Generac Power Systems GN190H Service And Repair Manual Download Page 6

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DIMENSIONS AND FEATURES

GENER

PTO SIDE VIEW

BOTTOM VIEW — MOUNTING HOLES

Summary of Contents for GN190H

Page 1: ......

Page 2: ...f and advise the service trade of all conceivable procedures or methods by which a service might be per formed nor of any possible hazards and or results of each proce dure or method We have not under...

Page 3: ...SHAFT REPLACEMENT 19 Inspection 19 Removal 19 Installation 19 LINKAGE INSTALLATION 19 GOVERNOR ADJUSTMENT 19 20 Initial Adjustment 19 20 Running Adjustment 20 SECTION 4 OPTIONAL IDLE CONTROL 22 23 GE...

Page 4: ...40 Installation 41 CYLINDER SERVICE 41 Inspection 41 Reboring the Cylinder 41 SECTION 11 CRANKSHAFT AND CAMSHAFT 42 45 CAMSHAFT REMOVAL 42 Removal of Crankcase Cover 42 Camshaft Removal 42 CRANKSHAFT...

Page 5: ...ns that if not strictly complied with may result in personal injury CAUTION After this heading you can read instruc tions for handing installing operating or servicing the engine that if not strictly...

Page 6: ...4 DIMENSIONS AND FEATURES G E N E R A C PTO SIDE VIEW BOTTOM VIEW MOUNTING HOLES...

Page 7: ...5 DIMENSIONS AND FEATURES FRONT VIEW...

Page 8: ...6 DIMENSIONS AND FEATURES G E N E R A C STARTER SIDE VIEW PTO CRANKSHAFT OPTIONS VIEW...

Page 9: ...FT 6 ROCKER COVER BREATHER 7 CONNECTING ROD 8 PISTON RING SET 9 OIL PICK UP ASSEMBLY 10 CRANKCASE COVER GASKET 11 PISTON 12 PISTON PIN 13 SNAP RING 14 TAPPET 15 PUSH ROD 16 OIL PUMP 17 CYLINDER HEAD G...

Page 10: ...ugh the open intake valve into the cylinder When the piston reaches BDC the intake stroke is over B COMPRESSION As the piston reaches bottom dead center BDC both the intake and exhaust valves are clos...

Page 11: ...ines Engine Models GN 190 GN 191 and GN 220 are desig nated as small frame engines The CHART on Page 3 lists most engine models that were available at the time this manual was published Some of the di...

Page 12: ...Thereafter change oil and filter every 50 hours of oper ation Change oil every 25 hours if operating under extremely dusty or dirty conditions or in very hot weather NOTE Engine may be equipped with...

Page 13: ...overnor Arm 1 13 Oil Seal 2 14 Governor Gear Assembly 1 15 Governor Gear C Ring 1 16 Governor Spool 1 17 1 8 NPT Pipe Plug 1 18 Camshaft Assembly 1 19 Crankcase Gasket 1 20 Valve Stem Seal 1 21 Cylind...

Page 14: ...ize dimension If the cylinder is worn excessively or damaged the crankcase must be replaced A standard size piston and rings can then be used OVERSIZE VALVES Oversize valves are not available at this...

Page 15: ...13 NOTES...

Page 16: ...e the paper filter 4 Clean the paper filter by tapping gently on a flat surface If it is very dirty replace it 5 Clean the air cleaner cover Then install the foam pre cleaner into the cover 6 Insert t...

Page 17: ...fuel and the ingestion of dirt Prior to ser vicing any carburetor be sure to check for evidence of these conditions Gasoline that is left in the system for long periods can form gum or varnish deposi...

Page 18: ...am aged or defective 4 If so equipped inspect the MAIN JET ADJUSTMENT Replace if necessary NOTE Later production carburetor may not be equipped with a MAIN JET ADJUSTMENT 5 The FLOAT BOWL Item 3 must...

Page 19: ...Float Pin 8 1 Inlet Valve 9 1 Fuel Inlet 10 1 Cap Screw 11 1 Throttle Shaft Felt Washer 12 1 Throttle Shaft Spring 13 1 Screw 14 1 Throttle Valve 15 1 Throttle Shaft 16 1 Idle Jet 17 1 Spring 18 1 Idl...

Page 20: ...ING d GOVERNOR SPOOL and e GOVERNOR SHAFT A lockpin and washer retain the governor shaft in the crankcase cover The governor gear assembly houses the governor flyweights Flyweight movement causes the...

Page 21: ...r See Section 11 Use care to avoid damage to the shaft boss area of the crankcase cover Clamp the shaft in a vise then tap the flange with a wooden or plas tic mallet to remove the shaft INSTALLATION...

