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34

Section 9 — Exploded Views and Parts Lists

Commercial-Industrial-Residential Portable Generator System

GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589-R

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Содержание 005308-0

Страница 1: ...OUBLESHOOTING ELECTRICAL DATA PARTS WARRANTY 1 800 333 1322 Portable Generator COMMERCIAL INDUSTRIAL RESIDENTIAL MODEL 005308 0 17 500 Watt Portable Generator and 60 amp manual transfer switch with built in load center AUTHORIZED DEALER SUPPORT ...

Страница 2: ... 2 9 Automatic Idle Control 12 2 10 Cold Weather Operation De Icer 12 2 11 Low Oil Pressure Shutdown 12 2 11 1 Initial Start up 12 2 11 2 Sensing Low Oil Pressure 12 2 11 3 Restarting 12 2 12 Charging a Battery 13 Section 3 Maintenance 14 3 1 Maintenance Schedule 14 3 2 Product Specifications 14 3 2 1 Generator Specifications 14 3 2 2 Engine Specifications 14 3 3 General Recommendations 15 3 3 1 G...

Страница 3: ...ent 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 your generator The generator produces dangerously high voltage that can cause extremely hazardous electrical shock Avoid contact with bare wires terminals etc Never permit any unqualif...

Страница 4: ... of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS Never operate in an enclosed area or indoors For safety reasons GENERAC recommends that the maintenance of this equipment is carried out by a GENERAC Authorized Dealer The engine exhaust fumes contain carbon monoxide which can be DEADLY This dangerous gas if breathed in sufficient conce...

Страница 5: ...ocal 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 operating condition Keep a fire extinguish...

Страница 6: ...ver the road use Refer to Figure 2 shown on opposite page and install the wheel kit as follows Place the generator on a hard flat surface Stand at the engine end of the unit and gently tilt the generator forward high enough to place wooden blocks beneath the cradle This will allow space to install the wheel assemblies Attach an axle bracket assembly with attached sleeve to either side of the frame...

Страница 7: ... Connect the RED battery cable to the battery Positive terminal After making sure that the connection is tight slip the rubber boot over the terminal connection Connect the BLACK battery cable to the battery Negative terminal Make sure the connection is tight Double check all connections to ensure they are in the correct location and secure See Figure 3 at right Figure 3 Battery Connections Sectio...

Страница 8: ...ghting 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 o...

Страница 9: ...njury 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 suc...

Страница 10: ...t is protected by two 30 Amp push to reset circuit breakers 2 2 5 12 VOLT DC 10 AMP RECEPTACLE This receptacle allows you to recharge a 12 Volt automotive or utility style storage battery with the battery charge cables provided This receptacle can not recharge 6 Volt batteries and can not be used to crank an engine having a discharged battery See the section Charging a Battery page 13 before attem...

Страница 11: ...nected at one time This total should not be greater than a the rated wattage amperage capacity of the generator or b circuit breaker rating of the receptacle supplying the power See Don t Overload the Generator below 2 4 DON T OVERLOAD THE GENERATOR Overloading a generator in excess of its rated wattage capacity can result in damage to the generator and to connected electrical devices Observe the ...

Страница 12: ...rimmer 500 Allow 3 times the listed watts for starting these devices 10 Section 2 Operation Residential Portable Generator System 2 6 BEFORE STARTING THE GENERATOR Prior to operating the generator engine oil and gasoline will need to be added as follows 2 6 1 ADDING ENGINE OIL NOTE When adding oil to the engine crankcase in the future use only high quality detergent oil rated with API service clas...

Страница 13: ...ing storage Alcohol blended fuels called gasohol ethanol or methanol can attract moisture which leads to separation and formation of acids during storage Acidic gas can damage the fuel system of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer See Storage on page 18 Never use engine or carburetor cleaner products in the fuel ...

Страница 14: ...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 2100RPM 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...

Страница 15: ...ry 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 If the battery is equipped with vent caps make sure they are installed and are tight If necessary...

Страница 16: ...urs 1 6 gallons per hour Consumption 1 2 Load Check Oil Level Service Air Pre Cleaner Change Oil and Oil Filter Clean Spark Arrestor Screen Adjust Valve Clearance Service Air Cleaner Replace Spark Plugs Change oil after first 8 hours of operation then every season Change oil and oil filter every month when operating under heavy load or in high temperatures Clean more often under dirty or dusty ope...

Страница 17: ... to wipe exterior surfaces clean A soft bristle brush may be used to loosen caked on dirt oil etc A vacuum cleaner may be used to pick up loose dirt and debris Low pressure air not to exceed 25 psi may be used to blow away dirt Inspect cooling air slots and openings on the generator These openings must be kept clean and unobstructed 3 3 3 ENGINE MAINTENANCE DANGER When working on the generator alw...

