Section 6 — Electrical Data Section 3 — Maintenance

Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System

Wiring Diagram – Drawing No. 0E0228

TOR RELAY
CB1 - 5AMP AUT O RESE T BREAKER

FSS - F UEL SHU T OFF SOLENOID

IM2 - I GNITION MODULE, CYL. 2

IM1 - I GNITION MODULE, CYL. 1
3.3 GENERAL RECOMMENDATIONS

CLOSES T TO BEARING

BLOCK
D - ENGINE SHU TDOWN DIODE
3.3.3 ENGINE MAINTENANCE

BA

R1 - 25 OHM, 2 5W RESISTOR

SSR - S TART / STOP RELAY

RE

OR

SP2 - S PARK PLUG, CYL. 2

SP1 - S PARK PLUG, CYL. 1
EMBLY

D2 - 600 V 12A DIODE

LOP - L OW OIL PRESSU

SCR - S TARTER CONTAC

REGULATOR
VOLTAGE

SC - STARTER CONTACT
The warranty of the generator does not cover items that have

TB1, TB 2 - TERMINAL
0
4
DANGER! When working on the generator, always disconnect

SM - STARTER MOTOR
GND - G ROUND BAR
STATOR

BA - BRUSH ASS

F1 - 10A FUSE
been subjected to operator abuse or negligence. To receive full negative cable from battery. Also disconnect spark plug wires

LEGEND
value from the warranty, the operator must maintain the

1
2
3
4
5
6
from spark plug and keep wire away from spark plug.

77

PIN
PIN
PIN
PIN
PIN
PIN

R1
PIN #
generator as instructed in this manual.

66

11
12

D2

RECTIFI ER

RECTIFI ER
0
55

10

6
6

BATTERY

BATTERY
4

CHARGE

CHARGE
162
9
77A

44S
8
2
3.3.4 CHECKING OIL LEVEL

11S
7
66A
55A
Some adjustments will need to be made periodically to properly

6
44S

5
11S

14
4
4

6
maintain the generator. See the “BEFORE STARTING THE GENERATOR” section on page
22

66
77
77

77
2

66
44

66
10 for information on checking the oil level. The oil level should
1
11

77A

66A
77A
66A
All adjustments in the Maintenance section (3) of this manual be checked before each use, or at least every eight hours of

0
2 operation. Keep the oil level maintained.
22

should be made at least once each season. Follow the

CB1

13A
15
14
55

14

15
requirements in the "Maintenance Schedule" chart on page 14.

0
162
55

55
3.3.5 CHANGING THE OIL AND OIL FILTER
55A

55A
44

11S
44S
11

NOTE: Once a year you should replace the spark plug

RESET BKR
10A AUTO
Change the oil and filter after the first eight hours of operation.
TB2
IDLE CONTROL
TRANSFORMERS

/
B. and replace the air filter. A new spark plug and clean
Change the oil every 100 hours thereafter. If you are running this
TB1

1
RED

BLK

GOVERNOR
ENGINE SHUTDOWN P.C.
3
BLK

air filter assure proper fuel-air mixture and help your

4

15A
unit under dirty or dusty conditions, or in extremely hot weather,
5
6
7

J2

ELECTRONIC

14
engine run better and last longer.
8

J1

change the oil more often.

9
12 11 10

12Vdc OUTLET

0
14
0
229
83
11

3.3.1 GENERATOR MAINTENANCE

15B

86
22

167

0
Use the following instructions to change the oil while
86
44A

Generator maintenance consists of keeping the unit clean and dry. the engine is still warm:

14
0
44

CONTROL

Operate and store the unit in a clean dry environment where it will
ON/OFF

SWITCH
IDLE

• Clean area around oil drain hose and plug.

229

167
Y
120/240 V

14
50A OUTLET

83
44A
GREEN

WHITE

not be exposed to excessive dust, dirt, moisture or any corrosive

0
0
OFF
ON

• Remove oil drain plug from end of hose and oil fill plug to drain
14
11
X

vapors. Cooling air slots in the generator must not become

15B

0
C.B.
50A

oil completely into a suitable container.

0

0
clogged with snow, leaves, or any other foreign material.
55A
18
11A
0

11A

15
11

• When oil has completely drained, install oil drain plug and
12
4

8
44

14
0

0
11

14
22

55
SSR
10
11

6
44

44

Check the cleanliness of the generator frequently and clean when tighten securely.
44
22

13

15
1

9
44
0
0

11

dust, dirt, oil, moisture or other foreign substances are visible on

14
0

15
Y
G

• Place a suitable container beneath the oil filter and turn filter
15

GND
30A TWISTLOK
120/240 V

22

its exterior surface.

C.B.

C.B.
30A

30A

counterclockwise to remove. Discard according to local

0

0 0
WHITE

44B
X

0
22

0
0

regulations.
11

0
11B

CAUTION! Never insert any object or tool through the air

0

0
22
120V/20 A

• Coat gasket of new filter with clean engine oil. Turn filter
GFCI

0
44

cooling slots, even if the engine is not running.

22

F1

clockwise until gasket contacts lightly with filter adapter. Then

0

44
2

WHITE WHITE
11
C.B.
20A
LOAD

LINE

tighten an additional 3/4 turn.

22
22

SCR
22

HOT HOT

Note: DO NOT use a garden hose to clean generator.

3

86
1

18

85
87

30
44C

• Fill oil sump with recommended oil. (See “Before Starting the
87a

Water can enter the engine fuel system and cause

86
22

0
15

13

17
16
167

Generator” on page 10 for oil recommendations).

120V/20 A

14

problems. In addition, if water enters the generator

DUPLEX

15

15
22

22

15

13
0

through cooling air slots, some water will be retained • Wipe up any spilled oil.
11
2

PIN #

WHITE WHITE
11
10

12
1

7
8
9
C.B.
20A

in voids and crevices of the rotor and stator winding

167
15

HOT HOT
3
1

16
0

insulation. Water and dirt buildup on the generator

11C

13

13

internal windings will eventually decrease the

15
22

insulation resistance of these windings.

