Generac Portable Generator 005308 0 User Manual
Portable Generator  
Owner’s  
Manual  
• SAFETY  
• ASSEMBLY  
• OPERATION  
• TROUBLESHOOTING  
• ELECTRICAL DATA  
• PARTS  
COMMERCIAL • INDUSTRIAL • RESIDENTIAL  
• WARRANTY  
MODEL: 005308-0  
17,500 Watt Portable Generator  
and 60 amp manual transfer switch  
with built-in load center  
AUTHORIZED DEALER SUPPORT:  
1-800-333-1322  
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We also strongly recommend instructing other users to properly  
start and operate the unit. This prepares them if they need to  
operate the equipment in an emergency.  
INTRODUCTION  
Thank you for purchasing this model of portable generator 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 when utility  
power is unavailable due to a power outage.  
CAUTION! Always disconnect spark plug wire and place the wire  
where it cannot contact the spark plug to prevent accidental  
starting when setting up, transporting, adjusting or making  
repairs to your generator.  
READ THIS MANUAL THOROUGHLY  
If you do not understand any portion of this manual, contact your  
nearest GENERAC® Authorized Dealer for starting, operating and  
servicing procedures.  
• The generator produces dangerously high voltage that can  
cause extremely hazardous electrical shock. Avoid contact with  
bare wires, terminals, etc. Never permit any unqualified person  
to operate or service the generator.  
Throughout this publication, and on tags and decals affixed to the  
generator, DANGER, WARNING, CAUTION and NOTE blocks are  
used to alert you to special instruction about a particular  
operation that may be hazardous if performed incorrectly or  
carelessly. Observe them carefully. Their definitions are as  
follows:  
• Never handle any kind of electrical cord or device while  
standing in water, while barefoot or while hands or feet are  
wet. Dangerous electrical shock will result.  
• The National Electric Code requires the frame and external  
electrically conductive parts of the generator be properly  
connected to an approved earth ground. Local electrical codes  
may also require proper grounding of the generator. Consult  
with a local electrician for grounding requirements in your area.  
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ƽ DANGER ƽ  
After this heading, you can read instructions that, if not strictly  
complied with, will result in serious personal injury, severe  
property damage and/or including without limitation, death.  
• Use a ground fault circuit interrupter in any damp or highly  
conductive area (such as metal decking or steel work).  
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• Do not use worn, bare, frayed or otherwise damaged electrical  
cord sets with the generator.  
ƽ WARNING ƽ  
After this heading, you can read instructions that, if not strictly  
complied with, may result in serious personal injury and/or  
property damage.  
• Operate generator only on level surfaces and where it will not  
be exposed to excessive moisture, dirt, dust or corrosive  
vapors.  
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ƽ CAUTION ƽ  
• 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.  
After this heading, you can read instructions that, if not strictly  
complied with, could result in damage to equipment and/or  
property.  
NOTE: After this heading, you can read explanatory statements  
that require special emphasis. These safety warnings cannot  
eliminate the hazards that they indicate. Common sense and  
strict compliance with the special instructions while performing  
the service are essential to preventing accidents.  
• Never 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 EXPLOSION may result.  
Four commonly used safety symbols accompany the DANGER,  
WARNING and CAUTION blocks. The type of information each  
indicates follows:  
• Generator exhaust gases contain DEADLY carbon monoxide  
gas.This dangerous gas, if breathed in sufficient  
concentrations, can cause unconsciousness or even death.  
Operate this equipment only in the open air where adequate  
ventilation is available.  
ƽ This symbol points out important safety  
information that, if not followed, could endanger  
personal safety and/or property of you and others.  
Ʒ This symbol points out potential explosion hazard.  
Ƹ This symbol points out potential fire hazard.  
• Allow at least 2 feet of clearance on all sides of generator or  
you could damage the unit. Never operate the unit inside any  
room or enclosure where the free flow of cooling air into and  
out of the unit might be obstructed. Review “Cold Weather  
Operation” on page 12.  
Ꮨ This symbol points out potential electrical shock hazard.  
The operator is responsible for proper and safe use of the  
equipment. We strongly recommend that the operator read this  
“Owner’s Manual” and thoroughly understand all instructions  
before using this equipment.  
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ƽ DANGER ƽ  
NEVER operate your generator indoors, in an attached garage or  
near an open window.  
1
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IMPORTANT SAFETY INSTRUCTIONS  
Residential Portable Generator System  
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit's  
ƽinstallation site. Safety should be stressed to all operators and potential operators of this equipment.  
• Never start or stop the unit with electrical loads connected to  
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ƽ DANGER ƽ  
receptacles AND with connected devices turned ON. Start the  
engine and let it stabilize before connecting electrical loads.  
Disconnect all electrical loads before shutting down the  
generator.  
ƽ Despite the safe design of this generator, operating this  
equipment imprudently, neglecting its maintenance or being  
careless can cause possible injury or death. Permit only  
responsible and capable persons to operate or maintain this  
equipment.  
• Do not insert objects through unit's cooling slots.  
• Never operate generator: in rain; indoors or in any enclosed  
compartment; if connected electrical devices overheat; if  
electrical output is lost; if engine or generator sparks; if flames  
or smoke are observed while unit is running; if unit vibrates  
excessively.  
Ꮨ Potentially lethal voltages are generated by these  
machines. Ensure all steps are taken to render the  
machine safe before attempting to work on the generator.  
ƽ Parts of the generator are rotating and/or hot during  
Note: Your generator is equipped with a spark arrestor muffler.  
The spark arrestor must be maintained in effective working  
order by the owner/ operator. In the State of California, a spark  
arrestor is required by law (Section 4442 of the California  
Public Resources Code). Other states may have similar laws.  
Federal laws apply on federal lands.  
operation. Exercise care near running generators.  
ƽ GENERAL HAZARDS ƽ  
• 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  
concentrations, can cause unconsciousness or even death.  
This exhaust system must be properly maintained. You must  
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 or permit even partial blockage of ventilation  
provisions, as this can seriously affect safe operation of the  
generator. The generator MUST be operated outdoors.  
• When working on this equipment, remain alert at all times.  
Never work on the equipment when you are physically or  
mentally fatigued.  
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.  
• Inspect the generator regularly, and contact your nearest  
GENERAC® Authorized Dealer for parts needing repair or  
replacement.  
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 unit are, therefore,  
not all-inclusive. If you use a procedure, work method or  
operating technique GENERAC® does not specifically recommend,  
you must satisfy yourself that it is safe for you and others. You  
also must make sure the procedure, work method or operating  
technique that you choose does not render the generator unsafe.  
• 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.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
Residential Portable Generator System  
Ꮨ ELECTRICAL HAZARDSᏘ  
Ʒ EXPLOSION HAZARDS Ʒ  
•
All generators covered by this manual produce dangerous  
electrical voltages and can cause fatal electrical shock. Utility  
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 you must work  
around an operating unit, stand on an insulated, dry surface  
to reduce shock hazard.  
• 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.  
• Do not handle any kind of electrical device while standing in  
water, while barefoot, or while hands or feet are wet.  
DANGEROUS ELECTRICAL SHOCK MAY RESULT.  
• 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.  
1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL  
ELECTRIC CODE.  
2. Article X, NATIONAL BUILDING CODE, available from the  
American Insurance Association, 85 John Street, New York,  
N.Y. 10038.  
• In case of accident caused by electric shock, immediately shut  
down the source of electrical power. If this is not possible,  
attempt to free the victim from the live conductor. AVOID  
DIRECT CONTACT WITH THE VICTIM. Use a non-conducting  
implement, such as a rope or board, to free the victim from the  
live conductor. If the victim is unconscious, apply first aid and  
get immediate medical help.  
3. AGRICULTURAL WIRING HANDBOOK, available from the Food  
and Energy Council, 909 University Avenue, Columbia, MO  
65201.  
4. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF FARM  
STANDBY ELECTRICAL SYSTEMS, available from the  
American Society of Agricultural Engineers, 2950 Niles Road,  
St. Joseph, MI 49085.  
• Never wear jewelry when working on this equipment. Jewelry  
can conduct electricity resulting in electric shock, or may get  
caught in moving components causing injury.  
5. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS  
CODE.  
Ƹ FIRE HAZARDS Ƹ  
• For fire safety, the generator must be operated and maintained  
properly. Operation always must  
comply with applicable  
codes, standards, laws and regulations. Adhere strictly to local,  
state and national electrical and building codes. Comply with  
regulations the Occupational Safety and Health Administration  
(OSHA) has established. Also, ensure that the generator is  
operated in accordance with the manufacturer’s instructions  
and recommendations. Do not alter the construction of  
generator or change controls which might create an unsafe  
operating condition.  
• Keep a fire extinguisher near the generator at all times.  
Extinguishers rated “ABC” by the National Fire Protection  
Association are appropriate for use on the standby electric  
system. Keep the extinguisher properly charged and be familiar  
with its use. If you have any question pertaining to fire  
extinguishers, consult your local fire department.  
3
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Section 1 – General Information  
Residential Portable Generator System  
1.1 UNPACKING  
1.2 ASSEMBLY  
• Set the palleted carton on a rigid flat surface.  
The generator requires some assembly prior to using it. If  
problems arise when assembling the generator, please call the  
Generator Helpline at 1-800-333-1322.  
• Remove staples along bottom of carton that fasten carton to  
pallet. Open carton from top.  
• Remove all packaging material.  
• Remove separate accessory box.  
• Lift carton off the generator.  
1.2.1 ASSEMBLING THE WHEEL KIT  
The wheel kit is designed to greatly improve the portability of the  
generator. A socket wrench with a 9/16” socket, a 1/2” socket, a  
1/2” wrench and a pair of pliers are the tools that will be needed  
for assembly of the wheel kit.  
• Remove generator from shipping pallet by removing bolts  
through the shipping brackets.  
Note: The wheel kit is not intended for over-the-road use.  
Figure 1 - Bracket Removal  
• Refer to Figure 2 shown on opposite page and install the wheel  
kit as follows:  
• Place the generator on a hard flat surface.  
• Stand at the engine end of the unit and gently tilt the generator  
forward, high enough to place wooden blocks beneath the  
cradle. This will allow space to install the wheel assemblies.  
Shipping  
Bracket (x4)  
• Attach an axle bracket assembly with attached sleeve to either  
side of the frame. Ensure the sleeve faces outward.  
• Slide the axle through the sleeves on the axle brackets.  
• Slide one wheel with flat washer to the outside and a spacer to  
the inside onto each end of the axle. Make sure the air inflation  
valve on the wheel is facing outward.  
• Insert retaining pins and using pliers, bend out the ends to  
prevent the pins from falling out of the axle. Remove the  
wooden blocks.  
1.1.1 ACCESSORY BOX  
Check all contents. If any parts are missing or damaged locate an  
authorized dealer at 1-800-333-1322.  
1.2.2 ASSEMBLING THE HANDLE  
Contents include:  
• Attach the handle by aligning one side of the handle on the  
cradle, then spread the handle around the cradle and let it  
spring into place. Secure the handle to the frame using the  
5/16’ hex head bolts provided. Check each fastener to ensure  
that it is secure.  
• Wheel Axle  
•
•
•
•
•
•
•
•
Bolt-on tubular handle  
2 – Pneumatic Wheels  
2 – Axle Bracket Assemblies  
Bolt-on Foot  
• 2 – Washers  
• 2 – Wheel Spacers  
• 2 – Cotter Pins  
• Battery Charge Cable  
• Air Filter  
Spark Plug Wrench •  
Oil Filter  
• 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.  
• Pre-cleaner  
2 – Quarts Oil  
• Remove the shipping brackets from the cradle, if you have not  
already done so.  
• 26 Wire Nuts  
6 – Carriage Bolts, Washers,  
Nuts  
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Section 1 - General Information  
Residential Portable Generator System  
Figure 2 - Handle Assembly  
Figure 3 - Battery Connections  
1.2.3 BATTERY CONNECTION  
• The battery shipped with the generator has been provided fully  
charged. Caution must be taken when connecting the battery.  