Страница 18: ...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 ne...

Страница 19: ...en it is up as high as it can go Insert 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 Use an 10mm allen wrench to turn the pivot ball stu...

Страница 20: ...ine 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 an...

Страница 21: ...h fuel 4 Spark plug wire not connected to 4 Connect wire to spark plug spark plug 5 Bad spark plug 5 Replace spark plug 6 Water in gasoline 6 Drain fuel tank fill with fresh fuel 7 Overchoking 7 Put choke knob to No Choke position 8 Low oil level 8 Fill crankcase to proper level 9 Excessive rich fuel mixture 9 Contact Authorized Service Facility 10 Intake valve stuck open or closed 10 Contact Auth...

Страница 22: ...d length will be determined by the materials you will be drilling and cutting open end wrenches or adjustable wrenches socket wrenches or nut drivers standard and Phillips screwdrivers sledge hammer level pencil channel lock pliers wire cutters strippers and safety goggles ITEMS YOU MUST PURCHASE 60 AMP double pole circuit breaker must be the same type as in your main electrical distribution panel...

Страница 23: ...ou have clearance on each side of the wall drill a small pilot hole through the wall to mark the location With hole saw drill hole through the sheathing and siding 4 Measure the lengths of wire and conduit needed to reach the Manual Transfer Switch Allow extra length to clear the joists studs While adhering to all local electrical codes route the customer supplied conduit and wiring along ceiling ...

Страница 24: ...ring 9 Locate manual transfer switch with built in emergency load center within one foot of main distribution panel The manual transfer switch should be located to the right of the main distribution panel Hold transfer switch against the mounting surface Level the transfer switch and mark the mounting holes Drill the appropriate size pilot holes Mount the manual transfer switch to mounting surface...

Страница 25: ...rom a circuit breaker that protects a circuit you want to have powered in the event of a power failure Wire nut the black wire to the matching circuit lead wire from the emergency circuit breaker from load center in the transfer switch All circuit wires are color coded and labeled for easy identification Repeat this process with remaining circuits to be powered by the generator Trace each black ho...

Страница 26: ...e receptacle which is inserted and twist locked into the power inlet box At the other end is the male connector NEMA 14 50 which plugs into the portable generator s control panel and is locked in place by the supplied spring retainer The power inlet box must be locked to ensure safety and to discourage tampering 24 Section 6 Operation of Generator with Manual Transfer Switch 17 500 WATT PORTABLE C...

Страница 27: ...supplying power to the load center circuits in the manual transfer switch TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored you will want to transfer back to that power source and shut down the generator This can be accomplished as follows 1 Switch the 50 Amp circuit breaker on the generator control panel to the OFF or Open position 2 Release the retainer clip from the NEM...

Страница 28: ...6 Operation of Generator with Manual Transfer Switch INTERCONNECTION DRAWING GENERAC 17 5 KW GENERATOR CONNECTED TO THE EXTERNAL CONNECTION BOX MANUAL TRANSFER SWITCH AND HOME S MAIN ELECTRICAL DISTRIBUTION PANEL ...

Страница 29: ...27 Section 7 Notes Residential Portable Generator System ...

Страница 30: ...ISTLOK WHITE WHITE 0 4 5 WHITE WHITE 2 WHITE WHITE 120V 20A 120V 20A GFCI GFCI X Y G C B C B CONTRO SWITC IDL ON OF 60A 60A 50A 60A OUTLET 50A 60A OUTLET 120 240V 120 240V 50A 50A 22 11 44 15B 229 14 167 0 86 0 0 15 15 0 55A 55 0 14 18 18 14 14 44A 44A 11A 11A 44A 44A 11A 11A 11 11 44 44 22 22 44 44 44 44 44 44 11 11 11 11 11 11 11 11 44 44 11 11 44 44 44B 44B 44 44 11B 11B 11 11 22 22 0 0 22 22 2...

Страница 31: ...IFIER CHARGE CHARGE BATTERY BATTERY CHARGE CHARGE BATTERY BATTERY RECTIFIER RECTIFIER D2 D2 R1 R1 22 22 ENGINE SHUTDOWN P C B ENGINE SHUTDOWN P C B ELECTRONIC GOVERNOR ELECTRONIC GOVERNOR CONTROL CONTROL SWITCH SWITCH IDLE IDLE ON OFF ON OFF 22S 22S 55 55 11S 11S 55A 55A TB2 TB2 TB1 TB1 BLK BLK CB1 CB1 BLK BLK RED RED 1 2 11 11 44 44 OUTLET IDLE CONTROL IDLE CONTROL TRANSFORMERS TRANSFORMERS 8 PIN...