17
0

SC
0

ACTUATOR

0
GOVERNOR
120V/30 A

(START)
TWISTLOK

86

SM
14
STOP
RUN
0

0
0

IC

3.3.2 TO CLEAN THE GENERATOR

RED
G

11

FSS
C.B.
30A

• Use a damp cloth to wipe exterior surfaces clean.

WHITE

11D

LOP

0
22

• A soft, bristle brush may be used to loosen caked on dirt, oil, etc.
D

BATTERY
+
44

ENGIN E WIRING

12V
120V/30 A

IM1

IM2
TWISTLOK

• A vacuum cleaner may be used to pick up loose dirt and debris.

0

-
0

BLACK
22
G

• Low pressure air (not to exceed 25 psi) may be used to blow

C.B.
30A
WHITE

away dirt. Inspect cooling air slots and openings on the

44D
22

SP1
22

SP2

generator. These openings must be kept clean and

unobstructed.
22 15
 Section 3 — Maintenance Section 6 — Electrical Data
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
Schematic – Drawing No. 0E0229-A

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 12500 GPS 15000
Model # 004451-1 004582-1
Rated Max. Power 12.5 kW 15.0 kW
Surge Power 18.75 kW 22.5 kW
Rated AC Voltage 120/240 120/240
Rated Max AC Load
Current @ 240V 52.0 Amps 62.5 Amps
Current @ 120V 104.0 Amps 125.0 Amps
Rated Frequency 60 Hz @ 3600 RPM
Phase Single Phase
Rated DC Voltage 12 Volts
Rated Max DC Load
Current @ 12 Volts 10 Amperes

3.2.2 ENGINE SPECIFICATIONS

Rated Horsepower
@ 3600 RPM 27 30
Displacement 763cc 992cc
Spark Plug Type Champion RC14YC or Equivalent
Spark Plug Gap 0.030 inch or (0.76 mm)
Gasoline Capacity 16 U.S. gallons
Oil Type Summer – SAE 30 or 10W-30 Winter – Synthetic 5W-20 or 5W-30
Oil Capacity w/ Filter Change = 1.5 Qts. w/o Filter Change = 1.2 Qts.
Run Time/Fuel 10 Hours / 1.6 gallons per hour
Consumption-1/2 Load

14 23
 Section 7 — Exploded Views and Parts Lists Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589E

2.12 CHARGING A BATTERY

 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.

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.

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.

24 13
 Section 2 — Operation Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 1) – Drawing No. 0E8589E

• Move engine CHOKE knob to “Full Choke” position. ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
2.9 AUTOMATIC IDLE CONTROL
Figure 17 - Full Choke Position 1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING 36 0C5731 1 ASSEMBLY, HOUSING COVER
This feature is designed to greatly improve fuel economy. When WITH SLEEVE WITH SLEEVE
2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT 37 0C3006 10 SCREW, HHFC M10-1.5 X 55
this switch is turned “On,” the engine will only run at its normal
3 090388 3 SCREW, TAPTITE M6-1.0 X 12 BP 38 080318 8 SCREW HHFC M6-1.0 X 25
fast governed engine speed when electrical load is connected. 4 0C5372 1 ASSEMBLY, BREATHER 39 0C8808 2 HOOK, LIFTING
When the load is removed, the engine will run at a reduced speed 5 0C3005 1 GASKET, BREATHER COVER 40 0C2981C 1 ROCKER, COVER
of 2100 RPM. With the switch “Off,” the engine runs at the 6 0E3372B 1 SEPARATOR, OIL BREATHER 41 0C2979 2 GASKET, VALVE COVER
normal fast engine speed all the time. Always have the 7 0D8067A 1 ASSEMBLY, HEAD #1 42 086515 8 KEEPER, VALVE SPRING
switch OFF when starting and stopping the engine. 8 071983 4 RETAINER, PISTON PIN 20 43 0D2274 4 RETAINER, VALVE SPRING
9 0D5269 1 ROCKER, COVER 44 0D3867 4 SPRING, VALVE
10 043790A 1 BARBED EL 90 3/8NPT X 3/8 45 078672 2 SEAL, VALVE STEM D7
11 0E2950 2 PISTON, LC (GT-990) 46 0C5371 4 WASHER, VALVE SPRING
2.10 COLD WEATHER OPERATION/ 0E2985 2 PISTON, HC (GT-760) 47 072694 4 STUD, ROCKER ARM PIVOT
DE-ICER 12 021533 2 SET, PISTON RING 90MM 48 0C3027 2 O-RING, 3/8" X 1/2"
13 0E1466 2 PIN PISTON 49 0D5313 4 ROCKER ARM
Under certain weather conditions (temperatures below 40° F (4° 14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR 50 0D3998 4 NUT, HEX M8-1.0 GB YELLOW
C) and a high dew point), the engine may experience icing of the 15 0D4788 2 PLUG STD PIPE 3/8 STEEL SQ HD CHROME
carburetor and/or the crankcase breather system. To eliminate 16 093064 1 ASSEMBLY, OIL FILL CAP 51 0D6024 2 PLATE, PUSH ROD GUIDE
this problem, this generator engine is fitted with a winter/summer 17 0C2977 1 GASKET, CRANK CASE 52 0C2976 12 SCREW HHFC M8-1.25 X 65
• To start engine, press and hold the Start/Run/Stop switch in valve. this directs hot air into the carburetor during cold weather 18 0C5943 1 SEAL, OIL PASSAGE 53 086516 2 VALVE, EXHAUST
19 0E4357E 1 ASSEMBLY, CRANKSHAFT 54 0C2229 2 VALVE, INTAKE
the “Start” position. The engine will crank and attempt to start. operation. Always make sure the winter/summer valve is in the
HORIZONTAL DIRECT DRIVE 55 083897 4 TAPPET, SOLID
When the engine starts, release the switch to the run position. correct location relative to the weather conditions. (GT-990) 56 0D8067B 1 ASSEMBLY, HEAD #2
• When the engine starts, move choke knob to “1/2 Choke” position until 0E4356E 1 ASSEMBLY, CRANKSHAFT 57 0D9853D 4 PUSHROD 147
the engine runs smoothly and then to “Run” position. If engine falters, HORIZONTAL DIRECT DRIVE 58 0C2978 2 GASKET, HEAD
move choke knob to “1/2 Choke” position until the engine runs 2.11 LOW OIL PRESSURE SHUTDOWN (GT-760) 59 0D6008 1 KIT GEAR COVER
20 0E3223 2 ASSEMBLY, CONNECTING ROD 60 0D4010 1 KIT GASKET
smoothly and then to “Run” position. SYSTEM (GT-990) 61 0D6007 1 KIT PISTON & RINGS
Note: If engine fires, but does not continue to run, 0E3222 2 ASSEMBLY, CONNECTING ROD 62 0D4012 1 KIT BREATHER ASSEMBLY
The engine is equipped with a low oil pressure sensor that shuts (GT-760) 63 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1
move choke lever to “Full Choke” and repeat starting
down the engine automatically when the oil pressure drops below 21 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8 64 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2
instructions.
10 psi. If the engine shuts down by itself and the fuel tank has 22 0E6098 1 SCREEN, OIL PICKUP 65 0D4015 1 KIT OIL RELIEF
enough gasoline, check engine oil level. 23 0D4123A 1 ASSEMBLY, OIL PUMP
24 078699E 2 SLEEVE, SEAMED DOWEL 10 DIA. Item 59 (Kit) includes 3, 30, 35, 65
items
2.8 STOPPING THE ENGINE 2.11.1 INITIAL START-UP 25 0C3011 2 COVER, OIL RELIEF Item 60 (Kit) includes 2, 5, 17, 18, 34, 35, 40, 57, 139, 153.
items
26 0C3009 2 SPRING, OIL RELIEF Item 61 (Kit) includes 8, 11, 12, 13
items
• Shut off all loads, then unplug the electrical loads from A delay built into the low oil shutdown system allows oil pressure Item 62 (Kit) includes 4, 5, 6
items
27 0C3010 2 BALL, 1/2D OIL RELIEF
generator panel receptacles. Never start or stop the engine to build during starting. The delay allows the engine to run for 28 093873 2 WASHER, LOCK RIB M6 Item 63 (Kit) includes 7, 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52,
items
with electrical devices plugged in and turned on. about 10 seconds before sensing oil pressure. 29 0C5315 1 GEROTOR, OUTER 53, 54, 57, 58
Item 64 (Kit) includes items 41, 42, 43, 44, 45, 46, 47, 49, 50, 51, 52, 53,
• Turn “Off” the Idle Control switch (if on). 30 0C5998 1 CLAMP, OIL TUBE 54, 56, 57, 58
31 0D4497 1 PLUG-CRANKCASE GOVERNOR Item 65 (Kit) includes items 25, 26, 27
• Let engine run at no-load for several minutes to stabilize the 2.11.2 SENSING LOW OIL PRESSURE BORE
internal temperatures of engine and generator. 32 0C3971E 1 ASSEMBLY, DIPSTICK WITH
If the system senses low oil pressure during operation, the engine HANDLE
• Move Start/Run/Stop switch to “Off” position. shuts down. 33 0D3745 1 TUBE, DIPSTICK
• Close fuel valve. 34 0C3027 3 O-RING, OIL CLR
35 0E9842 1 SEAL, 42 I.D. CRANKSHAFT
IMPORTANT: Do not overload the generator. Also, do not 2.11.3 RESTARTING
overload individual panel receptacles. These outlets are protected If you try to restart the engine within 10 seconds after it shuts
against overload with push-to-reset-type circuit breakers. If down, the engine may NOT start. The system needs 5 to 10
amperage rating of any circuit breaker is exceeded, that breaker seconds to reset.
opens and electrical output to that receptacle is lost. Read “Don’t
Overload the Generator” on page 9 carefully. 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.

