Engine SHORT BLOCK ITEM DESCRIPTION PART NO QTY ITEM DESCRIPTION PART NO QTY N A Long Block Assembly 21942E 1 28 M8 1 25 x 35mm Screw 89230 6 190cc used with Item 8A 29 Spring Washer 99922 1 Long Block Assembly 21943E 1 30 Valve Spring Retainer A1720 2 190cc used with Item 8B 31 Valve Spring 88401 2 Long Block Assembly 21944E 1 32 Valve Spring Wear Washer 84186 2 220cc used with Item 8A 33 Geroter Set 83192 1 Long Block Assembly 21945E 1 34 O Ring 86254 1 220cc used with Item 8B 36 Cylinder Head Assembly 21705B 1 1 Control Rod Assembly 78621 1 37 Exhaust Valve 90082 1 2 Piston Pin 76389 1 38 Intake Valve 90081 1 3A Piston Ring Set 190cc 78660 1 39 Push Rod 88396A 2 3B Piston Ring Set 220cc 88411 1 40 Tappet 83235 2 4 Gear Cover Assembly A8897A 1 41 Oil Pick up Assembly 80336 1 5 M8 x 52mm Head Bolt 77168 5 42 Rocker Cover Gasket 96362 1 6A Piston 190cc 90325 1 43 Pivot Ball Stud 77161 2 6B Piston 220cc 88057 1 44 GN 190 220 Rocker Arm 77160 2 7 Pin Retainer Ring 76390 2 45 Rocker Arm Jam Nut 76307 2 8A Tapered Crankshaft Assm 83337A 1 46 Push Rod Guide Plate 88403 1 8B Straight Crankshaft Assm 83338A 1 47 1 4 NPT Pipe Plug 72657 2 9 Governor Pin 78658 1 48 Rocker Cover Assembly 88412 1 10 Gov Arm Thrust Washer 78659 1 49 Plastic Oil Fill Plug 76329 1 11A Crankcase Assm 190cc 89213K 1 11B Crankcase Assm 220cc 89213J 1 12 Governor Arm A7637 1 13 Oil Seal 81695
22. engine will not run properly and may get damaged if it is run with a dirty air cleaner system Clean or replace the paper air filter Figure 7 every 50 hours of operation or once a year whichever comes first Clean or replace the filter more often if the engine is operated under dusty or dirty conditions Clean the foam pre filter every 25 hours of operation or sooner under dusty or dirty conditions Generac GN 190 220 Engine MAINTENANCE gt CAUTION Never run this equipment without the complete clean or replace the foam pre filter air cleaner system installed on the engine This could result in premature wear to the engine A Wash the pre filter in soapy water B Squeeze the pre filter dry with a clean cloth DO Use the following instructions to clean or replace the NOT TWIST ir cleaner components n air Sealer components NOTE If the pre filter is still dirty after washing and drying it 1 Loosen the two screws on the air cleaner cover Remove the replace it with a new one ir C Apply enough clean engine oil to saturate the pre Figure 7 Removing the Air Cleaner Cover filter D Wrap the pre filter in a clean dry cloth and squeeze Pre Filter may out the excess oil DO NOT TWIST Set the pre filter stick to cover aside 4 Toclean or replace the paper air filter A Clean the air filter by tapping it gently on a solid surface NOTE If the filter is too dirty replace
23. g 12 84329 1 3 Pin Male HSG 25B 86643 1 50Hz Gov Spring 13 00185271 1 White Wire Assembly 26 66476 1 M6 X 12 HHCS 15 82981 2 M6 X 30 Taptite 28 83781 1 Governor Brkt 16 81675 1 Ignition Col 29 86384 1 Governor Rod 17 84274 1 Tinnerman Clamp 30 86037 1 Anti Lash Spring 18 87221A 1 L O S Module 100 83782 1 Idle Coil ASM 19 45756 1 M6 x 10mm Screw 101 66311 1 M8 1 25 Jam Nut 20 72347 1 Sparkplug D OOR Generac GN 190 220 Engine EXPLODED VIEW STEPPER MOTOR FLYWHEEL RECOIL STARTER ITEM PART QTY DESCRIPTION 85 78608A 1 Air Box Cover 86 90695A 1 Blower Housing 87 89739 1 Lower Wrapper 88 66476 9 M6 X 12 HHCS 89 A2799 1 Recoil Assembly ITEM QTY DESCRIPTION 90 2842 1 Recoil Cup 55 83512 2 M8 X 15 Taptite 91 78651C 1 Backplate 78 82774 1 Woodruff Key 92 59636 1 4 X 3 37 Long 79A SRV77182T 1 191 Flywheel 93 86296 1 Governor Rod 79B SRV77182E 1 220 Flywheel 94 88905 1 Extension Spring 80 83312 1 Conical Washer 95 89477 1 Spring Clip 81 81810 1 M16 Hex Nut 96 89478 1 Snap Button 82 92984 1 Top Wrapper 97 40976 1 SHCS M8 1 25 X 20 83 45756 4 M6 X 10 Taptite 98 90192 1 Carb Wear Washer 84 78609 2 Cover Bolts 99 92059 1 Stepper Motor Generac GN 190 220 Engine CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Corporation are pleased to explain the Emission Control System Warranty on your new utility or lawn and garden eq
24. gine at high speed when not operating the equipment This engine requires an adequate flow of cooling air for its continued proper operation Never operate the equipment inside any room or enclosure where the free flow of cooling air into and out of the equipment might be obstructed Without sufficient cooling air flow the engine quickly overheats damaging the engine or nearby property Do not smoke around the engine Wipe up any fuel or oil spills immediately Never leave oily or fuel soaked rags around the engine Keep the area around the engine clean and free of debris Keep hands feet clothing etc away from moving parts of this engine Never operate the engine a in the rain b in any enclosed compartment c if the engine speed changes d if the engine sparks e if flame or smoke is observed while the engine is running Never work on this engine or handle any electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRIC SHOCK will result Generac GN 190 220 Engine This engine meets the 1998 and later California emissions regulations To ensure that your engine continues to meet these regulations refer to the following information and instructions in this owner s manual SERVICE INFORMATION Service on this engine within and after the warranty period can be performed by any authorized service dealer Service technicians are factory trained and capable of hand