Negative  
Cable  
Positive  
Cable  
• Cut the tie wrap cable holding the RED and BLACK battery  
cables to the stator.  
• Connect the RED battery cable to the battery Positive terminal  
(+). After making sure that the connection is tight, slip the  
rubber boot over the terminal connection.  
• Connect the BLACK battery cable to the battery Negative  
terminal (–). Make sure the connection is tight.  
• Double check all connections to ensure they are in the correct  
location and secure. See Figure 3 at right.  
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Section 2 – Operation  
Residential Portable Generator System  
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.  
OPERATION  
2.1 KNOW THE GENERATOR  
Read the Owner’s Manual and Safety Rules before operating  
this generator.  
2) 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies  
electrical power for the operation of 120 Volt AC, 20 Amp,  
single-phase, 60 Hz electrical lighting, appliance, tool and  
motor loads.  
Compare the generator to this illustration to become familiarized  
with the locations of various controls and adjustments. Save this  
manual for future reference.  
3) 120 Volt AC, 20A Duplex GFCI Receptacle –  
Supplies ground fault protected electrical power for  
operation of 120 volt AC 20 amp, single-phase, 60 Hz electric  
lighting, appliances, tools and motor loads.  
Figure 4 - Control Panel  
4) 120 Volt AC, 30 Amp Locking Receptacle – Supplies  
electrical power for the operation of 120 Volt AC, 30 Amp,  
single-phase, 60 Hz electrical lighting, appliance, tool and  
motor loads.  
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.”  
(Section 2, page 12.)  
10) Circuit Breakers (AC) – Each receptacle is provided with a  
push-to-reset circuit breaker to protect the generator against  
electrical overload. (50 amp uses toggle reset)  
Figure 5 - Generator Controls  
11) Fuel Tank – Tank holds 16 U.S. gallons of fuel.  
12) Grounding Lug – Ground the generator to an approved earth  
11  
ground here. See page 9 for details.  
7
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.  
Figure 6 - Engine Control Panel  
15  
12  
14  
8
9
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Section 2 – Operation  
Residential Portable Generator System  
14) Start/Run/Stop Switch – Controls the operation of the  
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.  
generator.  
15) Oil 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 8 - 120 VAC, 20 Amp GFCI Receptacle  
2.2 CORD SETS AND CONNECTION  
PLUGS  
2.2.1 AC, 20 AMP, DUPLEX RECEPTACLE  
This is a 120 Volt outlet protected against overload by a 20 Amp  
push-to-reset circuit breaker. Use each socket to power 120 Volt AC,  
single phase, 60 Hz electrical loads requiring up to a combined 2400  
watts (2.4 kW) or 20 Amps of current. Use only high quality, well-  
insulated, 3-wire grounded cord sets rated for 125 Volts at 20 Amps  
(or greater).  
Keep extension cords as short as possible, preferably less than 15  
feet long, to prevent voltage drop and possible overheating of wires.  
Figure 7 - 120 Volt AC, 20 Amp, Duplex Receptacle  
Testing the GFCI: Test the GFCI outlet every month as follows:  
• Plug a test lamp into the receptacle.  
• Start the generator, the test lamp should be on.  
• Press the “Test” button located on the front of the receptacle  
to trip the device.  
• This should stop the flow of electricity making the lamp shut  
off. The yellow trip indicator should now be on.  
• To restore the flow of electricity, press the “Reset” button on  
the front of the receptacle. If the GFCI does not perform in this  
manner, do not use the receptacle. Contact a local service  
dealer.  
• This outlet is protected against overload by a 20A push-to-  
reset circuit breaker. Use the outlet to power 120V AC, single-  
phase, 60 Hz, electrical loads requiring up to a combined 2400  
watts (2.4 kW) or 20 amps of current.  
2.2.2 120V AC, 20 AMP, GFCI RECEPTACLE  
This unit is equipped with a ground fault circuit interrupter (GFCI).  
This device meets applicable federal, state and local codes.  
2.2.3 120V AC, 30 AMP RECEPTACLE  
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.  
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.  
7
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Section 2 – Operation  
Residential Portable Generator System  
Figure 9 - 120 VAC, 30 Amp Receptacle  
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 attempting  
to recharge a battery.  
Figure 11 - 12 Volt DC, 10 Amp Receptacle  
Use this receptacle to operate 120 Volt AC, 60 Hz, single phase  
loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps.  
The outlet is protected by a 30 Amp push-to-reset circuit breaker.  
2.2.6 120/240 VOLT AC, 50 AMP RECEPTACLE  
2.2.4 120/240V AC, 30 AMP RECEPTACLE  
Use the supplied NEMA 14-50 plug with this receptacle. Connect  
a 4-wire cord set rated for 250 Volts AC at 50 Amps to the plug.  
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 12 - 120/240 VAC, 50 Amp Receptacle  
Figure 10 - 120/240 VAC, 30 Amp Receptacle  
50 A  
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.  
Use this receptacle to operate 120 Volt AC, 60 Hz, single phase  
loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps  
or 240 Volt AC, 60 Hz, single phase loads requiring up to 7200  
watts (7.2 kW) of power at 30 Amps. The outlet is protected by  
two 30 Amp push-to-reset circuit breakers.  
8
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Section 2 – Operation  
Residential Portable Generator System  
2.3.2 CONNECTING ELECTRICAL LOADS  
2.3 HOW TO USE THE GENERATOR  
If you have any problems operating your generator, please call the  
generator helpline at 1-800-333-1322.  
DO NOT connect 240 Volt loads to 120 Volt receptacles. DO NOT  
connect 3-phase loads to the generator. DO NOT connect 50 Hz  
loads to the generator.  
• Let engine stabilize and warm up for a few minutes after  
starting.  
2.3.1 GROUNDING THE GENERATOR  
The National Electrical Code requires that the frame and  
external electrically conductive parts of this generator be  
properly connected to an approved earth ground. Local electrical  
codes may also require proper grounding of the unit. For that  
purpose, generally, connecting a No. 10 AWG (American Wire  
Gauge) stranded copper wire to the grounding wing nut and to an  
earth-driven copper or brass grounding rod (electrode) provides  
adequate protection against electrical shock. However, local  
codes may vary widely. Consult with a local electrician for  
grounding requirements in your area.  
• 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.  
2.4 DON’T OVERLOAD THE  
GENERATOR  
Figure 13 - Grounding the Generator  
Overloading a generator in excess of its rated wattage capacity  
can result in damage to the generator and to connected electrical  
devices. Observe the following to prevent overloading the unit:  
• Add up the total wattage of all electrical devices to be  
connected at one time. This total should NOT be greater than  
the generator's wattage capacity.  
Generator Ground Lug  
• The rated wattage of lights can be taken from light bulbs. The  
rated wattage of tools, appliances and motors can usually be  
found on a data plate or decal affixed to the device.  
• If the appliance, tool or motor does not give wattage, multiply  
volts times ampere rating to determine watts (volts x amps =  
watts).  
• Some electric motors, such as induction types, require about  
three times more watts of power for starting than for running.  
This surge of power lasts only a few seconds when starting  
such motors. Make sure you allow for this high starting  
wattage when selecting electrical devices to connect to your  
generator:  
Proper grounding of the generator will help prevent electrical  
shock in the event of a ground fault condition in the generator or  
in connected electrical devices. Proper grounding also helps  
dissipate static electricity, which often builds up in ungrounded  
devices.  
1. Figure the watts needed to start the largest motor.  
2. Add to that figure the running watts of all other connected  
loads.  
The Wattage Reference Guide on page 10 is provided to assist you  
in determining how many items your generator can operate at one  
time. (Note: All figures are approximate. See data plate on  
appliance for wattage requirements.)  
9
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Section 2 – Operation  
Residential Portable Generator System  
2.5 WATTAGE REFERENCE GUIDE  
Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts  
*Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . .1700  
*Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . .3800  
*Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . .6000  
Battery Charger (20 Amp) . . . . . . . . . . . . . . . . . . . . .500  
Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000  
Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200  
Circular Saw (6-1/2") . . . . . . . . . . . . . . . . . . .800 to 1000  
*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . .5750  
*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . . .700  
*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . .1150  
Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750  
*Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . . . .2000  
*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . . .1800  
*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . .1400  
Curling Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700  
*Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650  
Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200  
Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500  
Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400  
Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200  
Electric Range (per element) . . . . . . . . . . . . . . . . . .1500  
Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250  
*Freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700  
*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . .875  
*Garage Door Opener . . . . . . . . . . . . . . . . . . .500 to 750  
Hair Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200  
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100  
Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts  
Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450  
Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500  
Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200  
*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800  
Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200  
Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100  
Microwave Oven . . . . . . . . . . . . . . . . . . . . . .700 to 1000  
*Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1100  
Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . .300  
Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . .400  
Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . . . .225  
Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . .150  
*Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . . .600  
Paint Sprayer, Airless (handheld) . . . . . . . . . . . . . . . .150  
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 200  
*Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700  
Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200  
*Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . . .2800  
*Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . . .2000  
*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . .1500  
*Sump Pump . . . . . . . . . . . . . . . . . . . . . . . .800 to 1050  
*Table Saw (10") . . . . . . . . . . . . . . . . . . . . .1750 to 2000  
Television . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500  
Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650  
Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500  
*Allow 3 times the listed watts for starting these devices.  
• Above 40°F, use SAE 10W-30 or SAE 30.  
• Below 40°F, use synthetic 5W-20 or 5W-30.  
2.6 BEFORE STARTING THE  
GENERATOR  
Although multi-viscosity oils (5W-30, 10W-30, etc.) improve  
starting in cold weather, these multi-viscosity oils will result in  
increased oil consumption when used above 32°F. Check your  
engine oil level more frequently to avoid possible damage from  
running low on oil.  
Prior to operating the generator, engine oil and gasoline will need  
to be added, as follows:  
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  
classification SG, SH or SL SAE 30 weight. Use no special  
additives.  
• Place generator on a level surface.  
• Clean area around oil fill and remove oil fill cap and dipstick.  
•
•
Wipe dipstick clean.  
Select the oil’s viscosity grade according to the expected  
operating temperature. Do not use SAE 10W-40.  
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.  
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Section 2 – Operation  
Residential Portable Generator System  
2.6.2 ADDING GASOLINE  
2.7 TO START THE ENGINE  
-------------  
-------------  
ƽ WARNING ƽ  
Ꮨ
WARNING: Never start or stop engine with electrical devices  
plugged into the receptacles AND devices turned on.  
Ʒ WARNING: Never fill fuel tank indoors. Never fill fuel tank  
when engine is running or hot. DO NOT light a cigarette or  
smoke when filling the fuel tank.  
• Unplug all electrical loads from the unit's receptacles before  
starting the engine.  
ƽ Caution: Do not overfill the fuel tank. Always leave room  
• Make sure the unit is in a level position.  
• Open the fuel shut-off valve.  
for fuel expansion.  
• Use regular UNLEADED gasoline with the generator engine. Do  
not use premium gasoline. Do not mix oil with gasoline.  
Figure 15 - Fuel Shut-off Valve  
• Clean area around fuel fill cap, remove cap.  
• Slowly add unleaded regular gasoline to fuel tank. Be careful  
not to overfill. Allow about 1/2" of tank space for fuel  
expansion, as shown here.  
•
Install fuel cap and wipe up any spilled gasoline.  
Figure 14 - Fuel Tank  
• Locate the Idle Control ON/OFF switch on the control panel and  
set it to the “OFF” position.  
Figure 16 - Idle Control Switch  
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 "Storage" on page 18. Never use  
engine or carburetor cleaner products in the fuel tank as  
permanent damage may occur.  
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Section 2 – Operation  
Residential Portable Generator System  
• Move engine CHOKE knob to “Full Choke” position.  