Page 22: ...ilable 5 If the frequency or rpm reading is incorrect turn the SPEED ADJUST NUT Figure 3 3 on the governor until fre quency or rpm is within limits 6 If frequency or rpm is unstable turn the IDLE SPEE...

Page 23: ...21 NOTES...

Page 24: ...through the primary windings of a sensing transformer A proportional voltage and current will then be induced into the transformer s secondary windings c Current from the transformer secondary winding...

Page 25: ...the idle control switch to ON The idle control solenoid should energize and engine speed should decelerate to idle speed 7 If necessary back the carburetor s idle speed stop screw out so that governor...

Page 26: ...e the pulley and the engine is cranked When the rope is allowed to return the starter dogs do not engage the pulley REWIND ASSEMBLY REMOVAL The rewind starter assembly is retained to the engine blower...

Page 27: ...Install SPRING STARTER DOGS and DOG SPRINGS 3 Install RETAINER PAWL and SCREW Tighten the SCREW to 65 75 inch pounds 4 Wind the PULLEY counterclockwise until tight Then allow it to unwind until the ho...

Page 28: ...speed to provide sufficient torque to crank the engine The required engine cranking speed is relatively slow so the starter motor is equipped with a small drive pinion that meshes with the teeth of a...

Page 29: ...In most cases battery failure requires replacement of the battery The lead acid cells found in many products however still require mainte nance Maintenance of lead acid batteries falls into three cat...

Page 30: ...ts if temperature is above 80 F Subtract the required points if below 80 F see Figure 6 3 5 Check and record readings of the remaining cells in the same manner 6 When all cells have been checked subtr...

Page 31: ...ER SHROUD see Figure 7 1 4 Remove the remaining capscrew from the UPPER SHROUD see Figure 7 1 NOTE The blower cover is notched at the point where the governor rod and anti lash spring pass through it...

Page 32: ...l Assembly SPARK PLUG The spark plug should be cleaned and regapped periodi cally The plug should be replaced every 100 hours of operation or once annually whichever comes first Recommended spark plug...

Page 33: ...apidly If spark jumps the gap of the spark tester you may assume the ignition system is operating sat isfactorily Figure 8 5 Testing Ignition System NOTE If the flywheel key is sheared or partially sh...

Page 34: ...take and exhaust pivot ball studs rocker arms and push rods are identical However the wear patterns will be different Figure 9 3 Rocker Arms and Push Rod Guide Plate 3 Remove the PUSH RODS see Figure...

Page 35: ...n 0 039 inch 1mm If valves are in usable con dition grind or cut the valve faces to a 45 angle see Figure 9 6 Figure 9 6 VALVE SEATS Valve seats are not replace able If they are burned or pitted they...

Page 36: ...haft is removed Intake and exhaust valve tappets are iden tical However once a wear pattern has been established the two parts should not be interchanged Figure 9 10 Tappet VALVE SPRINGS Inspect the v...

Page 37: ...again to the second torque specification TORQUE SPECIFICATION CYLINDER HEAD BOLTS First Sequence TORQUE 15 foot pounds or 180 inch pounds CYLINDER HEAD BOLTS Second Sequence TORQUE 22 foot pounds or 2...

Page 38: ...Loosen the rocker arm jam nut Use an allen wrench to turn the pivot ball stud while checking the clearance between the rockerarmandvalvestemwithafeelergauge seeFigure9 16 Figure 9 16 Adjusting Valve C...

Page 39: ...NOTES 37...

Page 40: ...and separate the piston from the connecting rod CHECK PISTON FOR WEAR The piston is slightly elliptical Its larger diameter is 90 from the wrist pin boss its smaller diameter is in line with the wris...

Page 41: ...they might break Use a ring compressor when installing the piston into the cylinder When installing NEW rings deglaze the cylinder walls with a commercially available deglazing tool DESCRIPTION A pist...

Page 42: ...ng rings into the piston grooves Figure 10 7 Match Marks Facing Up b Install the oil ring assembly first c Install the second compression ring with its chamfer facing up d Finally install the top comp...

Page 43: ...ated with clean engine oil as well as the crankpin and connecting rod cap 8 Guide the connecting rod large diameter bearing over the crankshafts crankpin rod journal 9 Install the connecting rod cap w...

Page 44: ...s of cover Be aware that the oil pump rotors may drop out as the crankcase cover is removed Figure 11 1 Crankcase Cover Removal CAMSHAFT REMOVAL See Figure 11 2 1 Tip the engine over onto the flywheel...

Page 45: ...Make sure they are not worn or spread apart Remove burrs from edges of keyways to prevent scratching the bearing 2 Inspect the crankshaft gear for chipping or cracking If timing gear is damaged the c...