25. l system of your new engine To the extent that there is any conflict in terms between the ECS Warranty and the Generac Corporation Warranty the ECS Warranty shall apply except in any circumstances in which the Generac Corporation Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Corporation Warranty describe important rights and obligations with respect to your new engine Warranty service can only be performed by a Generac Corporation Authorized Service Outlet At the time of requesting warranty service evidence must be presented of the date of the sale to the original purchaser The purchaser shall pay any charges for making service calls and or for transporting the products to and from the place where the inspection and or warranty work is performed The purchaser shall be responsible for any damage or loss incurred in connection with the transportation of any engine or any part s thereof submitted for inspection and or warranty work IF YOU HAVE ANY QUESTIONS REGARDING YOUR WARRANTY RIGHTS AND RESPONSIBILITIES YOU SHOULD CONTACT GENERAC CORPORATION AT 1 800 222 3136 Generac GN 190 220 Engine EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and Later Model Year Utility and Lawn and Garden Equipment Engines A Applicability This warranty shall apply to 1995 and later model year utility and lawn and garden equipment engines The ECS Warranty Period ECS Warra
26. ling all service needs When contacting an authorized service dealer or the factory about parts and service always supply the complete model number and serial number of your unit as given on its data plate decal The warranty and replacement parts for this engine are included in the owner s manual When ordering engine components you must provide the authorized service dealer with the engine identification number which is located on the engine identification decal See the illustration below for the location of the decal oj Generac Corporation KO Eng Identif No XXXXXX Displacement XXX GENERAL INFORMATION TABLE OF CONTENTS RULES FOR SAFE OPERATION 2 3 GENERAL INFORMATIONI 4 5 Service Information T 4 Engine Identification Decal Location 4 Oil and Fuel 1 RA EE O 5 OPERATION lo ZE 6 7 Before Starting the Engine sss 6 Starting the Engine a asa 6 7 Stopping the Engine esej 7 Low Pressure Shutdown System 7 MAINTENANCE seen 8 13 General Maintenance Recommendations 8 Service and Adjustments ENEE 8 10 Carburetor Adjustments EEN 11 Checking Adjusting Valve to Rocker Arm Clearanc
27. nty Period shall begin on the date the new engine or equipment is delivered to its original end use purchaser and shall begin on the date the new engine or equipment is delivered to its original end use purchaser and shall continue for 24 consecutive months thereafter B General Emissions Warranty Coverage Generac Corporation warrants to the original end use purchaser of the new engine or equipment and to each subsequent purchaser that each of its utility and lawn and garden equipment engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pursuant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period will 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 only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts which 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 Corporation according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period
28. nutes before using the equipment STOPPING THE ENGINE 1 Remove the load on the engine and let it run for 30 seconds 2 Turn off the engine by moving the RUN STOP SWITCH to the STOP position 3 Close the fuel shut off valve if so equipped LOW PRESSURE SHUTDOWN SYSTEM 3 Move the choke lever to the HALF CHOKE POSITION The engine is equipped with a low oil pressure sensor that shuts and pull the recoil handle Figure 4 two 2 times down the engine automatically when the oil pressure drops below 8 psi If the engine shuts down by itself and the fuel tank has enough If the engine STILL FAILS TO START repeat gasoline check the engine oil level Steps 1 3 4 Move the choke lever to the RUN POSITION by sliding it M INITIAL STARTUP to the right away from the valve cover and under the A delay built in the shutdown system allows oil pressure to build arrow during starting The delay allows the engine to run for about 10 5 Allow the engine to warm up for two 2 minutes before seconds before sensing oil pressure using the equipment EM SENSING LOW PRESSURE If this engine is equipped with a primer bulb use If the system senses low oil pressure during operation the the following instructions engine shuts down As the system shuts down the low oil light comes ON see Figure 2 page 6 However once the engine stops rotating this light will go OFF i RESTARTING THE ENGINE If you try to restart the engine within 5 s