2.9 AUTOMATIC IDLE CONTROL  
Figure 17 - Full Choke Position  
This feature is designed to greatly improve fuel economy. When  
this switch is turned “On,” the engine will only run at its normal  
fast governed engine speed when electrical load is connected.  
When the load is removed, the engine will run at a reduced speed  
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 dew point), the engine may experience icing of the  
carburetor and/or the crankcase breather system. To eliminate  
this problem, this generator engine is fitted with a winter/summer  
valve. this directs hot air into the carburetor during cold weather  
operation. Always make sure the winter/summer valve is in the  
correct location relative to the weather conditions.  
• To start engine, press and hold the Start/Run/Stop switch in  
the “Start” position. The engine will crank and attempt to start.  
When the engine starts, release the switch to the run position.  
• When the engine starts, move choke knob to “1/2 Choke”  
position until the engine runs smoothly and then to “Run”  
position. If engine falters, move choke knob to “1/2 Choke”  
position until the engine runs smoothly and then to “Run”  
position.  
2.11 LOW OIL PRESSURE SHUTDOWN  
SYSTEM  
The engine is equipped with a low oil pressure sensor that shuts  
down the engine automatically when the oil pressure drops below  
10 psi. If the engine shuts down by itself and the fuel tank has  
enough gasoline, check engine oil level.  
Note: If engine fires, but does not continue to run, move choke  
lever to “Full Choke” and repeat starting instructions.  
2.8 STOPPING THE ENGINE  
2.11.1 INITIAL START-UP  
• Shut off all loads, then unplug the electrical loads from  
generator panel receptacles. Never start or stop the engine  
with electrical devices plugged in and turned on.  
A delay built into the low oil shutdown system allows oil pressure  
to build during starting. The delay allows the engine to run for  
about 10 seconds before sensing oil pressure.  
• Turn “Off” the Idle Control switch (if on).  
2.11.2 SENSING LOW OIL PRESSURE  
• Let engine run at no-load for several minutes to stabilize the  
internal temperatures of engine and generator.  
If the system senses low oil pressure during operation, the engine  
shuts down.  
• Move Start/Run/Stop switch to “Off” position.  
• Close fuel valve.  
2.11.3 RESTARTING  
IMPORTANT: Do not overload the generator. Also, do not  
overload individual panel receptacles. These outlets are protected  
against overload with push-to-reset-type circuit breakers. If  
amperage rating of any circuit breaker is exceeded, that breaker  
opens and electrical output to that receptacle is lost. Read “Don’t  
Overload the Generator” on page 9 carefully.  
If you try to restart the engine within 10 seconds after it shuts  
down, the engine may NOT start. The system needs 5 to 10  
seconds to reset.  
If you do restart the engine after such a shutdown and have not  
corrected the low oil pressure, the engine runs for about 10  
seconds as described above and then stops.  
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Section 2 – Operation  
Residential Portable Generator System  
2.12 CHARGING A BATTERY  
Ʒ DANGER! Storage batteries give off explosive hydrogen gas  
while recharging. An explosive mixture will remain around  
the battery for a long time after it has been charged. The  
slightest spark can ignite the hydrogen and cause an  
explosion. Such an explosion can shatter the battery and  
cause blindness or other serious injury.  
ƽ DANGER! Do not permit smoking, open flame, sparks or  
any other source of heat around a battery. Wear protective  
goggles, rubber apron and rubber gloves when working  
around a battery. Battery electrolyte fluid is an extremely  
caustic sulfuric acid solution that can cause severe burns. If  
spill occurs flush area with clear water immediately.  
Your generator has the capability of recharging a discharged 12  
Volt automotive or utility style storage battery. Do not use the unit  
to charge any 6 Volt batteries. Do not use the unit to crank an  
engine having a discharged battery.  
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.  
• If the battery is equipped with vent caps, make sure they are  
installed and are tight.  
• If necessary, clean battery terminals.  
• Connect battery charge cable connector plug to panel  
receptacle identified by the words "12-VOLT D.C."  
• Connect battery charge cable clamp with red handle to the  
positive (+) battery terminal.  
• Connect battery charge cable clamp with black handle to the  
negative (-) battery terminal.  
• Start engine. Let the engine run while battery recharges.  
Engine idle control switch must be in off position for battery  
charging.  
• When battery has charged, shut down engine.  
Note: Use an automotive hydrometer to test battery state of  
charge and condition. Follow the hydrometer manufacturer's  
instructions carefully. Generally, a battery is considered to be  
at 100% state of charge when specific gravity of its fluid (as  
measured by hydrometer) is 1.260 or higher.  
13  
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Section 3 — Maintenance  
Residential Portable Generator System  
3.1 MAINTENANCE SCHEDULE  
Follow the calendar intervals. More frequent service is required when operating in adverse conditions noted below.  
Operation Maintenance  
Daily  
Every Season  
Every Season  
Every Season  
Check Oil Level  
✓
Service Air Pre-Cleaner  
Change Oil and Oil Filter‡  
✓**  
✓*  
Clean Spark Arrestor Screen  
Adjust Valve Clearance  
Service Air Cleaner  
✓
✓
✓**  
Replace Spark Plugs  
✓
‡
*
Change oil after first 8 hours of operation then every season.  
Change oil and oil filter every month when operating under heavy load or in high temperatures.  
** Clean more often under dirty or dusty operating conditions. Replace air cleaner parts if very dirty..  
PRODUCT SPECIFICATIONS  
3.2.1 GENERATOR SPECIFICATIONS  
MODEL  
GPS 17,500  
005308-0  
17.5 kW  
Model #  
Rated Max. Power  
Surge Power  
26.2 kW  
Rated AC Voltage  
Rated Max AC Load  
Current @ 240V  
Current @ 120V  
Rated Frequency  
Phase  
Rated DC Voltage  
Rated Max DC Load  
Current @ 12 Volts  
120/240  
72.9 Amps  
145.8 Amps  
60 Hz @ 3600 RPM  
Single Phase  
12 Volts  
10 Amperes  
3.2.2 ENGINE SPECIFICATIONS  
Rated Horsepower  
@ 3600 RPM  
33  
992cc  
Displacement  
Spark Plug Type  
Spark Plug Gap  
Champion RC14YC or Equivalent  
0.040 inch or (1.01 mm)  
Gasoline Capacity  
Oil Type  
Oil Capacity  
16 U.S. gallons  
Summer – SAE 30 or 10W-30 Winter – Synthetic 5W-20 or 5W-30  
w/ Filter Change = 1.5 Qts. w/o Filter Change = 1.2 Qts.  
10 Hours / 1.6 gallons per hour  
Run Time/Fuel  
Consumption-1/2 Load  
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Section 3 — Maintenance  
Residential Portable Generator System  
3.3.3 ENGINE MAINTENANCE  
3.3 GENERAL RECOMMENDATIONS  
DANGER! When working on the generator, always disconnect  
negative cable from battery. Also disconnect spark plug wires  
from spark plug and keep wire away from spark plug.  
The warranty of the generator does not cover items that have  
been subjected to operator abuse or negligence. To receive full  
value from the warranty, the operator must maintain the generator  
as instructed in this manual.  
3.3.4 CHECKING OIL LEVEL  
See the “BEFORE STARTING THE GENERATOR” section on page  
10 for information on checking the oil level. The oil level should  
be checked before each use, or at least every eight hours of  
operation. Keep the oil level maintained.  
Some adjustments will need to be made periodically to properly  
maintain the generator.  
All adjustments in the Maintenance section (3) of this manual  
should be made at least once each season. Follow the  
requirements in the "Maintenance Schedule" chart on page 14.  
3.3.5 CHANGING THE OIL AND OIL FILTER  
Change the oil and filter after the first eight hours of operation.  
Change the oil every 100 hours thereafter. If you are running this  
unit under dirty or dusty conditions, or in extremely hot weather,  
change the oil more often.  
NOTE: Once a year you should replace the spark plug and  
replace the air filter. A new spark plug and clean air filter  
assure proper fuel-air mixture and help your engine run better  
and last longer.  
Use the following instructions to change the oil while the  
engine is still warm:  
3.3.1 GENERATOR MAINTENANCE  
• Clean area around oil drain hose and plug.  
Generator maintenance consists of keeping the unit clean and dry.  
Operate and store the unit in a clean dry environment where it will  
not be exposed to excessive dust, dirt, moisture or any corrosive  
vapors. Cooling air slots in the generator must not become  
clogged with snow, leaves, or any other foreign material.  
• Remove oil drain plug from end of hose and oil fill plug to drain  
oil completely into a suitable container.  
• When oil has completely drained, install oil drain plug and  
tighten securely.  
• Place a suitable container beneath the oil filter and turn filter  
counterclockwise to remove. Discard according to local  
regulations.  
Check the cleanliness of the generator frequently and clean when  
dust, dirt, oil, moisture or other foreign substances are visible on  
its exterior surface.  
• Coat gasket of new filter with clean engine oil. Turn filter  
clockwise until gasket contacts lightly with filter adapter. Then  
tighten an additional 3/4 turn.  
ƽCAUTION! Never insert any object or tool through the air  
cooling slots, even if the engine is not running.  
• Fill oil sump with recommended oil. (See “Before Starting the  
Generator” on page 10 for oil recommendations).  
Note: DO NOT use a garden hose to clean generator. Water can  
enter the engine fuel system and cause problems. In addition,  
if water enters the generator through cooling air slots, some  
water will be retained in voids and crevices of the rotor and  
stator winding insulation. Water and dirt buildup on the  
generator internal windings will eventually decrease the  
insulation resistance of these windings.  
• Wipe up any spilled oil.  
3.3.2 TO CLEAN THE GENERATOR  
• Use a damp cloth to wipe exterior surfaces clean.  
• A soft, bristle brush may be used to loosen caked on dirt, oil, etc.  
• A vacuum cleaner may be used to pick up loose dirt and debris.  
• Low pressure air (not to exceed 25 psi) may be used to blow  
away dirt. Inspect cooling air slots and openings on the  
generator. These openings must be kept clean and  
unobstructed.  
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Section 3 — Maintenance  
Residential Portable Generator System  
To clean or replace foam pre-cleaner:  
3.3.6 REPLACING THE SPARK PLUG  
• Remove air cleaner cover, then foam pre-filter.  
Use Champion RC14YC spark plug or equivalent. The correct air  
gap is 1.01 mm (0.040 in.). Replace the plug once each year.  
This will help your engine start easier and run better.  
•
Wash pre-cleaner in soapy water. Squeeze pre-filter dry in  
clean cloth (DO NOT TWIST).  
1. Stop the engine and pull the spark plug wire off of the spark  
plug.  
• Clean air cleaner cover before re-installing it.  
To clean or replace paper air filter:  
2. Clean the area around the spark plug and remove it from the  
cylinder head.  
• Remove air cleaner cover; then remove foam pre-filter (service  
if necessary) and remove paper filter.  
3. Set the spark plug's gap to 1.01 mm (0.040 in.). Install the  
correctly gapped spark plug into the cylinder head.  
• Clean paper filter by tapping it gently on a solid surface. If the  
filter is too dirty, replace it with a new one. Dispose of the old  
filter properly.  
Figure 18 - Spark Plug Gap  
• Clean air cleaner cover then slip pre-cleaner over filter. Next  
insert new paper filter into the base of the air cleaner. Re-  
install air cleaner cover.  
Note: To order a new air filter, please contact the nearest  
authorized service center at 1-800-333-1322.  
3.5 CLEAN SPARK ARRESTOR SCREEN  
The engine exhaust muffler has a spark arrestor screen. Inspect  
and clean the screen at least once each year. If unit is used  
regularly, inspect and clean more often.  
NOTE: If you use your generator on any forest-covered, brush-  
covered or grass-covered unimproved land, it must equipped  
with a spark arrestor. The spark arrestor must be maintained in  
good condition by the owner/operator.  
3.4 SERVICE AIR CLEANER  
Your engine will not run properly and may be damaged if you run  
it using a dirty air cleaner. Clean or replace the air cleaner paper  
filter once a year. Clean or replace more often if operating under  
dusty conditions. Clean foam pre-cleaner every month or more  
often under dusty conditions.  