Page 46: ...se cover for damage and wear Figure 11 7 a Measure the Inside diameter of the bearing bore b If the bore is worn excessively replace the crankcase cover CRANKCASE BEARING BORE IN CRANKCASE COVER DESIG...

Page 47: ...gear side of the crankcase Figure 11 10 Timing Mark on Crankshaft Gear NOTE If the crankshaft gear is spun on the crankshaft the timing will be off If this happens the crankshaft must be replaced CAMS...

Page 48: ...Through the crankshaft to the crankpin and connecting rod bearing Figure 12 1 Lubrication System Diagram OIL PICKUP ASSEMBLY DESCRIPTION The oil pickup assembly consists of a plastic body and an oil...

Page 49: ...PUMP ROTOR TIP CLEARANCE DESIGN CLEARANCE 0 0000 0 0010 inch 0 000 0 025mm INNER ROTOR I D DESIGN DIAMETER 0 354 0 355 inch 9 000 9 019mm INNER ROTOR THICKNESS DESIGN THICKNESS 0 312 0 315 inch 7 95 8...

Page 50: ...rings The CHECK VALVE allows excess pressure to be vented out of the crankcase and to atmosphere through the BREATHER TUBE Two small DRAIN HOLES allow condensed oil vapors to return to the crankcase...

Page 51: ...ing marks on the crankshaft and camshaft gears are properly aligned 4 Place the crankcase cover gasket onto the crankcase flange 5 Apply engine oil to the crankshaft and camshaft journals 6 Apply engi...

Page 52: ...Then install the filter and tighten until its seal contacts the filter adapter After the filter seal contacts the adapter tighten 3 4 to 1 turn more See Figure 12 12 Section 12 12 Optional Oil Filter...

Page 53: ...Switch With Optional Oil Filter Figure 12 15 Low Oil Switch Without Optional Oil Filter TORQUE SPECIFICATION OIL FILTER ADAPTER BOLT TORQUE 9 foot pounds or 108 inch pounds TORQUE SPECIFICATION LOW OI...

Page 54: ...nt valve clearance Warped cylinder head Warped valve stem Worn or broken piston ring s Worn or damaged cylinder bore Broken connecting rod Worn valve seats or valves Worn valve guides CHECK IGNITION S...

Page 55: ...nce e Reset to correct clearance 3 Engine misses under load a Incorrect spark plug a Install correct spark plug b Spark plug is fouled b Clean and regap spark plug c Spark plug porcelain is cracked c...

Page 56: ...FORCE REQUIRED TO COMPRESS SPRING TO 1 39 INCH 35 2mm 14 8 16 3 pounds 19 8 21 8 pounds 19 8 21 8 pounds 6 7 7 4kg 9 0 9 9kg 9 0 9 9kg VALVE CLEARANCE INTAKE 0 001 0 003 inch 0 001 0 0022 inch 0 001 0...

Page 57: ...1 025 inch 1 024 1 025 inch 26 00 26 03mm 26 00 26 03mm 26 00 26 03mm GOVERNOR ARM DIAMETER DESIGN DIAMETER 0 235 0 237 inch 0 235 0 237 inch 0 235 0 237 inch 5 97 6 03mm 5 97 6 03mm 5 97 6 03mm CRAN...

Page 58: ...184 inch 1 183 1 184 inch 1 183 1 184 inch 30 06 30 07mm 30 06 30 07mm 30 06 30 07mm SMALL END INSIDE DIAMETER DESIGN DIAMETER 2 196 2 213 inch 2 196 2 213 inch 2 196 2 213 inch 55 8 56 2mm 55 8 56 2m...

Page 59: ...GN WIDTH 0 057 0 059 inch 0 057 0 059 inch 0 057 0 059 inch 1 47 1 49mm 1 47 1 49mm 1 47 1 49mm TOP RING END GAP DESIGN END GAP 0 005 0 016 inch 0 005 0 016 inch 0 005 0 016 inch 0 15 0 40mm 0 15 0 40...

Page 60: ...T TAPPET DESIGN LIFT 0 027 0 055 inch 0 027 0 055 inch 0 027 0 055 inch 0 70 1 40mm 0 70 1 40mm 0 70 1 40mm OIL PUMP MODEL GN 190 GN 191 GN 220 PUMP TIP CLEARANCE DESIGN CLEARANCE 0 0000 0 0010 inch 0...

Page 61: ...in lbs 18 ft lbs 216 in lbs 18 ft lbs 216 in lbs Ignition Coil Bolts 5 ft lbs 60 in lbs 5 ft lbs 60 in lbs 5 ft lbs 60 in lbs Spark Plug 13 ft lbs 156 in lbs 13 ft lbs 156 in lbs 13 ft lbs 156 in lbs...

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Generac Power Systems GN190H, Service And Repair Manual

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