29. ration shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac Corporation 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 owner Such use shall not reduce Generac Corporation ECS warranty obligations 9 Unapproved add on modified parts may not be used to modify or repair a Generac Corporation engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac Corporation shall not be liable hereunder for failures of any warranted parts of a Generac Corporation engine caused by the use of such an unapproved add on or modified part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Carburetor assembly and it s internal components 3 Ignition system including a Fuel filter a Spark plug b Carburetor gaskets b Ignition module c Intake pipe 4 Catalytic muffler if so equipped 2 Air cleaner assembly a Muffler gasket if so equipped a Air filter element b Exhaust manifold if so equipped 5 Crankcase breather assembly and its components
30. stor screen as follows Inspect the screen and replace if it is torn perforated or otherwise damaged see Steps 1 4 below DO NOT USE a defective screen If the screen is not damaged clean it with a commercial solvent If the spark arrestor is found to be damaged or defective replace it as follows 1 Remove the four 4 screws that connect the heat shield to the muffler Figure 9 2 Remove the four 4 screws that attach the spark arrestor screen Figure 9 3 Replace damaged screen with new screen Part No 83083 4 Reattach the screen and the heat shield with the four 4 screws Resintall the heat shield to the muffler with the four 4 screws MAINTENANCE gt Figure 9 Removing Heat Shield Spark Arrestor Screen 83083 SERVICE AND ADJUSTMENTS EM ENGINE SPEED CAUTION The engine speed was properly adjusted at A the factory and should require no additional adjustment Do not attempt to change engine speed If you believe the engine is running too fast or too slow take your engine to an authorized service center for repair and adjustment CHANGING THE ENGINE GOVERNED SPEED WILL VOID THE ENGINE WARRANTY Your engine runs at a constant speed This constant operating speed is maintained by a mechanical flyweight type fixed speed governor DO NOT try to adjust the governed speed setting for the following reasons Operating the
31. uipment engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the State s stringent anti smog standards Generac Corporation will warrant the emission control system on your utility or lawn and garden equipment for the periods of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your utility or lawn and garden equipment engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Also included may be the compression release system and other emission related assemblies Where a warrantable condition exists Generac Corporation will repair your utility or lawn and garden equipment engine at no cost to you for diagnosis parts and labor MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year utility and lawn and garden equipment engines are warranted for two years as hereinafter noted If during such warranty period any emission related part on your engine is defective in materials or workmanship the part will be repaired or replaced by Generac Corporation OWNER S WARRANTY RESPONSIBILITIES As the utility or lawn and garden equipment engine owner you are responsible for the performance of the required maintenance listed in your owners manual Generac Corporation recommends that you retain all receipts covering m
32. y conditions or in extremely hot weather change the oil more often Use the following instructions to change the oil while the engine is still warm 1 Clean the area around the oil drain plug remove the plug and drain the oil completely into a suitable container Figure 6 Figure 6 Oil Filter and Drain Plug Oil Filter Drain Plug MAINTENANCE gt 2 When the oil is drained install and tighten the oil drain plug 3 lf your engine is equipped with an oil filter use the following instructions A Place a suitable container beneath the oil filter and turn the filter counterclockwise to remove the filter B Coat the gasket of a new filter with engine oil Turn the new filter clockwise until the gasket contacts the filter adapter then tighten an additional 3 4 turn 4 Remove the oil fill plug and insert a clean funnel into the plug opening Fill the crankcase with the recommended oil until the oil level is at point of overflowing Approxi mately 620ml 21 oz are required without an oil filter 770ml 29 oz with an oil filter POUR SLOWLY 5 When the crankcase is filled to the proper level install and tighten the oil fill plug i SERVICING THE AIR CLEANER Your equipment s air cleaner is one of the most important areas to maintain This
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