Clean and inspect the spark arrestor as follows:  
• Remove the screen retaining bracket by removing the screw.  
• Slide the spark arrestor screen out from the tail pipe.  
Figure 20 - Air Cleaner  
• Inspect screen and replace if torn, perforated or otherwise  
damaged. DO NOT USE a defective screen. If screen is not  
damaged, clean it with commercial solvent.  
Cover  
• Replace the screen and the retaining bracket.  
Pre-Cleaner  
Base  
Filter  
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Section 3 — Maintenance  
Residential Portable Generator System  
When valve clearance 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/lbs. torque. After tightening the jam nut,  
recheck valve clearance to make sure it did not change.  
Figure 21 - Spark Arrestor  
Figure 22 - Valve Clearance Adjustment  
3.6 ADJUSTING VALVE CLEARANCE  
After the first 50 hours of operation, you should adjust the valve  
clearance in the engine.  
• Install new valve cover gasket.  
• Re-attach the valve cover.  
Important: If you feel uncomfortable about doing this procedure  
or you don't have the proper tools, please take your generator in  
to the nearest service center to have the valve clearance adjusted.  
This is a very important step to insure longest life for your engine.  
NOTE: Start all four screws before tightening or you will not be  
able to get all the screws in place. Make sure the valve cover  
gasket is in place.  
To adjust valve clearance:  
• Re-attach the spark plug wire to the spark plug.  
• Repeat the process for the other cylinder.  
• 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 with a #2 or  
#3 phillips screwdriver.  
• Make sure the piston is at Top Dead Center (TDC) of its  
compression stroke (both valves closed). To get the piston at  
TDC, remove the intake screen at the front of the engine to gain  
access to the flywheel nut. Use a large socket and socket  
wrench to rotate the nut and hence the engine. While watching  
the piston through the spark plug hole. The piston should  
move up and down. The piston is at TDC when it is up as high  
as it can go.  
• Loosen the rocker jam nut. Use an 10mm allen wrench to turn  
the pivot ball stud while checking clearance between the rocker  
arm and the valve stem with a feeler gauge. Correct clearance  
is 0.002-0.004 inch (0.05-0.1 mm).  
NOTE: You must hold the rocker arm jam nut in place as you  
turn the pivot ball stud.  
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Section 3 — Maintenance  
Residential Portable Generator System  
3.7 GENERAL  
3.9 OTHER STORAGE TIPS:  
The generator should be started at least once every seven days  
and be allowed to run at least 30 minutes. If this cannot be done  
and you must store the unit for more than 30 days, use the  
following information as a guide to prepare it for storage.  
• Do not store gasoline from one season to another.  
• Replace your gasoline can if your can starts to rust. Rust  
and/or dirt in your gasoline will cause problems with the  
carburetor and fuel system.  
• If possible, store your unit indoors and cover it to give  
protection from dust and dirt. BE SURE TO EMPTY THE FUEL  
TANK.  
ƷƸDANGER! 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.  
• If it is not practical to empty the fuel tank and the unit is to be  
stored for some time, use a commercially available fuel  
stabilizer added to the gasoline to increase the life of the  
gasoline.  
3.8 LONG TERM STORAGE  
• Cover your unit with a suitable protective cover that does not  
retain moisture.  
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  
storage.  
ƽ DANGER NEVER cover your generator while engine and  
exhaust area are warm.  
To avoid engine problems, the fuel system should be emptied  
before storage of 30 days or longer, as follows:  
• Remove all gasoline from the fuel tank.  
ƷƸDANGER! Drain fuel into approved container outdoors,  
away from open flame. Be sure engine is cool. Do not  
smoke.  
•
Start and run engine until engine stops from lack of fuel.  
• While engine is still warm, drain oil from crankcase. Refill with  
recommended grade.  
• Remove spark plugs and pour about 1/2 ounce  
(15 ml) of engine oil into the cylinders. Cover spark plug hole  
with rag. Press the “Start” button and allow engine to crank for  
2 seconds. Then press the “Stop” button.  
ƽCAUTION! Avoid spray from spark plug holes when cranking  
engine.  
• Install and tighten spark plugs. Do not connect spark plug  
wires.  
• Clean the generator outer surfaces. Check that cooling air  
slots and openings on generator are open and unobstructed.  
• Store the unit in a clean, dry place.  
18  
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Section 4 — Troubleshooting  
Commercial-Industrial-Residential Portable Generator System  
4.1 TROUBLESHOOTING  
SYMPTOM  
CAUSE  
SOLUTION  
Engine is running, but no AC  
output is available.  
1. Circuit breaker is open.  
2. Poor connection or defective cord set. 2. Check and repair.  
3. Connected device is bad.  
1. Reset circuit breaker.  
3. Connect another device that is in  
good condition.  
4. Contact Authorized Service Facility.  
4. Fault in generator.  
Engine runs good but bogs  
down when loads are connected.  
1. Short circuit in a connected load.  
2. Generator is overloaded.  
3. Engine speed is too slow.  
4. Shorted generator circuit.  
1. Disconnect shorted electrical load.  
2. See “Don’t Overload the Generator” on page 9.  
3. Contact Authorized Service Facility.  
4. Contact Authorized Service Facility.  
Engine will not crank.  
10 amp fuse at rear of generator  
control panel has melted open.  
Replace fuse with only an identical  
10-amp replacement fuse.  
Engine will not start; or starts  
and runs rough.  
1. Dirty air cleaner.  
2. Out of gasoline.  
3. Stale gasoline.  
4. Spark plug wire not connected to  
spark plug.  
1. Clean or replace air cleaner.  
2. Fill fuel tank.  
3. Drain fuel tank and fill with fresh fuel.  
4. Connect wire to spark plug.  
5. Bad spark plug.  
6. Water in gasoline.  
7. Overchoking.  
5. Replace spark plug.  
6. Drain fuel tank; fill with fresh fuel.  
7. Put choke knob to No Choke position.  
8. Fill crankcase to proper level.  
9. Contact Authorized Service Facility.  
10. Contact Authorized Service Facility.  
11. Contact Authorized Service Facility.  
8. Low oil level.  
9. Excessive rich fuel mixture.  
10. Intake valve stuck open or closed.  
11. Engine has lost compression.  
Engine shuts down during  
operation.  
1. Out of gasoline.  
2. Low oil level.  
3. Fault in engine.  
1. Fill fuel tank.  
2. Fill crankcase to proper level.  
3. Contact Authorized Service Facility.  
Engine lacks power.  
1. Load is too high.  
2. Dirty air filter.  
1. See “Don’t Overload the Generator” on page 9.  
2. Replace air filter.  
3. Engine needs to be serviced.  
3. Contact Authorized Service Facility.  
Engine “hunts” or falters.  
1. Choke is opened too soon.  
1. Move choke to halfway position until  
engine runs smoothly.  
2. Carburetor is running too rich or too  
lean.  
2. Contact Authorized Service Facility.  
No Battery Charge DC output.  
1. Battery posts are corroded.  
2. Battery cable is bad.  
3. Battery is defective.  
1. Clean battery posts.  
2. Replace cable.  
3. Check battery condition; replace if  
defective.  
4. Receptacle is bad.  
4. Contact Authorized Service Facility.  
19  
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Section 5—Installation for Manual Transfer Switch  
KIT INCLUDES:  
1. Power Inlet Box  
Pre-wired with the 50 amp male receptacle, this box is located  
outside the home where the generator will be operated.  
1.  
2. Pre-wired Manual Transfer Switch and  
Emergency Load Center with 16 Circuits  
Installed within 1 foot of the home’s main distribution panel. This  
transfer switch will provide smooth and safe transition between  
utility and generator power. Eliminates the need to run extension  
cords to every item requiring back up power.  
2.  
3. 2’ Pre-wired Conduit for Easy Connection to the Home’s  
Main Distribution Panel  
26 UL listed wire nuts (not shown)  
TOOLS REQUIRED:  
3.  
Drill, drill bits, hole saw (type and 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)  
Ground rod (8 foot) with grounding strap (No. 10 AWG stranded copper)  
Padlock (To lock external connection box after installation is complete)  
Silicone caulk  
Fasteners - to mount transfer switch, connection box and plug house/cord hanger  
Intermediate wiring* from Manual Transfer Switch to the Power Inlet Box  
*Individual wires in conduit or wiring in a jacketed cable must be sized for 50 Amp  
service and of construction approved by the National Electric Code and other  
applicable local codes.  
20  
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Section 5—Installation for Manual Transfer Switch  
THESE INSTRUCTIONS ARE TO SERVE AS A GUIDE ONLY!  
ANY ELECTRICAL WORK PERFORMED MUST MEET NFPA 70-NEC AND ANY LOCAL CODES THAT APPLY.  
1
Portable Generator Placement  
Drill Pass Through Hole  
Generator should be placed as far away from  
house as power cord will allow. It is understood  
that the cord should not be pulled tight and it  
will lay along the ground between the external  
connection box and generator panel.  
3
1-3/4”  
Diameter Hole  
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/floor joists and wall studs to  
the location where the conduit will pass through the  
wall to the exterior of the house.  
2
FIGURE A  
1. PLAN THE LOCATION OF YOUR GENERATOR  
(Fig. A) shows the GENERAC 17,500 watt portable  
generator placed outside the home and connected to  
the weather protective external box. The ground rod  
and ground strap show a suggested location only.  
When fully installed the ground rod will not protrude  
above ground level. NOTE: Do not place the generator  
directly under a window.  
5
Feed Conduit and Wires  
Silicone  
Caulk  
Select an area outside of your home about 10 feet away  
where you can easily transport the portable generator  
to and from. Keep in mind that the generator must have  
free air flow for proper operation and to ensure there is  
no possibility for exhaust gases to build up.  
2. Drive an 8-foot grounding rod into the ground to grade  
5. From the inside of the house, feed the end of the  
(so that no part is exposed above ground).  
customer supplied conduit through the wall to outside.  
3
Drill Hole Through House  
6
Threaded Lock Nut  
1-3/4”  
Diameter Hole  
3. Determine where the user supplied conduit will pass  
through the house from inside to outside. When you  
are certain you have clearance on each side of the wall,  
drill a small pilot hole through the wall to mark the  
location.  
6. Remove the threaded lock nut from the conduit  
coupling.  
21  
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Section 5—Installation for Manual Transfer Switch  
8. Connect the black, red, and white wires to the same  
7a Prepare Box For Connections  
color coded lugs on the back of the receptacle. Failure  
to match wires may result in damage to generator and  
house wiring. Strip wire insulation back 1/2” and  
torque lug screws to 25 in/lbs. The green wire is to be  
stripped back 1/2”, inserted into the ground lug and  
torque lug screw to 25 in/lbs. Reinstall internal cover  
plate and screw. Close and lock cover.  
Knockout  
--- ƽ WARNING ƽ ---  
The power inlet box must be locked to ensure safety and  
to discourage tampering.  
9
Mounting Manual Transfer Switch  
7a. Lift cover of the power inlet box and remove the  
internal cover plate screws and internal cover plate.  
Remove the knock out in the lower center of the box.  
From the rear of the connection box, feed wires into  
box. Slip the lock nut over wires tighten securely onto  
conduit coupling.  
1 ft  
7b Mount Box  
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 with appropriate fasteners.  
7b. Using appropriate fasteners, mount power inlet box over  
pre-drilled hole to fully conceal the hole. Seal around the  
hole and conduit with insulating material and/or silicone  
caulk from both outside and inside of house.  
ƽ DANGER: Although you may choose to perform electrical  
connections yourself, Generac Power Systems, Inc.  
recommends that a licensed electrician or individual with  
complete knowledge of electricity perform the procedures in  
sections 10a and 10b.  