12 25
 Section 7 — Exploded Views and Parts Lists Section 2 — Operation
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589E

2.6.2 ADDING GASOLINE Figure 15 - Fuel Shut-off Valve

-------------
WARNING
-------------
 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.

Caution: Do not overfill the fuel tank. Always
leave room for fuel expansion.
• Use regular UNLEADED gasoline with the generator engine. Do
not use premium gasoline. Do not mix oil with gasoline.
• Clean area around fuel fill cap, remove cap.
• Slowly add unleaded regular gasoline to fuel tank. Be careful
not to overfill. Allow about 1/2" of tank space for fuel
• Locate the Idle Control ON/OFF switch on the control panel and
expansion, as shown here.
set it to the “OFF” position.
• Install fuel cap and wipe up any spilled gasoline.
Figure 16 - Idle Control Switch
Figure 14 - Fuel Tank

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.

2.7 TO START THE ENGINE

 WARNING! Never start or stop engine with electrical
devices plugged into the receptacles AND devices turned on.
• Unplug all electrical loads from the unit's receptacles before
starting the engine.
• Make sure the unit is in a level position.
• Open the fuel shut-off valve.
26 11
 Section 2 – Operation Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
GT-990 & GT-760 Engine (Page 2) – Drawing No. 0E8589E

ITEM PART # QTY. DESCRIPTION

ITEM PART NO#.QTY. DESCRIPTION
2.5 WATTAGE REFERENCE GUIDE 66 0D6592 1 WINGNUT, AIRBOX
Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts Device . . . . . . . . . . . . . . . . . . . . . . .Running Watts 67 0D4511 1 PRECLEANER, AIR 115 0F1338B 1 ASSY, IGN COIL W/DIODE NO ADV
*Air Conditioner (12,000 Btu) . . . . . . . . . . . . . . . . .1700 Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450 68 0D9723 1 ELEMENT, AIR CLEANER 116 0C4147 1 PUMP, IMPULSE
*Air Conditioner (24,000 Btu) . . . . . . . . . . . . . . . . .3800 Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 69 0E5302 1 STUD M6-1.0 X 73 117 022264 2 WASHER LOCK M4
*Air Conditioner (40,000 Btu) . . . . . . . . . . . . . . . . .6000 Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200 70 0D4183 1 ADAPTOR, SPIT BACK 118 0D6142 2 SCREW PPHM M4-0.7 X 40
Battery Charger (20 Amp) . . . . . . . . . . . . . . . . . . . . .500 *Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 71 0D6327 1 GASKET, SPITBACK 119 0D5399A 1 ELBOW, RUBBER 90 DEG.
Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 Lawn Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200 72 0D2774B 1 BASE, AIRBOX (GT-990) 120 0E7585 2 SPARKPLUG, CHAMPION RC14YC
Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200 Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 0E4870 1 BASE, AIRBOX (GT-760) 121 0E4271 1 STARTER, DELCO REMY SD80
Circular Saw (6-1/2") . . . . . . . . . . . . . . . . . . .800 to 1000 Microwave Oven . . . . . . . . . . . . . . . . . . . . . .700 to 1000 73 0D5125 1 SPRING, WINTER/SUMMER VALVE 122 022129 3 WASHER LOCK M8-5/16
*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . .5750 *Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1100 74 0D2930 1 VALVE, SUMMER / WINTER 123 061906 2 SCREW HHC M8-1.25 X 85 G8.8
*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . . .700 Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . .300 75 0D4612A 1 SNORKEL, AIR INTAKE 124 022145 1 WASHER, FLAT M8
*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . .1150 Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . .400 76 0D6143 1 TUBE, HEAT RISER 50.8 I.D. 125 045771 1 NUT, HEX M8-1.25 G8
Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750 Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . . . .225 77 0D2775 1 COVER, AIRBOX 126 0D1131 1 GUARD,FAN
*Compressor (1 HP) . . . . . . . . . . . . . . . . . . . . . . . .2000 Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . .150 78 0D5014A 1 KNOB, AIRBOX 17mm 127 0C3022B 1 HOUSING, BLOWER GASOLINE
*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . . .1800 *Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . .600 79 0D5014B 1 KNOB, AIRBOX 95MM COOLER
*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . .1400 Paint Sprayer, Airless (handheld) . . . . . . . . . . . . . . . .150 80 049721 1 SCREW HHC M6-1.0 X 35 128 0C9763 4 NUT, GROMMET 1/4 PLUG
Curling Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 200 81 022097 1 WASHER LOCK M6-1/4 129 0C3034 1 NUT,HEX M24
*Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650 *Refrigerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 82 022473 1 WASHER FLAT 1/4 130 0C3033 1 WASHER, M24
Disc Sander (9") . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200 Slow Cooker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 83 052857 4 NUT LOCK FLANGE M6-1.0 131 0C3032 1 PLATE, FAN
Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 *Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . . .2800 84 0D6021 4 STUD, METRIC 132 0A5992 2 WASHER SHAKEPROOF INT M8 SS
Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 *Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . . .2000 85 0C9093A 1 HOSE, BREATHER 133 051754 2 SCREW HHC M8-1.25 X 12 G8.8
Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200 *Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . .1500 86 0D4522 1 CONTROLLER ASSEMBLY 134 0C3031 1 FAN, NYLON
Electric Range (per element) . . . . . . . . . . . . . . . . . .1500 *Sump Pump . . . . . . . . . . . . . . . . . . . . . . . .800 to 1050 87 074908 2 SCREW HHTT M5-0.8 X 10 135 0E4997 1 ASSY,GROUND WIRE CONNECTOR
Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250 *Table Saw (10") . . . . . . . . . . . . . . . . . . . . .1750 to 2000 89 0E3398 1 ASSEMBLY, WIRE 136 045756 4 SCREW TAPTITE M6-1X10 YELLOW
*Freezer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 Television . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500 90 0E2548 1 CARBURETOR (GT-990) CHROME
*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . .875 Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650 0E5077 1 CARBURETOR (GT-760) 137 0C3725A 1 FLYWHEEL ASSEMBLY
*Garage Door Opener . . . . . . . . . . . . . . . . . . .500 to 750 Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 91 0D4026 1 GASKET, CARB TO SPACER 138 0C3016A 1 PLATE, BACKING GT990 WITH OIL
Hair Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200 *Allow 3 times the listed watts for starting these devices. (GT-990) COOL
Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100 0D4024 1 GASKET, CARB/AIRBOX (GT-760) 139 082774 1 KEY, WOODRFF 4 X 19D
92 048031C 4 CLAMP HOSE BAND 1/4 140 0C3043 2 GASKET, MANIFOLD / PORT
• Above 40°F, use SAE 10W-30 or SAE 30. 93 030340 12" HOSE ¼ ID 141 0C9764 4 PLASTITE,1/4-15 X 3/4
94 0D4023 1 GASKET, MANIFOLD TO CARB 142 0C3026 1 COOLER, OIL
2.6 BEFORE STARTING THE • Below 40°F, use synthetic 5W-20 or 5W-30. (GT-990) 143 0C7649 4 CLAMP HOSE .38-.87
GENERATOR Although multi-viscosity oils (5W-30, 10W-30, etc.) improve 0D5282 1 GASKET, MANIFOLD TO CARB 144 0C9806 2 HOSE, 3/8" I.D. X 6" LONG
starting in cold weather, these multi-viscosity oils will result in (GT-760) 145 035461A 2 BARBED STR 1/4NPT X 3/8 WITH
Prior to operating the generator, engine oil and gasoline will need increased oil consumption when used above 32°F. Check your 95 086061G 1 SLEEVING 1/2" I.D. VIBRA SEAL
to be added, as follows: engine oil level more frequently to avoid possible damage from
96 0D6313 1 FILTER, FUEL 146 070185B 1 OIL FILTER
97 070008 4 WASHER FLAT M8 147 0C7292 1 NIPPLE, 3/4"-16 UNF
running low on oil. 98 070006 4 WASHER LOCK M8 148 0D3083 1 ASSEMBLY, OIL DRAIN HOSE
2.6.1 ADDING ENGINE OIL
• Place generator on a level surface. 99 049821 4 SCREW SHC M8-1.25 X 30 149 0C3025 1 SWITCH, OIL PRESS
NOTE: When adding oil to the engine crankcase in 100 0C9911 1 MANIFOLD, INTAKE 150 0D4550 1 BRACKET, AIRBOX SUPPORT
• Clean area around oil fill and remove oil fill cap and dipstick. 101 051714 1 NUT HEX M3-0.5 151 0C3018 1 WRAPPER, UPPER CYLINDER 1
the future, use only high quality detergent oil rated
with API service classification SF or SG SAE 30 • Wipe dipstick clean. 102 0D5411 1 ROD, SUMMER / WINTER VALVE 152 0C3019 1 WRAPPER, LOWER CYLINDER 1
weight. Use no special additives. 103 0D5445 1 BUSHING, MINI CONTROL PANEL 153 046964A 1 BRASS ST ELBOW 1/4 NPT
• Slowly fill engine with oil through the oil fill opening until it 104 0D5416A 1 KNOB, CONTROL SUMMER / 154 0E0409 1 ASSY, ROD, GOV. STEPPER
Select the oil’s viscosity grade according to the expected reaches the full mark on the dipstick. Stop filling occasionally WINTER MOTOR
operating temperature. Do not use SAE 10W-40. to check oil level. DO NOT OVERFILL. 105 0D5398 1 CHOKE ASSEMBLY 155 0C8563 6 SCREW HHHC M6-1.0 X12
106 0E6043 2 SCREW TAPTITE M5-0.8 X 8 ZP 157 0D9784 2 NUT, LOCK HEX M3-0.5 (GT-990)
• Install dipstick. Install oil fill cap and finger tighten securely.
107 0D3432 1 PANEL, CONTROL FACE PLATE 0E4869 2 NUT, HEX W/TOOTH WASHER M3-
• Check engine oil level before starting each time thereafter. 108 045756 24 SCREW TAPTITE M6-1.0X 10 0.5 (GT-760)
YELLOW CHROME 158 031879 1 WASHER FLAT #4 (GT-990)
109 0D4767 1 SWITCH ROCKER 0E4868 1 WASHER FLAT #4 (GT-760)
110 0D1142A 1 WRAPPER, LOWER CYLINDER 2 159 0D6098 1 SPACER, ROD (GT-760 ONLY)
111 0D1143 1 WRAPPER, UPPER CYLINDER 2 160 0D6147 7 SCREW HHFC M6-1.0 X 10mm
112 0F1177 1 ASSEMBLY, GROUND WIRE 161 0F1338A 1 ASSY, IGN COIL W/DIODE NO ADV
113 022097 4 WASHER LOCK M6-1/4
114 092079 4 SCREW TAPTITE M6-1.0 X 25 BP
10 27
 Section 7 — Exploded Views and Parts Lists Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
Generator – Drawing No. 0D4488-D