Страница 32: ...R ELECTRONIC ELECTRONIC C1 10 C1 10 77A 77A 77 77 77 77 C1 8 C1 8 55 55 C1 5 C1 5 77A 77A C1 3 C1 3 55A 55A CONTROL CONTROL PRINTED CIRCUIT PRINTED CIRCUIT 167 167 5 229 229 TR2 TR2 86 86 22S 22S 8 9 10 10 6 7 83 83 TR1 TR1 0 15B 15B 2 3 4 1 BOARD BOARD 11S 11S 22S 22S 11S 11S TB2 TB2 22S 22S 18 18 GOVERNOR GOVERNOR C2 1 C2 1 D3 D3 D2 D2 15 15 15B 15B 4 6 18 18 15B 15B 229 12 12 0 5 14 14 14 14 22...

Страница 33: ... NEUTRAL NEUTRAL NEUTRAL NEUTRAL NEUTRAL NEUTRAL CIRCUIT 13 CIRCUIT 13 CIRCUIT 11 CIRCUIT 11 CIRCUIT 3 CIRCUIT 3 CIRCUIT 1 CIRCUIT 1 CIRCUIT 7 CIRCUIT 7 CIRCUIT 5 CIRCUIT 5 CIRCUIT 15 CIRCUIT 15 CIRCUIT 15 CIRCUIT 15 CIRCUIT 11 CIRCUIT 11 GROUND BAR GROUND BAR ORG ORG LT BLU LT BLU DRK BLU DRK BLU PNK PNK YEL WHT YEL WHT YEL YEL BRN WHT BRN WHT BRN BRN WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT GRN G...

Страница 34: ...32 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Manual Transfer Switch with Load Center Drawing No 0G0939 B ...

Страница 35: ...RCUIT BREAKER 20A 1P 6 0E7888D 1 CIRCUIT BREAKER 40A 2P 7 0E7888E 2 CIRCUIT BREAKER 50A 2P 8 0E7888F 1 CIRCUIT BREAKER 60A 2P 9 0G0863 1 HARNESS 50 AMP PLUGS 10 0G0750 1 HARNESS LOAD CENTER TO MAIN PANEL 11 0G1494 1 POWER INLET BOX Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Manual Transfer Switch with Load Center Drawing No 0G0939 B ...

Страница 36: ...5 6 8 11 12 13 25 26 27 3 30 35 65 7 41 42 43 44 45 46 47 49 50 51 52 53 54 57 58 41 42 43 44 45 46 47 49 50 51 52 53 54 56 57 58 2 5 17 18 34 35 40 57 139 153 59 60 61 63 65 62 64 14 18 45 40 43 44 42 41 53 46 47 52 49 50 51 55 54 56 57 58 17 48 35 37 36 33 30 38 16 27 3 25 24 26 3 160 34 32 31 19 23 22 28 21 29 20 1 10 160 15 2 7 5 6 4 13 11 8 12 9 39 ...

Страница 37: ...998 1 CLAMP OIL TUBE 31 0D4497 1 PLUG CRANKCASE GOVERNOR BORE 32 0C3971E 1 ASSEMBLY DIPSTICK WITH HANDLE 33 0D3745 1 TUBE DIPSTICK 34 0C3027 3 O RING OIL CLR 35 0E9842 1 SEAL 42 I D CRANKSHAFT ITEM PART NO QTY DESCRIPTION 36 0G1526 1 ASSY GEAR COVER ADAPTOR W SLEEVE 37 0C3006 10 SCREW HHFC M10 1 5 X 55 38 080318 8 SCREW HHFC M6 1 0 X 25 39 0G1839 2 LIFT HOOK GT990 760 40 0D2723D 1 COVER ROCKER W O...

Страница 38: ...119 116 125 127 122 78 84 149 143 146 145 143 140 144 142 67 86 66 80 71 37 72 74 75 DETAIL A 153 87 69 81 73 68 70 82 83 151 150 85 79 135 141 138 137 154 128 129 108 132 131 130 134 133 126 155 DETAIL A 104 96 152 108 97 139 101 160 100 90 107 93 91 92 77 94 76 95 105 108 106 109 89 103 102 92 99 98 93 110 160 121 155 157 147 112 113 113 114 157 115 161 114 124 111 123 ...

Страница 39: ...LOW CHROME 109 0D4767 1 SWITCH ROCKER 110 0D1142A 1 WRAPPER LOWER CYLINDER 2 111 0D1143 1 WRAPPER UPPER CYLINDER 2 112 0F1177 1 ASSEMBLY GROUND WIRE 113 022097 4 WASHER LOCK M6 1 4 ITEM PART NO QTY DESCRIPTION 114 092079 4 SCREW TAPTITE M6 1 0 X 25 BP 115 0F1338B 1 ASSY IGN COIL W DIODE NO ADV 116 0F6263 1 PUMP IMPULSE 118 0G0926 2 SCREW HHFCS M6 1 0 X 16 G8 8 119 0G0832 1 ELBOW RUBBER 90 DEG GASO...