8
Receptacle  
Green  
Red  
ƽ DANGER: Switch service main circuit breaker to “OFF” or  
open position prior to removal of cover or removal of any  
wiring of the main electrical distribution panel. The wires  
connected to the service main circuit breaker remain live or  
“HOT”. Avoid contact with these wires and the service main  
circuit breaker connection lugs.  
Black  
White  
Existing Wire  
22  
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Section 5—Installation for Manual Transfer Switch  
9a. The 2 foot conduit that is pre-wired into the manual  
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.  
transfer switch is not fastened to the side of the  
enclosure when shipped. To secure the conduit to the  
manual switch enclosure proceed as follows. Remove  
the cover panel of the manual transfer switch with  
emergency load center. Insert the 2 foot conduit into  
the knockout and tighten the lock nut securely on the  
inside of the enclosure.  
Trace each black (hot) wire connected and wire nut  
the white (neutral) wire from the same Romex cable  
(circuit) to the matching circuit number on the white  
(neutral) wire from the emergency load center. Repeat  
for each circuit. (See page 31)  
10  
Connection of Emergency Circuits  
The emergency load center in the transfer switch  
supplies the following circuits: (5) 15A/120V, (5)  
20A/120V, (1) 20A/240V, (1) 40A/240V and (1)  
50A/240V.  
11  
Install 60 AMP Circuit Breaker  
UL approved wire nuts are included with installation kit.  
NOTE: Balance must be maintained when moving circuit  
locations from main electrical distribution panel to emergency  
load center. Circuit breaker positions alternate buss bars  
vertically. Circuits sharing a neutral wire should either be  
moved together to adjacent positions in emergency load center  
or not moved. If you are unsure of proper procedure or if your  
installation differs from that described in this guide, consult a  
licensed professional at this time.  
11. Install the 60 Amp double pole circuit breaker that you  
have purchased into main electrical distribution panel.  
This circuit breaker must be compatible with your  
main electrical distribution panel. It may be  
necessary to reposition remaining circuit breakers or  
remove circuit breakers that have been disconnected  
to accommodate the insertion of the 60 Amp double  
pole circuit breaker. Connect white wire to the main  
distribution panel neutral bar. Connect solid green  
wire to main electrical panel ground bar. Connect the  
black and red wires to the 60 Amp double pole circuit  
breaker. Replace electrical distribution panel cover.  
10a. Remove the main electrical distribution panel cover.  
Remove appropriate size knockout from the bottom  
or side of the main panel. (A 2-foot flexible conduit is  
pre-wired from the manual transfer switch with built-  
in load center). Remove threaded lock nut from  
conduit coupling. Feed all wires through knockout  
into main panel. Slip lock nut over wires and tighten  
securely onto conduit coupling.  
NOTE: Circuits to be moved must be protected by same size  
breaker. For example, a 15 amp 120V circuit in emergency load  
center will replace a 15 amp 120V circuit in main panel.  
NOTE: Both grounded and ungrounded conductors for each  
circuit must be moved to the emergency panel and connected to  
to the new wiring from the emergency panel using supplied  
locknuts.  
Your GENERAC Manual  
Transfer Switch is now installed.  
10b. In your main panel, remove the black (hot) wire from  
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  
NOTE: If additional circuits are required to be protected.  
Generac offers an additional 30A manual transfer switch and  
30A Power Inlet Kit (Model 5341). This kit can be ordered direct  
from the factory 1-800-747-1530 (Option 2).  
23  
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Section 6—Operation of Generator with Manual Transfer Switch  
17,500 WATT PORTABLE COMPONENTS  
USING THE ULTRA SOURCE PORTABLE  
The GENERAC® portable generator with manual transfer switch  
gives you the ability to provide power safely and conveniently  
to vital items in your home including hard wired items.  
Included in the kit is a power Inlet box with built-in 50 Amp  
twistlock male receptacle and a 15 foot electrical power cord.  
The power cord is made up of 4 wires, power (black & red),  
neutral (white) and ground (green). At one end is the 50 Amp  
female 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.  
Power Inlet Box  
with 50 Amp Male Receptacle  
Portable Generator Control Panel  
12 Volt DC  
Receptacle  
NEMA 14-50  
Receptacle  
15 Foot Power Cord with  
50 Amp Plug and Receptacle  
NEMA 14-50,  
50 Amp Receptacle  
NEMA 14-50, 50 Amp Plug  
24  
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Section 6—Operation of Generator with Manual Transfer Switch  
TRANSFER TO GENERATOR POWER SOURCE  
WHEN UTILITY POWER FAILS  
TRANSFER BACK TO UTILITY POWER  
SOURCE  
1. Move generator to within approximately 10 feet of the  
power inlet box. Connect ground strap to the  
generator’s grounding lug and to the grounding rod.  
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:  
2. Open the door of the Manual Transfer Switch. Slide the  
mechanical interlock connecting the 60 Amp and 50  
Amp circuit breakers at the top of the panel to turn “Off”  
the “Utility” circuit breaker. Both circuits will be in the  
“Off” position.  
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 NEMA 14-50 plug and  
remove the plug from the outlet on the generator. Twist  
and remove the 50 Amp female receptacle from the  
power inlet box. Close and lock the box. Coil the power  
cord and place it with the generator.  
3. Flip the “Standby” circuit breaker handle to the “On”  
position. Close the door of the Manual Transfer Switch.  
4. Open the power inlet box. Insert and lock the 50 Amp  
female receptacle into the male receptacle in the  
external connection box. Insert the 50 Amp plug into the  
50 Amp NEMA 14-50 receptacle located on the  
underside of the generator’s control panel. A retaining  
clip is supplied on the control panel. Secure the  
retaining clip over the end of the plug. The retaining clip  
ensures that the plug remains in place during generator  
operation.  
3. After the generator has run for a couple minutes to cool  
down, turn off the generator.  
4. Open the door of the Manual Transfer Switch and slide  
the mechanical interlock to turn “OFF” the “STANDBY”  
circuit breaker. Both circuit breakers will be in the “OFF”  
position.  
5. Flip the “UTILITY” circuit breaker handle to the “ON”  
position. Close the door of the Manual Transfer Switch.  
5. Before starting the generator, verify the 50 Amp circuit  
breaker on the generator’s control panel is in the “Off”  
or “Open” position.  
6. The Utility is now supplying power.  
7. Disconnect the ground strap from the grounding rod  
and the generator’s grounding lug. Retain the ground  
strap with the generator. Return the generator to its  
storage location.  
6. Start the generator and allow it to warm up for a couple  
of minutes. Switch the 50 Amp circuit breaker on the  
generator control panel to the “ON” or “Closed”  
position.  
Choose a lamp or light fixture located in a frequently  
occupied area of the building as a signal light to tell  
you when utility power has been restored. This light  
should be on a utility powered circuit only, so it  
operates independent of the generator.  
7. The generator is now supplying power to the load center  
circuits in the manual transfer switch.  
25  
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Section 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  
26  
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Section 7 - Notes  
Residential Portable Generator System  
27  
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Section 8 — Electrical Data  
Commercial-Industrial-Residential Portable Generator System  
Wiring Diagram, Portable Generator – Drawing No. 0G0731  
22  
120/240V  
(50A/60A)) OUTLET  
120/240V  
30A TWISTLOK  
120V/20A  
DUPLEX  
120V/20A  
GFCI  
120V/30A  
TWISTLOK  
120V/30A  
TWISTLOK  
0
0
22  
22  
0
0
WHITE  
WHITE  
X
G
GREEN  
LOAD  
LINE  
1
3
1
3
2
22  
22  
0
2
WHITE  
G
G
Y
22  
22  
X
11B  
22  
0
WHITE  
Y
4
5
4
5
22  
0
22  
22  
44D  
11D  
11C  
44C  
0
0
22  
0
22  
22  
0
0
0
11A  
44A  
22  
0
22  
22  
0
44  
44  
44  
22  
30A  
C.B.  
11B  
44B  
11B  
44  
11  
11  
44  
0
44  
30A  
C.B.  
30A  
C.B.  
20A  
C.B.  
20A  
44C  
44  
11  
44D  
11D  
11C  
C.B.  
50A/  
60A  
C.B.  
44  
11  
11  
11A  
30A  
C.B.  
ON  
11  
OFF  
44  
11  
11  
44  
44  
11  
11  
11A 44A  
44  
ENGINE WWIRING  
14  
18  
15  
GOVERNOR  
ACTUATOR  
14  
18  
0
1
5
2
4
15B  
6
8
9
10  
12  
IC  
15  
18  
15  
1
18  
15  
SSR  
13  
14  
229  
14  
0
D
2
SP1  
SP2  
0
0
167  
0
IM1  
IM2  
(START)  
RUN  
0
3
4
0
0 0 0 0  
15  
86  
0
167  
167  
STOP  
D
17 15  
15  
86  
86  
13  
5
6
86  
13  
0
F1  
LOP  
15  
0
15  
15  
0
14  
14  
17  
16  
7
8
9
14  
17  
16  
15  
0 0 0 0 0  
FSS  
GND  
55A  
55  
17  
14  
0
0 0 055  
87  
86  
15  
13  
0
10  
11  
15  
13  
0
87a  
85  
SCR  
30  
0
14  
0
12  
PIN #  
0
0
RED  
BLACK  
13  
16  
SM  
13  
- +  
12V  
BATTERY  
SC  
28  
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Section 8 — Electrical Data  
Commercial-Industrial-Residential Portable Generator System  
Wiring Diagram, Portable Generator – Drawing No. 0G0731  
22  
11  
IDLE CONTROL  
TRANSFORMERS  
STATOR  
22  
11  
22  
11  
22  
44  
11S  
22S  
55A  
RED  
11  
44  
1
44  
44  
77A  
2
2
66A  
11S  
22S  
55A  
3
6
4
83  
5
167  
55  
6
229  
77  
66  
7
15B  
0
86  
CLOSESST TO BEARING  
BLK  
BLK  
8
9
55  
2
TB1  
BA  
10  
4
0
11  
TB2  
12  
PIN #  
83  
229  
0
167 15B 86  
CB1  
11S 55A  
22S 55  
ON/OFF  
IDLE  
CONTROL  
SWITCH  
162  
4
77A  
66A  
77  
121110 9  
8
7
6
5
4
3
2
1
J2  
0
66  
6
ELECTRRONICC GGOVERNOR /  
ENGINEE SHUTDDOWN PP..C.B.  
15B  
0
229  
14  
0
J1  
14  
14  
14  
167  
0
14  
86  
0
0
R1  
D2  
15  
55A 162  
55  
4
77A  
66A  
77  
14  
VOLTAGE  
REGULATOR  
11S  
0
66  
6
22S  
4
0
6
4
15  
0
162  
0
14  
55A  
55  
55A  
55  
15  
77A  
15  
BATTERY  
CHARGE  
RECTIFIER  
15  
15  
66A  
0
10A AUTO  
RESET BKR  
LEGEND  
0
BA - BRUSH AASSEMBLY  
14  
77  
BATTERY  
CHARGE  
RECTIFIER  
CB1 - 6AMMP AUTO RRESET BBRREAKER  
D - ENGIINE SHUUTDOWNN DIODE  
D2 - 600V 112A DIODE  
13A  
66  
13A  
F1 - 10AA FUSE  
FSS - FUEEL SHUTT OOFF SOLLENOID  
GND - GROUUND BAR  
12Vdc OUTLET  
IM1 - IGNNITIONN MMODULE,, CYL. 1  
IM2 - IGNNITIONN MMODULE,, CYL. 2  
LOP - LOW OILL PRESSSURE  
R1 - 25 OOHM, 2255W RESIISTOR  
SC - STARTERR CONTTAACTOR  
SCR - STARRTER CONNTACTORR RELAY  
SM - STARTTER MOTOR  
0
15A 0  
15A  
SP1 - SPPARK PPLLUG, CYL. 1  
SP2 - SPPARK PPLLUG, CYL. 2  
SSR - STTART // SSTOP RELAY  
TB1, TB22 - TERMMINAL BBLOCK  
29  
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Section 8 — Electrical Data  
Commercial-Industrial-Residential Portable Generator System  
Schematic, Portable Generator – Drawing No. 0G0733  
POWER WINNDING  
DPE WINNDING  
BA  
FIELD  
BATTERY CCHARGE WINDING  
77A  
55A  
66A 11S  
C1-1  
11  
22S  
44  
2
6
4
0
C1-5  
C1-4  
C1-2  
C1-6  
C1-7  
C1-11  
C1-12  
22  
C1-3  
10A BATTTERY CHHARGE WWIINDING  
I.C.  