2.3.2 CONNECTING ELECTRICAL LOADS

2.3 HOW TO USE THE GENERATOR DO NOT connect 240 Volt loads to 120 Volt receptacles. DO
NOT connect 3-phase loads to the generator. DO NOT connect
If you have any problems operating your generator, please call the
50 Hz loads to the generator.
generator helpline at 1-800-333-1322.
• Let engine stabilize and warm up for a few minutes after
2.3.1 GROUNDING THE GENERATOR starting.

The National Electrical Code requires that the frame • Plug in and turn on the desired 120 or 240 Volt AC, single
and external electrically conductive parts of this phase, 60 Hz electrical loads.
generator be properly connected to an approved earth • Add up the rated watts (or amps) of all loads to be connected
ground. Local electrical codes may also require proper at one time. This total should not be greater than (a) the rated
grounding of the unit. For that purpose, generally, connecting a wattage/amperage capacity of the generator or (b) circuit
No. 10 AWG (American Wire Gauge) stranded copper wire to the breaker rating of the receptacle supplying the power. See
grounding wing nut and to an earth-driven copper or brass "Don't Overload the Generator" below.
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. 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
Generator Ground Lug the generator's wattage capacity.
• The rated wattage of lights can be taken from light bulbs. The
rated wattage of tools, appliances and motors can usually be
found on a data 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
Proper grounding of the generator will help prevent such motors. Make sure you allow for this high starting
electrical shock in the event of a ground fault condition in the wattage when selecting electrical devices to connect to your
generator or in connected electrical devices. Proper grounding generator:
also helps dissipate static electricity, which often builds up in 1. Figure the watts needed to start the largest motor.
ungrounded devices. 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.)

28 9
 Section 2 – Operation Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
Generator – Drawing No. 0D4488-D

Figure 9 - 120 VAC, 30 Amp Receptacle 2.2.5 12 VOLT DC, 10 AMP RECEPTACLE ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
This receptacle allows you to recharge a 12 Volt automotive or 1 0C6934 1 ADAPTOR, ENGINE 23 0A2038 1 WASHER FLAT 3/8 ZINC
utility style storage battery with the battery charge cables 2 0D2123 1 STATOR 12.5KW 24 022237 5 WASHER LOCK 3/8
provided. This receptacle can not recharge 6 Volt batteries and 0D2134 STATOR 15KW 25 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5
can not be used to crank an engine having a discharged battery. 0D2136 STATOR 18KW 26 022131 4 WASHER FLAT 3/8-M10 ZINC
See the section "Charging a Battery" (page 12) before attempting 3 0D21320SRV 1 ASSEMBLY, ROTOR WITH FAN 27 051731 4 SCREW HHC M8-1.25 X 50 G8.8
to recharge a battery. 12.5KW 28 022145 21 WASHER FLAT 5/16 ZINC
0D21330SRV ASSEMBLY, ROTOR WITH FAN 29 049820 4 NUT LOCK HEX M8-1.25 NYLON
15KW INSERT
Figure 11 - 12 Volt DC, 10 Amp Receptacle 0D2135 ROTOR 18KW 30 079246 5 SCREW HHC M6-1.0 X 16 WITH
4 0C6043B 1 CARRIER, REAR BEARING LOCK WASHER
5 0D2492 1 EXHAUST MANIFOLD 31 022129 18 WASHER LOCK M8-5/16
6 0D2726 1 MUFFLER 32 022259 12 NUT HEX 5/16-18 STEEL
7 0C4138 2 GASKET, EXHAUST 33 059637 2 SCREW TAPTITE 3/8-16 X 3/4 BP
8 0D3547 1 COVER, ALTERNATOR AIR IN 34 0D5100 1 SHIELD, MUFFLER HEAT
9 031971 1 BEARING 35 0D5823 1 U-BOLT & SADDLE
10 0C3168 3 5/16 SPECIAL LOCK WASHER 36 0C8565 4 SCREW SHC M8-1.25 X 18
11 0D1838 1 SCREW IHHC 3/8-24 X 15.50 G5 37 0D5833 1 PANEL, MUFFLER BOX BACK
12 0D3549 4 SCREW IHHC M8-1.25 X 400 G8.8 38 0D5834 1 PANEL, MUFFLER BOX END
Use this receptacle to operate 120 Volt AC, 60 Hz, single phase 13 0C7038E 1 BRACKET, ALT MOUNTING 39 090388 3 SCREW HHTT M6-1.0 X 12
loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps. 14 032712 4 SCREW HHTT #10-32 X 1.75 40 022473 5 WASHER FLAT 1/4
The outlet is protected by a 30 Amp push-to-reset circuit breaker. 15 0D4662 1 SCREW HHTT M8-1.2 X 20 41 N/A - NOT USED
16 0C7038D 1 ENGINE MOUNTING PLATE 42 0D5133 1 SPARK ARRESTOR SCREEN
2.2.4 120/240V AC, 30 AMP RECEPTACLE 2.2.6 120/240 VOLT AC, 50 AMP 17 0C7758 6 RUBBER MOUNT 43 0D5133A 1 RETAINER, SPARK ARREST
RECEPTACLE 18 0388050AF0 1 BATTERY CABLE, BLACK SCREEN
Use a NEMA L14-30 plug with this receptacle. Connect a suitable 19 0C2417A 1 EARTH STRAP 3/8X 3/8 44 045764 1 SCREW HHTT M4-0.7 X 8
4-wire grounded cord set to the plug and to the desired load. The Use a NEMA 14-50 plug with this receptacle. Connect a 4-wire 20 082121C 1 CLIP-J VINYL COAT .625 ID 45 0D6214 1 SHIELD, RUBBER MOUNT
cord set should be rated for 250 Volts AC at 30 Amps (or greater). cord set rated for 250 Volts AC at 50 Amps to the plug. 21 066386 1 ASSEMBLY, BRUSH HOLDER 46 066849 2 SCREW HHTT M5-0.8 X 16
22 0C2824 1 SCREW TAP-R #10-32 X 9/16
Figure 10 - 120/240 VAC, 30 Amp Receptacle Figure 12 - 120/240 VAC, 50 Amp Receptacle