Страница 40: ...dustrial Residential Portable Generator System Generator Drawing No 0G0742 A 10 33 11 38 8 39 24 12 14 23 21 46 34 31 13 32 31 39 17 28 42 43 44 19 32 10 17 16 2 4 9 3 15 37 35 5 30 20 6 1 7 25 40 19 32 22 24 26 31 36 28 32 31 28 27 45 29 29 18 28 10 40 41 30 ...

Страница 41: ...C2417A 1 EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VINYL COAT 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 0C2824 1 SCREW TAP R 10 32 X 9 16 ITEM PART NO QTY DESCRIPTION 23 0A2038 1 WASHER FLAT 3 8 ZINC 24 022237 5 WASHER LOCK 3 8 25 022511 4 SCREW HHC 3 8 16 X 1 1 4 G5 26 022131 4 WASHER FLAT 3 8 M10 ZINC 27 051731 4 SCREW HHC M8 1 25 X 50 G8 8 28 022145 21 WASHER FLAT 5 16 ZINC 29 049820 4 NUT LOC...

Страница 42: ...40 Section 9 Exploded Views and Parts Lists Commercial Industrial Residential Portable Generator System Control Panel Drawing No 0G0727 B ...

Страница 43: ...2097 1 WASHER LOCK M6 1 4 37 049813 1 NUT HEX M6 1 0 G8 ITEM PART NO QTY DESCRIPTION 38 065795 2 RECTIFIER BATTERY CHARGER 39 0D4804 2 TRANSFORMER IDLE CURRENT 40 0C1085 4 SCREW PPHM M3 0 5 X 8 41 051715 12 NUT HEX M4 0 7 G8 15 KW 8 NUT HEX M4 0 7 G8 17 5 KW 42 022264 14 WASHER LOCK M4 43 048505 1 CIRCUIT BREAKER 6 X 1 44 087962 1 CIRCUIT BREAKER 10 X 1 12VDC 1 4 QC 45 036261 2 RIVET POP 125 X 250...

Страница 44: ...enerator System Frame Handle Wheel Kit Drawing No 0E0695 B 42 33 14 15 7 34 6 11 35 10 49 8 5 7 9 12 13 39 40 26 24 38 39 20 17 19 22 21 36 6 7 42 6 5 7 26 32 52 47 46 45 50 25 17 17 18 16 44 43 48 3 7 6 36 41 4 23 29 51 30 29 27 28 2 31 37 1 ENGINE WIRE TO POWER Detail of Battery Tray ...

Страница 45: ... 12 26 064101 6 NUT LOCK FL 3 8 16 27 039214 6 BOLT CARR 3 8 16 X 1 28 0D9165 1 AXLE 3 4 DIA X 30 15 kW ITEM PART NO QTY DESCRIPTION 29 045900 2 WASHER FLAT 3 4 15 kW 30 0D7668 2 12 3 PNEUM WHEEL 3 4 AXLE 15 kW 31 0D4999 2 PIN COTTER 1 8 X 1 1 4 32 0D4044 2 BRACKET WHEEL SPACER 33 0D3700 4 NUT FLANGE M6 1 0 NYLOK 34 0D2497 1 HANDLE 35 022532 4 SCREW HHC 5 16 18 X 2 1 2 G5 36 027028 6 NUT LOCK HEX ...

Страница 46: ...enance 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 A...

Страница 47: ... 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 ...

Страница 48: ...alers not authorized in writing by Generac Power Systems Any generator used for trailer mounted applications 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...

Страница 49: ......

Страница 50: ...88 4 SCREW HHTT M6 1 0 X 12 26 064101 6 NUT LOCK FL 3 8 16 27 039214 6 BOLT CARR 3 8 16 X 1 28 0D9165 1 AXLE 3 4 DIA X 30 15 kW 0D2496 1 AXLE 3 4 DIA X 27 25 12 5 kW 29 045900 2 WASHER FLAT 3 4 15 kW 045900 4 WASHER FLAT 3 4 12 5 kW 30 0D7668 2 12 3 PNEUM WHEEL 3 4 AXLE 15 kW 0D2495 2 10 PNEUM WHEEL 3 4 AXLE 12 5 kW 31 0D4999 2 PIN COTTER 1 8 X 1 1 4 32 0D4044 2 BRACKET WHEEL SPACER 33 0D3700 4 NU...

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