RED  
77  
C1-10  
55  
66  
I.C.T.  
C1-9  
C1-8  
66A  
22S  
77  
66  
11S  
22  
2
6
4
0
I.C.T.  
44  
22  
0
77A  
BLK  
11  
11  
66A  
77A  
0
15  
BCR2  
CB1  
66  
77  
13A  
15A  
77  
12Vdc  
BCR1  
0
BLK  
BLK  
22S  
15  
4
ELECTRRONIC  
VOLTAGE  
REGULATOR  
11S  
22S  
4
0
6
162  
4
0
6
162  
2
0
CB2  
SW2  
C2-5  
LOP  
86  
0
15B  
229  
167  
83  
86  
0
86  
86  
0
0
C2-12  
C2-6  
167  
83  
0
0
0
BLK  
BLK  
0
15  
15  
F1  
15  
15  
13  
SSR  
14  
229  
15B  
0
4
13  
RED  
13  
86  
15B 167  
11S  
22S  
15  
0
0
229  
83  
TB2  
D1  
R1  
SC  
1210 9  
4 6  
18  
15B  
5
14  
22S  
11S  
BATTERY  
12V  
15  
SCR  
17  
C2-11  
13  
SM  
229  
13  
16  
TB1  
229  
83  
11S  
22S  
86  
15B 167  
C2-9  
BLACK  
14  
16  
17  
SC  
15  
167  
0
D2  
15  
14  
C2-8  
18  
IM1  
IM2  
1
2
3
4
5
6
7
15B  
83  
TR1  
17  
0
SP1  
C2-1  
CONTROL  
PRINTEDD CIRCUIT  
BOARD  
0
C2-3  
C2-4  
D3  
0
0
17  
0
167  
TR2  
86  
229  
SP2  
SW1  
167  
167  
15  
8
9
C2-10  
C2-2  
C2-7  
15  
22S  
GOVERNOR  
ACTUATOR  
15  
15  
14  
10  
11  
12  
J1  
11S  
J2  
15  
14  
0
120V  
GFCI  
120V  
DUPLEX  
FSS  
22  
22  
22  
11B  
0
120/240V  
50A/60A  
120/240V  
30A  
TWISTLOK  
R E S E T T E S T  
120V/30A  
TWISTLOK  
120V/30A  
TWISTLOK  
RESET  
TEST  
44C  
0
22 11C  
0
22 44D  
0
11D  
0
44B  
0
11B  
11A  
44A 0  
22  
C.B.  
20A  
C.B.  
20A  
C.B.  
30A  
C.B.  
30A  
C.B.  
30A  
C.B.  
30A  
C.B.  
50A/60A  
11  
11  
11  
22  
0
44  
22  
0
44  
22  
0
44  
LEGEND  
BA - BRUSSH ASSEMBLY  
FSS - FUELL SHUT OOFF SOLLENOID  
GND - GROUND BAR  
I.C.T. - IDLE CONTROL TRANSFORMER  
IM1 - IGNITION MODULE, CYL. 1  
IM2 - IGNITION MODULE, CCYL. 2  
LOP - LOW OIL PRESSURE  
SCR - STARTER CONTACTOR RELAY  
SM - STARTER MOTOR  
BCR1 - BATTERY CHAARGE RECTIFIER, 10A  
BCR2 - BATTERY CHARGE RECTIFIER  
CB1 - 10AMP AUTO RESET BREAKER  
CB2 - 6AMMP AUTO RRESET BRREAKER  
D1 - 600V 12A DIODE  
SP1 - SPARK PLUUG, CYL. 1  
SP2 - SPARK PLUG, CYL. 2  
SSR - START / STOP RELAY  
SW1 - START-RUN--STOPP RRELAY  
SW2 - IDLLE CONTTROL SWWITCH  
TB1, TB2 - TERMINAL BLOCK  
R1 - 25 OHM, 25W RESISTOR  
SC - STARTERR CONTTAACTOR  
D2, D3 - ENGINE SHUTDOWN DIODE  
F1 - 10A FUSE  
30  
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Section 8 — Electrical Data  
Commercial-Industrial-Residential Portable Generator System  
Wiring Diagram, Manual Transfer Switch – Drawing No. 0G1065  
GROUND(GRN)  
NEUTRAAL(WHT)  
NEUTRAL  
(WHT)  
CIRCUIT 9  
NEUTRAL  
(WHT)  
GROUND BAR  
CIRCUIT 11  
NEUTRAL  
(WHT)  
CIRCUIT 13  
NEUTRAL  
(WHT)  
CIRCUIT 15  
CIRCUIIT 1(BRNN)  
CIRCUIT 3(BRN/WHT)  
CIRCUIT 5(YEL)  
GROUND(GRN)*  
GEN2(RED)*  
CIRCUIT 7(YEL/WHT)  
CIRCUIT 9 (LT BLU)  
CIRCUIT 11(ORG)  
CIRCUIT 13(DRK BLU)  
CIRCUIT 15(PNK)  
GEN1(BLK)*  
NEUTRAL(WHT)*  
*-CUSTOMER SUPPLIED  
NEUTRAL BAR  
A N S D T B Y  
LOAD CENTER  
UTILITY  
NEUTRAL BAR  
CIRCUIT 16(PNK/YEL)  
CIRCUIT 14(BLU/YEL)  
CIRCUIT 12(ORG/YEL)  
CIRCUIT 10(GRY/YEL)  
CIRCUIT 8(VIO/YEL)  
CIRCUIT 6(VIO)  
CIRCUIT 4(ORG/WHT)  
CIRCUIT 2(ORG)  
MAIN 2(RED)  
MAIN 1(BLK)  
NEUTRAL  
(WHT)  
CIRCUIT 16  
NEUTRAL  
(WHT)  
CIRCUIT 14  
NEUTRAL  
(WHT)  
CIRCUIT 12  
NEUTRAL  
(WHT)  
CIRCUIT 10  
NEUTRAL  
(WHT)  
CIRCUIT 8  
NEUTRAL  
(WHT)  
CIRCUIT 6  
31  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
Manual Transfer Switch with Load Center – Drawing No. 0G0939-B  
32  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
Manual Transfer Switch with Load Center – Drawing No. 0G0939-B  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
0G0749  
0G0748  
0E7888  
0E7888B  
0E7888C  
0E7888D  
0E7888E  
0E7888F  
0G0863  
0G0750  
0G1494  
1
1
1
5
5
1
2
1
1
1
1
BOX LOAD CENTER W/HARDWARE  
CIRCUIT BREAKER INTERLOCK  
CIRCUIT BREAKER 20A 2P  
CIRCUIT BREAKER 15A 1P  
CIRCUIT BREAKER 20A 1P  
CIRCUIT BREAKER 40A 2P  
CIRCUIT BREAKER 50A 2P  
CIRCUIT BREAKER 60A 2P  
HARNESS, 50 AMP PLUGS  
HARNESS, LOAD CENTER TO MAIN PANEL  
POWER INLET BOX  
9
10  
11  
33  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589-N  
34  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589-N  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
0C5729  
1
ASSEMBLY, CRANKCASE HOUSING WITH  
SLEEVE  
36  
0C5731  
1
ASSEMBLY, HOUSING COVER WITH  
SLEEVE  
2
3
4
5
6
7
8
9
0E9843  
090388  
0C5372  
0C3005  
0E3372B  
0D8067A  
071983  
0G0693  
043790A  
0E2950  
0E2985  
021533  
0E1466  
0D4041  
0D4788  
093064  
0C2977  
0C5943  
0E4357E  
1
3
1
1
1
1
4
1
1
2
2
2
2
1
2
1
1
1
1
SEAL, 38 I.D. CRANKSHAFT  
SCREW, TAPTITE M6-1.0 X 12 BP  
ASSEMBLY, BREATHER  
GASKET, BREATHER COVER  
SEPARATOR, OIL BREATHER  
ASSEMBLY, HEAD #1  
RETAINER, PISTON PIN 20  
ASSY, ROCKER COVER W/BARB  
BARBED EL 90 3/8NPT X 3/8 W/ VS  
PISTON, LC (GT-990)  
PISTON, HC (GT-760)  
SET, PISTON RING 90MM  
PIN PISTON  
ASSEMBLY, CAMSHAFT & GEAR  
PLUG STD PIPE 3/8 STEEL SQ HD  
ASSEMBLY, OIL FILL CAP  
GASKET, CRANK CASE  
SEAL, OIL PASSAGE  
ASSEMBLY, CRANKSHAFT HORIZONTAL  
DIRECT DRIVE (GT-990)  
ASSEMBLY, CRANKSHAFT HORIZONTAL  
DIRECT DRIVE (GT-760)  
ASSEMBLY, CONNECTING ROD (GT-990)  
ASSEMBLY, CONNECTING ROD (GT-760)  
SCREW SHC M6-1.0 X 50 G8.8  
SCREEN, OIL PICKUP  
ASSEMBLY, OIL PUMP  
O-RING, 0.49 ID X 0.07 THICK  
COVER, OIL RELIEF  
SPRING, OIL RELIEF  
BALL, 1/2D OIL RELIEF  
37  
38  
39  
40  
0C3006  
080318  
0C8808  
0D2723D  
10  
8
2
SCREW, HHFC M10-1.5 X 55  
SCREW HHFC M6-1.0 X 25  
HOOK, LIFTING  
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  
O-RING, 3/8" X 1/2"  
1
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
0C2979  
086515  
0D2274  
0D3867  
078672  
0C5371  
072694  
0C3027  
0D5313  
0D3998  
0D6024  
0C2976  
086516  
0C2229  
083897  
0D8067B  
0D9853D  
0C2978  
0D6008  
0D4010  
0D6007  
0D4012  
0D8675A  
0D8675B  
0D4015  
2
8
4
4
2
4
4
2
4
4
2
12  
2
2
4
1
4
2
1
1
1
1
1
1
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
ROCKER ARM  
NUT, HEX M8-1.0 GB YELLOW CHROM  
PLATE, PUSH ROD GUIDE  
SCREW HHFC M8-1.25 X 65  
VALVE, EXHAUST  
VALVE, INTAKE  
TAPPET, SOLID  
ASSEMBLY, HEAD #2  
PUSHROD 147  
GASKET, HEAD  
KIT GEAR COVER  
KIT GASKET  
KIT PISTON & RINGS  
KIT BREATHER ASSEMBLY  
KIT HEAD ASSEMBLY CYLINDER 1  
KIT HEAD ASSEMBLY CYLINDER 2  
KIT OIL RELIEF  
0E4356E  
1
20  
0E3223  
0E3222  
0D2157  
0E6098  
0D4123A  
0E8152  
0C3011  
0C3009  
0C3010  
093873  
0F5458  
0C5998  
0D4497  
0C3971E  
0D3745  
0C3027  
0E9842  
2
2
2
1
1
1
2
2
2
2
1
1
1
1
1
3
1
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
WASHER, LOCK RIB M6  
SCREW, PLASTITE HI-LOW #10  
CLAMP, OIL TUBE  
PLUG-CRANKCASE GOVERNOR BORE  
ASSEMBLY, DIPSTICK WITH HANDLE  
TUBE, DIPSTICK  
Item 59 (Kit) includes items 3, 30, 35, 65  
Item 60 (Kit) includes items 2, 5, 17, 18, 34, 35, 40, 57, 139, 153.  