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase Use this receptacle to operate 120/240 Volt AC, 60 Hz electrical
loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps loads requiring up to 12,000 watts (12.0 kW) of power. This
or 240 Volt AC, 60 Hz, single phase loads requiring up to 7200 receptacle is protected by a 50 Amp 2-pole circuit breaker.
watts (7.2 kW) of power at 30 Amps. The outlet is protected by
two 30 Amp push-to-reset circuit breakers.

8 29
 Section 7 — Exploded Views and Parts Lists Section 2 – Operation
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
Control Panel – Drawing No. 0E0227B

Figure 8 - 120 VAC, 20 Amp GFCI Receptacle

2.2 CORD SETS AND CONNECTION
PLUGS

62
57
2.2.1 AC, 20 AMP, DUPLEX RECEPTACLE

61
This is a 120 Volt outlet protected against overload by a 20 Amp

38
push-to-reset circuit breaker. Use each socket to power 120 Volt AC,
58
single phase, 60 Hz electrical loads requiring up to a combined 2400
24 watts (2.4 kW) or 20 Amps of current. Use only high quality, well-

18
insulated, 3-wire grounded cord sets rated for 125 Volts at 20 Amps

17
52
4

(or greater).

49
47,48

51

30
29
54

31
Keep extension cords as short as possible, preferably less than 15

32
feet long, to prevent voltage drop and possible overheating of wires.

35
4

36

34
37

33
7
Figure 7 - 120 Volt AC, 20 Amp, Duplex Receptacle

45
17

25
53

42
18
50

41
22
Testing the GFCI: Test the GFCI outlet every month as follows:
• Plug a test lamp into the receptacle.
18

9 8

• Start the generator, the test lamp should be on.

41
17
55

28

42

42
41

59
• Press the “Test” button located on the front of the receptacle
16

59
19

to trip the device.

13 • This should stop the flow of electricity making the lamp shut
46
27

41

15
off. The yellow trip indicator should now be on.
26

42
8

59

• To restore the flow of electricity, press the “Reset” button on

39

the front of the receptacle. If the GFCI does not perform in this
manner, do not use the receptacle. Contact a local service
40

12

dealer.
23

• This outlet is protected against overload by a 20A push-to-

64

6
18

reset circuit breaker. Use the outlet to power 120V AC, single-
17

14

2.2.2 120V AC, 20 AMP, GFCI RECEPTACLE

20

phase, 60 Hz, electrical loads requiring up to a combined 2400

10
9
63

This unit is equipped with a ground fault circuit interrupter (GFCI). watts (2.4 kW) or 20 amps of current.
11

This device meets applicable federal, state and local codes.

2.2.3 120V AC, 30 AMP RECEPTACLE
A GFCI receptacle is different from conventional receptacles. In
56
21

the event of a ground fault, a GFCI will trip and quickly stop the Use a NEMA L5-30 plug with this receptacle. Connect a 3-wire
3

flow of electricity to prevent serious injury. cord set rated for 125 Volts AC at 30 Amps (or greater) to the
9
8

plug.
44

Definition: Instead of following its normal safe path, electricity

41

passes through a persons body to reach the ground. For example,

42
43

a defective appliance can cause a ground fault.

A GFCI receptacle does NOT protect against circuit overloads,

short circuits, or shocks. For example, electric shock can still
60

occur if a person touches charged electrical wires while standing

on a non-conducting surface, such as a wood floor.
5

1
2

30 7
 Section 2 – Operation Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
Control Panel – Drawing No. 0E0227B