Item 61 (Kit) includes items 8, 11, 12, 13  
Item 62 (Kit) includes items 4, 5, 6  
Item 63 (Kit) includes items 7, 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52,  
53, 54, 57, 58  
Item 64 (Kit) includes items 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, 53,  
54, 56, 57, 58  
Item 65 (Kit) includes items 25, 26, 27  
O-RING, OIL CLR  
SEAL, 42 I.D. CRANKSHAFT  
35  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589-N  
36  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589-N  
ITEM PART #  
QTY. DESCRIPTION  
WINGNUT, AIRBOX  
ITEM PART NO#. QTY. DESCRIPTION  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
89  
90  
0D6592  
0D4511  
0D9723  
0E5302  
0D4183  
0D6327  
0D2774B  
0D5125  
0D2930  
0D4612A  
0D6143  
0D2775  
0D5014A  
0D5014B  
049721  
022097  
022473  
0E8388  
0D6021  
0C9093A  
0D4522  
074908  
0E3398  
0F9035  
0F8603  
0D4026  
0D4024  
048031C  
0F9176  
0D4023  
0D5282  
086061G  
0D6313  
070008  
070006  
049821  
0C9911  
051714  
0D5411  
0D5445  
0D5416A  
0D5398  
0E6043  
0D3432  
045756  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
2
1
1
1
1
1
4
12"  
1
1
1
1
4
4
4
1
1
1
1
1
1
2
1
24  
114  
115  
116  
118  
119  
120  
121  
122  
123  
124  
125  
126  
127  
128  
129  
130  
131  
132  
133  
134  
135  
136  
092079  
0F1338B  
0F6263  
0G0926  
0G0832  
0E7585  
0E4271  
022129  
061906  
022145  
0F5467  
0D1131  
0F1169B  
0C9763  
0C3034  
0C3033  
0C3032  
0A5992  
051754  
0C3031  
0E4997  
045756  
4
1
1
2
1
2
1
3
2
1
1
1
1
4
1
1
1
2
2
1
1
4
SCREW TAPTITE M6-1.0 X 25 BP  
ASSY, IGN COIL W/DIODE NO ADV  
PUMP, IMPULSE  
SCREW, HHFCS M6-1.0 X 16 G8.8  
ELBOW, RUBBER 90 DEG. GASOLINE  
SPARKPLUG, CHAMPION RC14YC  
STARTER, DELCO REMY SD80  
WASHER LOCK M8-5/16  
SCREW HHC M8-1.25 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  
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 I.D.  
COVER, AIRBOX  
KNOB, AIRBOX 17mm  
KNOB, AIRBOX 95MM  
SCREW HHC M6-1.0 X 35  
WASHER LOCK M6-1/4  
WASHER FLAT 1/4  
NUT, HEX FLANGE WHIZ M6-1.0  
STUD, METRIC  
WASHER, M24  
PLATE, FAN  
WASHER SHAKEPROOF INT M8 SS  
SCREW HHC M8-1.25 X 12 G8.8  
FAN, NYLON  
ASSY,GROUND WIRE CONNECTOR  
SCREW TAPTITE M6-1X10 YELLOW  
CHROME  
HOSE, BREATHER  
CONTROLLER ASSEMBLY  
SCREW HHTT M5-0.8 X 10  
ASSEMBLY, WIRE  
CARBURETOR (GT-990)  
CARBURETOR (GT-760)  
GASKET, CARB TO SPACER (GT-990)  
GASKET, CARB/AIRBOX (GT-760)  
CLAMP HOSE BAND 1/4  
HOSE ¼ ID  
GASKET, MANIFOLD TO CARB (GT-990)  
GASKET, MANIFOLD TO CARB (GT-760)  
SLEEVING 1/2" I.D.  
FILTER, FUEL  
WASHER FLAT M8  
137  
138  
139  
140  
141  
142  
143  
144  
145  
146  
148  
149  
150  
151  
152  
153  
154  
155  
157  
0C3725A  
0F1170A  
082774  
0C3043  
0C9764  
0C3026  
0F6301  
0C9806  
035461  
070185B  
0D3083  
0C3025  
0D4550  
0C3018  
0C3019  
046964  
0E0409  
0C8563  
0D9784  
0E4869  
1
1
1
2
4
1
4
2
2
1
1
1
1
1
1
1
1
6
2
2
FLYWHEEL ASSEMBLY  
PLATE, BACKING GT990 W/OIL COOL  
KEY, WOODRFF 4 X 19D  
GASKET, MANIFOLD / PORT  
PLASTITE,1/4-15 X 3/4  
COOLER, OIL  
CLAMP, HOSE OETIKER 16.5mm  
HOSE, 3/8" I.D. X 6" LONG  
BARBED STR 1/4NPT X 3/8  
OIL FILTER  
ASSEMBLY, OIL DRAIN HOSE  
SWITCH, OIL PRESS  
BRACKET, AIRBOX SUPPORT  
WRAPPER, UPPER CYLINDER 1  
WRAPPER, LOWER CYLINDER 1  
BRASS ST ELBOW 1/4 NPT  
ASSY, ROD, GOV. STEPPER MOTOR  
SCREW HHHC M6-1.0 X12  
NUT, LOCK HEX M3-0.5 (GT-990)  
NUT, HEX W/TOOTH WASHER M3-0.5  
(GT-760)  
91  
92  
93  
94  
95  
96  
97  
98  
WASHER LOCK M8  
SCREW SHC M8-1.25 X 30  
MANIFOLD, INTAKE  
99  
100  
101  
102  
103  
104  
105  
106  
107  
108  
NUT HEX M3-0.5  
ROD, SUMMER / WINTER VALVE  
BUSHING, MINI CONTROL PANEL  
KNOB, CONTROL SUMMER / WINTER  
CHOKE ASSEMBLY  
SCREW TAPTITE M5-0.8 X 8 ZP  
PANEL, CONTROL FACE PLATE  
SCREW TAPTITE M6-1.0X 10 YELLOW  
CHROME  
160  
161  
162  
0D6147  
0F1338A  
048031G  
7
1
1
SCREW HHFC M6-1.0 X 10mm  
ASSY, IGN COIL W/DIODE NO ADV  
CLAMP, HOSE BAND GREEN  
109  
110  
111  
112  
113  
0D4767  
0D1142A  
0D1143  
0F1177  
022097  
1
1
1
1
4
SWITCH ROCKER  
WRAPPER, LOWER CYLINDER 2  
WRAPPER, UPPER CYLINDER 2  
ASSEMBLY, GROUND WIRE  
WASHER LOCK M6-1/4  
37  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
Generator – Drawing No. 0D4488-F  
38  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
Generator – Drawing No. 0D4488-F  
ITEM PART NO.  
QTY. DESCRIPTION  
ITEM PART NO.  
QTY. DESCRIPTION  
1
2
0C6934  
0D2123  
0D2134  
0D2136  
1
1
ADAPTOR, ENGINE  
STATOR 12.5KW  
STATOR 15KW  
STATOR 18KW  
ASSEMBLY, ROTOR WITH FAN  
12.5KW  
ASSEMBLY, ROTOR WITH FAN  
15KW  
23  
24  
25  
26  
27  
28  
29  
0A2038  
022237  
022511  
022131  
051731  
022145  
049820  
1
5
4
4
4
21  
4
WASHER FLAT 3/8 ZINC  
WASHER LOCK 3/8  
SCREW HHC 3/8-16 X 1-1/4 G5  
WASHER FLAT 3/8-M10 ZINC  
SCREW HHC M8-1.25 X 50 G8.8  
WASHER FLAT 5/16 ZINC  
NUT LOCK HEX M8-1.25 NYLON  
INSERT  
3
0D21320SRV  
1
0D21330SRV  
0D2135  
0C6043B  
0D2492  
0D2726  
0C4138  
0D3547  
031971  
0C3168  
0D1838  
0D3549  
0C7038E  
032712  
0D4662  
0C7038D  
0C7758  
0388050AF0  
0C2417A  
082121C  
066386  
ROTOR 18KW  
30  
079246  
5
SCREW HHC M6-1.0 X 16 WITH  
LOCK WASHER  
WASHER LOCK M8-5/16  
NUT HEX 5/16-18 STEEL  
SCREW TAPTITE 3/8-16 X 3/4 BP  
SHIELD, MUFFLER HEAT  
U-BOLT & SADDLE  
SCREW SHC M8-1.25 X 18  
PANEL, MUFFLER BOX BACK  
PANEL, MUFFLER BOX END  
SCREW HHTT M6-1.0 X 12  
WASHER FLAT 1/4  
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
1
1
1
2
1
1
3
1
4
1
4
1
1
6
1
1
1
1
1
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 M8-1.25 X 400 G8.8  
BRACKET, ALT MOUNTING  
SCREW HHTT #10-32 X 1.75  
SCREW HHTT M8-1.2 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  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
022129  
022259  
059637  
0D5100  
0D5823  
0C8565  
0D5833  
0D5834  
090388  
022473  
N/A  
18  
12  
2
1
1
4
1
1
3
5
-
1
1
NOT USED  
0D5133  
0D5133A  
SPARK ARRESTOR SCREEN  
RETAINER, SPARK ARREST  
SCREEN  
SCREW HHTT M4-0.7 X 8  
SHIELD, RUBBER MOUNT  
SCREW HHTT M5-0.8 X 16  
44  
45  
46  
045764  
0D6214  
066849  
1
1
2
0C2824  
39  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
Control Panel – Drawing No. 0G0727-B  
40  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
Control Panel – Drawing No. 0G0727-B  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
38  
39  
40  
41  
065795  
0D4804  
0C1085  
051715  
2
2
4
12  
8
14  
1
1
2
1
1
1
1
2
6
1
2
1
2
2
10  
3
2
2
14  
10  
1
RECTIFIER-BATTERY CHARGER  
TRANSFORMER, IDLE CURRENT  
SCREW PPHM M3-0.5 X 8  
NUT HEX M4-0.7 G8 (15 KW)  
NUT HEX M4-0.7 G8 (17.5 KW)  
WASHER LOCK M4  
1
2
3
4
5
087968  
090418  
0D6640  
090987  
0D8740  
0G0309  
068868  
0G1093  
1
1
1
6
1
1
2
4
SWITCH, ROCKER -/0  
OUTLET, 12VDC SNAP  
COVER, GOVERNOR CONTROL  
SCREW PPHM M3-0.5 X 12  
PANEL, SHEET METAL (15 KW)  
PANEL, SHEET METAL (17.5 KW)  
OUTLET 30A 120V RECEPT  
SCREW SFILHM #8-32 X 5/8 LG (17.5 KW  
ONLY)  
WASHER LOCK M3  
NUT HEX LOCK M3-0.5 NY INS  
CIRCUIT BREAKER 30A  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
022264  
048505  
087962  
036261  
0A2769  
032300  
028578  
055444  
075475  
082025  
0A2053  
055440  
045770  
0G0923  
0D5734  
074908  
075235  
077682  
080823  
038150  
CIRCUIT BREAKER 6 X 1  
6
7
CIRCUIT BREAKER 10 X 1 12VDC 1/4"QC  
RIVET POP .125 X .250 SS  
LUG GROUND 8 TABS  
HOLDER FUSE  
FUSE 10A X AGC10  
8
9
043182  
0D9784  
075207A  
075207  
0G1493  
043437  
0D4968  
0D4966  
0D1004E  
0E6480  
022471  
0D5045  
0F9719  
0D4409  
4
6
4
2
1
1
1
1
1
4
4
1
1
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
HEATSINK  
CIRCUIT BREAKER 20A  
OUTLET 50A 250V (17.5 KW ONLY)  
OUTLET 30A 125/250V  
SCREW PPHM M4-0.7 X 10  
NUT HEX LOCK M5-0.8 NYINS  
SCREW HHC M6-1.0 X 65 G8.8  
SCREW HHC M5-0.8 X 25 G8.8  
SCREW HHC M5-0.8 X 10 G8.8  
SPACER .25 X .50 X 2.5 (17.5 KW)  
SPACER .25 X .50 X 1.5 (15 KW)  
SCREW HHTT M5-0.8 X 10  
SCREW PPHM M5-0.8 X 30  
SCREW PPHM M5-0.8 X 80 (17.5 KW)  
SCREW PPHM M5-0.8 X 50 (15 KW)  
WASHER FLAT #8 (15 KW)  
WASHER FLAT #8 (17.5 KW)  
GASKET, PORTABLE CONTROL PANEL  
SCREW PPHM M4-0.7 X 16  
OUTLET 20A 120V DPLX  
OUTLET 20A 120V GFCI  
CIRCUIT BREAKER 50A 400V 2POLE  
NUT HEX M4-0.5 NYINS  
NUT HEX #8-32 (17.5 KW ONLY)  
DIN RAIL 59.5mm LONG  
ASSY PCB VREG AIR COOLED  
ELECTRONIC GOVERNOR / IDLE  
CONTROLLER  
RELAY PNL 12VDC SPST 30A  
RELAY 3PDT 12VDC  
CONTROL PANEL BOX (15 KW)  
CONTROL PANEL BOX (17.5 KW)  
BUSHING SNAP  
RIVET POP .156 X .160-.164 / #20  
BLOCK TERMINAL 20A 2 X 6 X 1100V  
BLOCK DOUBLE ROW TERMINAL 8  
POSITION  
RECTIFIER MSC 12A 600V  
WASHER MICA .203  
WASHER STEP NYLON .20  
NUT HEX #10-32  
WASHER FLAT #10  
56  
57  
58  
59  
22  
23  
24  
052844  
0F3100  
0G0503  
0F7424  
023484S  
0A1661  
048766  
0D3550  
1
1
1
1
1
2
1
1
60  
61  
62  
63  
64  
65  
66  
0D6140  
075476  
027565  
058000K  
0F3101  
0D4969  
0F5483  
2
A/R TAPE ELEC UL PERMACEL  
25  
26  
27  
28  
2
1
1
1
NUT TRIC M5-0.8  
RELAY BASE 3PDT 12VDC  
OUTLET 50A 125/250V (15 KW ONLY)  
HARNESS, CONTROL PANEL BACK(NOT  
SHOWN)  
HARNESS, CONTROL PANEL FRONT (NOT  
SHOWN)  
HARNESS, TERMINAL STRIP TO PCB (NOT  
SHOWN)  
SPRING RETAINER  
29  
30  
31  
32  
33  
34  
35  
36  
37  
049939  
070370  
030468  
022158  
023897  
057405  
022473  
022097  
049813  
1
1
1
1
1
1
1
1
1
67  
68  
69  
0D3546  
0D5809  
0G0615  
1
1
1
RESISTOR 25R 5% 25W  
WASHER FLAT 1/4  
WASHER LOCK M6-1/4  
NUT HEX M6-1.0 G8  
41  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
Frame, Handle & Wheel Kit – Drawing No. 0E0695-B  
42  
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Section 9 — Exploded Views and Parts Lists  
Commercial-Industrial-Residential Portable Generator System  
Frame, Handle & Wheel Kit – Drawing No. 0E0695-B  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
045900  
0D7668  
0D4999  
0D4044  
0D3700  
0D2497  
022532  
027028  
0D2271  
052762  
051713  
049226  
051716  
050190  
078299  
080270  
0D5142  
096021  
048031C  
0F9176  
075763  
075763A  
0E0318  
030795  
2
2
2
2
4
1
4
6
1
4
8
4
4
2
1
1
1
2
2
WASHER FLAT 3/4" (15 kW)  
12.3" PNEUM WHEEL 3/4" AXLE (15 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"  
1
2
3
4
5
6
7
8
057058  
0D5315  
0D4570  
0D22850SRV  
045771  
022129  
022145  
0D4565  
0D3545  
022287  
022473  
022097  
022127  
0388040AK0  
0D4575  
0D5202  
0D5199  
029809  
0C3168  
0D5198  
0E0317  
027007  
0D5303  
042909  
090388  
064101  
039214  
0D9165  
4
4
1
1
4
SCREW HHC M6-1.0 X 55  
RUBBER TANK MOUNT  
CAP, FUEL WITH GAUGE & VENT  
KIT, FUEL TANK  
NUT HEX M8-1.25  
10 WASHER LOCK M8-5/16  
14 WASHER FLAT 5/16  
1
2
2
2
2
2
1
1
1
4
1
1
1
1
2
4
2
4
6
6
1
BRACKET BATTERY  
9
BOLT,BATTERY J-BOLT  
SCREW HHC 1/4-20 X 3/4 G5  
WASHER FLAT 1/4  
WASHER LOCK M6-1/4  
NUT HEX 1/4-20  
BATTERY CABLE, RED  
BATTERY U1  
NUT WING 5/16-18 BRASS  
WASHER FLAT 5/16 BRASS  
NUT HEX 5/16-18 BRASS  
5/16 SPECIAL L/WASH  
SCREW HHC 5/16-18 X 1.5 BRASS  
BRACKET FRONT FOOT (15 kW)  
VIB MOUNT  
WASHER FLAT .25ID X 1"OD  
SCREW HHC M8-1.25 X 30  
SCREW HHTT M6-1.0 X 12  
NUT LOCK FL 3/8-16  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
BUSHING TANK DEXTOR  
VALVE, PLASTIC TANK  
AIR DEFLECTOR  
GROMMET .75 X .06 X .50  
CLAMP HOSE BAND ¼  
18" HOSE ¼ ID  
1
1
2
2
BOOT BATTERY CABLE  
BOOT STARTER CABLE  
SPACER, AXLE (15 kW)  
SCREW HHC 5/16"-18 X 1"  
BOLT CARR 3/8-16 X 1  
AXLE, 3/4"DIA X 30" (15 kW)  
43  
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Section 10 – Warranty  
Commercial-Industrial-Residential Portable Generator System  
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT  
YOUR WARRANTY RIGHTS AND OBLIGATIONS  
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the  
Emission Control System warranty on your new engine. In California, new off-road Large Spark-Ignition (LSI) engines must  
be designed, built and equipped to meet the state's stringent anti-smog standards. Generac will warrant the emission  
control. system on your engine one for the periods of time listed below provided there has been no abuse, neglect,  
unapproved modification or improper maintenance of your engine.  
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will  
repair your engine at no cost to you for diagnosis, replacement parts arid labor, should a warrantable condition occur.  
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:  
Emissions control systems on 2001 and later model year LSI engines are warranted for two years as hereinafter noted- If,  
during such warranty period, any emission-related component or system on your engine is found to be defective in  
materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.  
PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES:  
As the engine owner, you are responsible for the completion of all required maintenance as listed in your factory supplied  
Owner's Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your  
engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the  
completion of all scheduled maintenance.  
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage  
or responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect , improper maintenance or  
unapproved modifications, or the use of counterfeit and/ox "grey market" parts not made, supplied or approved by Generac.  
You are responsible for contacting a. Generac Authorized Warranty Facility as soon as a problem occurs. The  
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.  
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service  
Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll free number:  
1-800-333-1322  
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System  
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the "Generac Limited  
Warranties for Generac Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by  
Generac.The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms  
between the ECS Warranty and the Generac Warranty, the ECS warranty shall apply except in circumstances where the  
Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe  
important rights and obligations with respect to your new engine.  
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty  
service, evidence must be presented showing the date of the sale to the original purchaser/owner.  
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at one of the  
following addresses:  
ATTENTION WARRANTY DEPARTMENT  
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 297 • WHITEWATER, WI 53190  
Part 1  
44  
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Section 10 – Warranty  
Commercial-Industrial-Residential Portable Generator System  
EMISSION CONTROL SYSTEM WARRANTY  
Emission Control System Warranty (ECS warranty) for 2001 and later model year LSI engines:  
(a) Applicability:This warranty shall apply to 1995 and later model year engines.The ECS Warranty period shall begin on the date the new engine  
or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.  
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment and to  
each subsequent purchaser/owner that each of its engines is...  
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its authority, and  
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted emissions-  
related part to fail to be identical in all material respects to the part as described in the engine manufacturer's application for certification.  
The ECS Warranty pertains only to emissions-related parts on your engine, as follows:  
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner's Manual shall be  
warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac  
according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the  
ECS Warranty Period.  
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for  
the ECS Warranty Period. A statement in such written instructions to the effect of "repair or replace as necessary" shall not reduce the ECS  
Warranty Period.Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.  
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted  
for the period of time prior to first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part  
shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the  
ECS warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such  
emissions-related part.  
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a  
Generac Authorized Warranty Service Facility.  
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for  
diagnostic costs if the repair is deemed warrantable.  
(6) Generac shall be liable for damages to other original engine components or approved modifications caused by a failure under warranty of any  
emission-related part covered by the ECS Warranty.  
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected  
demand for such emission-related parts.  
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS warranty maintenance  
or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac 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:  
a) Spark plug  
b) Ignition module  
1.2) LPG/Natural Gas carburetion assembly and its internal components.  
a) Fuel controller (if so equipped)  
4) Catalytic Muffler Assembly (if so equipped) including:  
a) Muffler gasket  
b) Exhaust manifold  
b) Mixer and its gaskets (if so equipped)  
c) Carburetor and its gaskets (if so equipped)  
d) Primary gas regulator (if so equipped)  
e) LP liquid vaporizer (if so equipped)  
5) Crankcase Breather Assembly including:  
a) Breather connection tube  
2) Air Induction System including:  
a) Intake pipe/manifold  
* Generac engine types covered by this warranty statement include the following:  
b) Air cleaner  
1) Prepackaged Standby Generator  
2) Auxiliary Power Unit (APU) Generator  
3) Standby Generator  
Part 2  
45  
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Section 8 – Warranty  
Commercial-Industrial-Residential Portable Generator System  
GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR GENERAC®  
17,500 WATT PORTABLE GENERATOR WITH MANUAL TRANSFER SWITCH  
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its portable generator and accompanying  
transfer switch 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 portable generator prepackaged with transfer switch sold and rated for use in "Standby" applications and is not transferable.  
WARRANTY SCHEDULE  
Consumer applications are warranted for 2 (two) years. Commercial applications are warranted for 1 (one) year. Rental applications are warranted for 90  
(ninety) days.  
CONSUMER APPLICATION  
YEARS ONE and TWO - 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):  
•
•
Engine - All Components  
Alternator - All Components  
NOTE: For the purpose of this warranty "consumer use" means personal residential household use by original purchaser. This does not apply to units  
used for Prime Power in place of utility where utility power service normally exists. Once a generator has experienced commercial or rental use, it shall  
thereafter be considered a non-consumer use generator for the purpose of this warranty.  
All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate Manual.  
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:  
•
•
•
•
Generac portable generators that utilize non-Generac replacement parts.  
Costs of normal maintenance and adjustments.  
Failures caused by any contaminated fuels, oils or lack of proper oil levels.  
Repairs or diagnostics performed by individuals other than Generac authorized dealers not authorized in writing by  
Generac Power Systems.  
•
•
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.  
Products that are modified or altered in a manner not authorized by Generac in writing.  
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).  
Failure due to misapplication.  
Telephone, cellular phone, facsimile, internet access or other communication expenses.  
Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.  
Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.  
Rental equipment used while warranty repairs are being performed.  
Overnight freight costs for replacement part(s).  
Overtime labor.  
Starting batteries, fuses, light bulbs and engine fluids.  
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES  
AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty  
lasts, so the above limitation may not apply to you.  
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE  
FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states  
do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.  
This warranty gives you specific legal rights. You also have other rights from state to state.  
GENERAC® POWER SYSTEMS, INC.  
P.O. BOX 8 • WAUKESHA, WI 53187  
Revision 05/02/06  
Printed in U.S.A  
Part No. 0G0941  
Revision 0 (05/05/06)  
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