OPERATION 1) 12 Volt DC, 10 Amp Receptacle – This receptacle ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
allows the capability to recharge a 12 volt DC storage battery
with provided battery charge cables. 1 087968 1 SWITCH, ROCKER -/0 32 022158 1 NUT HEX #10-32
2.1 KNOW THE GENERATOR 2) 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies
2 090418 1 OUTLET, 12VDC SNAP 33 023897 1 WASHER FLAT #10
3 0D6640 1 COVER, GOVERNOR CONTROL 34 057405 1 RESISTOR 25R 5% 25W
Read the Owner’s Manual and Safety Rules before electrical power for the operation of 120 Volt AC, 20 Amp, 4 090987 6 SCREW PPHM M3-0.5 X 12 35 022473 1 WASHER FLAT 1/4
operating this generator. single-phase, 60 Hz electrical lighting, appliance, tool and 5 0D2502 1 PANEL, SHEET METAL 36 022097 1 WASHER LOCK M6-1/4
motor loads. 6 068868 2 OUTLET 30A 120V RECEPT 37 049813 1 NUT HEX M6-1.0 G8
Compare the generator to this illustration to become familiarized 38 065795 2 RECTIFIER-BATTERY CHARGER
3) 120 Volt AC, 20A Duplex GFCI Receptacle – 7 022985 2 WASHER FLAT #6
with the locations of various controls and adjustments. Save this 8 043182 10 WASHER LOCK M3 39 0D4804 2 TRANSFORMER, IDLE CURRENT
manual for future reference. Supplies ground fault protected electrical power for
9 051714 6 NUT HEX M3-0.5 G8 40 0C1085 4 SCREW PPHM M3-0.5 X 8
operation of 120 volt AC 20 amp, single-phase, 60 Hz electric 41 051715 18 NUT HEX M4-0.7 G8
10 075207A 4 CIRCUIT BREAKER 30A
lighting, appliances, tools and motor loads.
Figure 4 - Control Panel 11 075207 2 CIRCUIT BREAKER 20A 42 022264 18 WASHER LOCK M4
4) 120 Volt AC, 30 Amp Locking Receptacle – Supplies 12 0D4969 1 OUTLET 50A 125/250V 43 048505 1 CIRCUIT BREAKER 6 X 1
electrical power for the operation of 120 Volt AC, 30 Amp, 13 043437 1 OUTLET 30A 125/250V 44 087962 1 CIRCUIT BREAKER 10 X 1 12VDC
single-phase, 60 Hz electrical lighting, appliance, tool and 14 0D4968 1 OUTLET 20A 120V DPLX 1/4"QC
15 0D4966 1 OUTLET 20A 120V GFCI 45 036261 2 RIVET POP .125 X .129-.133 / #30
motor loads.
16 0D1004E 1 CIRCUIT BREAKER 50A 400V 46 0A2769 1 LUG GRND 8 TABS
5) 120/240 Volt AC, 30 Amp Locking Receptacle – 2POLE 47 032300 1 HOLDER FUSE
Supplies electrical power for the operation of 120 and/or 240 17 051716 8 NUT HEX M5-0.8 G8 48 028578 1 FUSE 10A X AGC10
Volt AC, 30 Amp, single-phase, 60 Hz, electrical lighting, 18 022152 8 WASHER LOCK #10 49 055444 1 HEATSINK
appliance, tool and motor loads. 19 0D5045 1 DIN RAIL 59.5mm LONG 50 075475 2 SCREW PPHM M4-0.7 X 10
20 067680 1 ASSEMBLY VOLTAGE REGULATOR 51 049815 4 SCREW HHC M5-0.8 X 16 G8.8
6) 120/240 Volt AC, 50 Amp Receptacle – Supplies 52 0A2053 1 SCREW HHC M6-1.0 X 65 G8.8
60HZ
electrical power for the operation of 120/240 Volt AC, 50 21 0D4409 1 ELECTRONIC GOVERNOR / IDLE 53 055440 2 SCREW HHC M5-0.8 X 25 G8.8
Amp, single-phase, 60 Hz, welder or motor loads. CONTROLLER 54 045770 1 SCREW HHC M5-0.8 X 10 G8.8
7) Air Cleaner – Filters intake air as it is drawn into the engine. 22 052844 1 RELAY PNL 12VDC SPST 30A 55 0D5734 2 SPACER .25 X .50 X 1.5
23 0F3100 1 RELAY 3PDT 12VDC 56 074908 18 SCREW HHTT M5-0.8 X 10
8) Choke Knob – Used when starting a cold engine. 57 075235 1 SCREW PPHM M5-0.8 X 30
24 0D2691 1 CONTROL PANEL BOX
9) Winter / Summer Valve – See “Cold Weather Operation.” 25 023484L 1 BUSHING SNAP 58 080823 2 SCREW PPHM M5-0.8 X 50
(Section 2, page 12.) 26 0A1661 2 RIVET POP .156 X .160-.164 / #20 59 038150 14 WASHER FLAT #8
27 048766 1 BLOCK TERMINAL 20A 2 X 6 X 60 0D6140 1 GASKET, PORTABLE CONTROL
10) Circuit Breakers (AC) – Each receptacle is provided with PANEL
1100V
a push-to-reset circuit breaker to protect the generator 28 0D3550 1 BLOCK DOUBLE ROW TERMINAL 8 61 075476 2 SCREW PPHM M4-0.7 X 16
against electrical overload. (50 amp uses toggle reset) POSITION 62 027565 A/R TAPE ELEC UL PERMACEL
Figure 5 - Generator Controls 11) Fuel Tank – Tank holds 16 U.S. gallons of fuel. 29 049939 1 RECTIFIER MSC 12A 600V 63 058000K 2 NUT TRIC M5-0.8
30 070370 1 WASHER MICA .203 64 0F3101 1 RELAY BASE 3PDT 12VDC
12) Grounding Lug – Ground the generator to an approved
31 030468 1 WASHER STEP NYLON .20
11 earth 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.
14) Start/Run/Stop Switch – Controls the operation of the
generator.
15) Oil Fill – Use this point to add oil to engine.
Figure 6 - Engine Control Panel

15 12

14 8 9
6 31
 Section 7 — Exploded Views and Parts Lists Section 1 - General Information
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
Frame, Handle & Wheel Kit – Drawing No. 0E0695-A

Figure 2 - Handle Assembly

1.2.3 BATTERY CONNECTION Figure 3 - Battery Connections

• The battery shipped with the generator has been provided fully
charged. Caution must be taken when connecting the battery. Negative Positive
• Cut the tie wrap cable holding the RED and BLACK battery Cable Cable
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.

32 5
 Section 1 – General Information Section 7 — Exploded Views and Parts Lists
Commercial-Industrial-Residential Portable Generator System Commercial-Industrial-Residential Portable Generator System
Frame, Handle & Wheel Kit – Drawing No. 0E0695-A

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
1.1 UNPACKING 1.2 ASSEMBLY 1 057058 4 SCREW HHC M6-1.0 X 55 29 045900 2 WASHER FLAT 3/4" (15 kW)
• Set the palleted carton on a rigid flat surface. The generator requires some assembly prior to using it. If 2 0D5315 4 RUBBER TANK MOUNT 045900 4 WASHER FLAT 3/4" (12.5 kW)
3 0D4570 1 CAP, FUEL WITH GAUGE & VENT 30 0D7668 2 12.3" PNEUM WHEEL 3/4" AXLE
• Remove staples along bottom of carton that fasten carton to problems arise when assembling the generator, please call the
4 0D22850SRV 1 KIT, FUEL TANK (15 kW)
pallet. Open carton from top. Generator Helpline at 1-800-333-1322. 0D2495 2 10" PNEUM WHEEL 3/4" AXLE
5 045771 4 NUT HEX M8-1.25
6 022129 10 WASHER LOCK M8-5/16 (12.5 kW)
• Remove all packaging material. 1.2.1 ASSEMBLING THE WHEEL KIT 31 0D4999 2 PIN COTTER 1/8 X 1-1/4
7 022145 14 WASHER FLAT 5/16
• Remove separate accessory box. 8 0D4565 1 BRACKET BATTERY 32 0D4044 2 BRACKET, WHEEL SPACER
The wheel kit is designed to greatly improve the portability of the 9 0D3545 2 BOLT,BATTERY J-BOLT 33 0D3700 4 NUT FLANGE M6-1.0 NYLOK
• Lift carton off the generator. generator. A socket wrench with a 9/16” socket, a 1/2” socket, a 10 022287 2 SCREW HHC 1/4-20 X 3/4 G5 34 0D2497 1 HANDLE
• Remove generator from shipping pallet by removing bolts 1/2” wrench and a pair of pliers are the tools that will be needed 11 022473 2 WASHER FLAT 1/4 35 022532 4 SCREW HHC 5/16-18 X 2-1/2 G5
through the shipping brackets. for assembly of the wheel kit. 12 022097 2 WASHER LOCK M6-1/4 36 027028 6 NUT LOCK HEX 5/16-18 NYLON
13 022127 2 NUT HEX 1/4-20 INSERT
Figure 1 - Bracket Removal Note:The wheel kit is not intended for over-the-road use. 14 0388040AK0 1 BATTERY CABLE, RED 37 0D2271 1 FRAME
15 0D4575 1 BATTERY U1 38 052762 4 SCREW HHC M5-0.8 X 45 G8.8
• Refer to Figure 2 shown on opposite page and install the wheel 16 0D5202 1 NUT WING 5/16-18 BRASS 39 051713 8 WASHER FLAT M5
kit as follows: 17 0D5199 4 WASHER FLAT 5/16 BRASS 40 049226 4 WASHER LOCK M5
18 029809 1 NUT HEX 5/16-18 BRASS 41 051716 4 NUT HEX M5-0.8
• Place the generator on a hard flat surface.
19 0C3168 1 5/16 SPECIAL L/WASH 42 050190 2 WASHER FLAT 1"
• Stand at the engine end of the unit and gently tilt the generator 20 0D5198 1 SCREW HHC 5/16-18 X 1.5 BRASS 43 078299 1 BUSHING TANK DEXTOR
Shipping forward, high enough to place wooden blocks beneath the 21 0E0317 1 BRACKET FRONT FOOT (15 kW) 44 080270 1 VALVE, PLASTIC TANK
cradle. This will allow space to install the wheel assemblies. 0D2498 1 BRACKET FRONT FOOT (12.5 kW) 45 0D5142 1 AIR DEFLECTOR
Bracket 22 027007 2 VIB MOUNT 46 096021 2 GROMMET .75 X .06 X .50
(x4) • Attach an axle bracket assembly with attached sleeve to either 23 0D5303 4 WASHER FLAT .25ID X 1"OD 47 048031C 2 CLAMP HOSE BAND ¼
side of the frame. Ensure the sleeve faces outward. 24 042909 2 SCREW HHC M8-1.25 X 30 48 030340 18" HOSE ¼ ID
25 090388 4 SCREW HHTT M6-1.0 X 12 49 075763 1 BOOT BATTERY CABLE
• Slide the axle through the sleeves on the axle brackets.
26 064101 6 NUT LOCK FL 3/8-16 50 075763A 1 BOOT STARTER CABLE
• Slide one wheel with flat washer to the outside and a spacer to 27 039214 6 BOLT CARR 3/8-16 X 1 51 0E0318 2 SPACER, AXLE (15 kW)
the inside onto each end of the axle. Make sure the air inflation 28 0D9165 1 AXLE, 3/4"DIA X 30" (15 kW) 52 030795 2 SCREW HHC 5/16"-18 X 1"
valve on the wheel is facing outward. 0D2496 1 AXLE, 3/4"DIA X 27.25" (12.5 kW)

• Insert retaining pins and using pliers, bend out the ends to
1.1.1 ACCESSORY BOX prevent the pins from falling out of the axle. Remove the
Check all contents. If any parts are missing or damaged locate an wooden blocks.
authorized dealer at 1-800-333-1322.
Contents include: 1.2.2 ASSEMBLING THE HANDLE
• Owner’s Manual • Attach the handle by aligning one side of the handle on the
• Bolt-on tubular handle cradle, then spread the handle around the cradle and let it
spring into place. Secure the handle to the frame using the
• Wheel Axle 5/16’ hex head bolts provided. Check each fastener to ensure
• 2 – Pneumatic Wheels that it is secure.
• 2 – Axle Bracket Assemblies • Using the handle, lift the unit high enough to place wooden
• 2 – Washers blocks under the unit. Attach the front support foot to the
• 2 – Wheel Spacers underside of the cradle using the 3/8” carriage bolts provided.
• 2 – Cotter Pins • Remove the shipping brackets from the cradle, if you have not
• Bolt-on Foot already done so.
• 6 – Carriage Bolts, Washers, Nuts
• Battery Charge Cable
• Spark Plug Wrench
• 2 Spark Plugs.
• Air Filter
• Pre-cleaner
4 33