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Generac 004692-0 Portable Generator User Manual

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1. Generac Power Systems Inc do CONTROL PANEL BOX f 224 225A CLOSEST TO BEARING 224A BA 225A ce 0 4 TX H BCR T r CB2 fia A A 5 ae 12 2258 4 10 2248 pec 7 14 4 7 0 11 6 11 11 22 5 66 225 19A 22 22 4 4 c3 4 Mi 3 lt 2 lt 6 6 i 4 224 162 162 55 c2 VOLTAGE REGULATOR 0 66 0 66A 4 55 8s 13 22 13 13 225 Ay GRD 351 224 194 23 4 13 44 23 56 35 11 13A 351 7 15A CONNECTION 23 a 18 13 nin n F Ge 194 9 els 13 G 66A 239 CB1 2 15 17 S 17 15 17 Sg e 225 Swi 8 2 2 15 i 3 3 6 6 2 1 15 15 ON 8 8 8 aa swa 240V GENERATOR sb AUTO OUTPUT TO TRANSFER 3 272752 SWITCH CONTACTOR 8 8 2 F MANUAL 25 ELECTRICAL DATA Section 7 Electrical Data Air cooled 8 5 kW Generator Electrical Schematic Drawing No 0D8501 11
2. i EN T 3 5 Du T L DU 8 s yee J Zuz x 9 bee U 2 385 _ d PES L LLI AAA D E AAA s 2 SY mm 5 Coen ES D HUN 3 Eg Lj ni 1 III a s o E i e gt F s E g e z gt 2 z 2 EFE 353 RS x lt d TH d 2 i 35 Wem t J mut E 22 Eg E Generac Power Systems Inc Section 7 Electrical Data Air cooled 8 5 kW Generator ELECTRICAL DATA gt Wiring Diagram Drawing No 0D8500 ENGINE WIRING 3 2 DIAGRAM KEY 4 BATTERY CHARGER 3 BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY 14 21 CB1 MAIN OUTPUT BREAKER 0 2 CIRCUIT BREAKER ALTERNATOR EXCITATION L LU D DIODE DSW PCB MOUNTED DIP SWITCH 2958 FS FUEL SOLENOID 2248 F1 FUSE 15 AMP 13
3. 22 3 225 EI 224 Ll BATTERY 2258 2 Sols 18A 18 13A 1 7 7 9 9 1 4 73 Je 13A 77 mi C241 0 Keess 77 BATTERY CHARGE 66 14 0 WINDING AA AAJ 66 2 2 22 0 4 1 2 4 uro 0 2 11 0 4 55 A A AA UJ im A LOP m ENGINE RUN 5 WINDING 1 4 Swe 22 FIELD STATOR o4 DD 22 0725 ELECTRONIC 4 C2 10 C2 9 VOLTAGE 4 4 REGULATOR 0 66 6 85 NEN 162 C1 6 86 S 6 4 2 0 351 C27 22 C28 2 Hn TAT 66 WINDING Je 23 1 4 Ji sas 194 3 23 DIAGRAM KEY Ge 6 18 BA BRUSH ASSEMBLY 714 BCR BATTERY CHARGE RELAY d 66A CB1 CIRCUIT BREAKER MAIN OUTPUT REENEN Sen CIRCUIT BREAKER ALT EXCITATION BOARD d 15 D DIODE FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 AMP HTO HIGH OIL TEMPERATURE SWITCH IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTER SCR STARTER CONTACTOR RELAY SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC 26 Generac Power Systems Inc
4. 4 2 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications Section 1 5 Page 6 For engine oil recommendations see Section 4 3 1 To check the engine oil level proceed as follows Figure 4 2 on page 17 1 Start the generator by moving the Auto Off Manual switch to the MANUAL position Allow it to run for a short while and then shut it down by moving the switch to the OFF position 2 Remove the dipstick and wipe it dry with a clean cloth 3 Install the dipstick then remove it again The oil level should be at the dipstick Full mark If nec essary add oil to the Full mark only DO NOT FILL ABOVE THE MARK caution amp Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 4 Install the dipstick 5 Reset the Auto Off Manual switch to its original position Figure 4 2 Oil Dipstick and Fill 8 5 kW Oil Dipstick Section 4 Maintenance 45 CHANGING THE ENGINE OIL 4 51 ENGINE OIL RECOMMENDATIONS Use oil of American Petroleum Institute API Service Class SG SH or SJ Use all season SAE 5W 30 Synthetic oil Organic break in oil is required before using synthetic oil NOTE The unit is supplied with break in oil See the Break in Procedure Section 3 1 Page 13 for the first required oil change caution amp Any attempt to crank or sta
5. Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire N because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from your body before touching the battery by first touching a grounded metal surface Be sure the Auto Off Manual switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off 3 or sparking may occur at the battery posts as you attach the cables and cause an explosion 4 8 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation you should adjust the valve clearance in the engine Important If you feel uncomfortable about doing this procedure or you
6. 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 impor tant 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 serv ice 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 the following address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 40 Generac Power Systems Inc Section 9 Warranty Air cooled 8 5 kW Generator WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and later model year 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 s
7. See Figure 1 2 Page 5 for the location of your air cleaner Use the following procedure 1 Turn the two screws counterclockwise to loosen 2 Remove the cover and air filter 3 Wipe away dust or debris from inside of the air box and around edges 4 Install the new air cleaner into the air box 5 Install the cover Turn the two cover screws clock wise to tighten See the Service Schedule Section 4 11 Page 19 for air cleaner maintenance See Section 1 5 1 Page 6 for air filter replacement part number Generac Power Systems Inc 17 MAINTENANCE 9 Section 4 Maintenance Air cooled 8 5 kW Generator Figure 4 4 12 kW and 15 kW Engine Air Cleaner 4 6 SPARK PLUG S Reset the spark plug s gap or replace the spark plug s as necessary See Section 4 11 Page 19 for maintenance requirements 1 Clean the area around the base of the spark plug s to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug s to clean 2 Remove the spark plug s and check the condi tion Replace the spark plug s if worn or if reuse is questionable See Section 4 11 Page 19 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge carefully bending the ground electrode Figure 4 5 Figure 4 5 Setting the Spark Plug Gap SET PLUG GAP AT 0 50 mm 0 020 inch Generac Power
8. Adequate unobstructed flow of cooling and venti lating air is critical to correct generator operation Do not alter the installation or permit even partial blockage of ventilation provisions as this can seri ously affect safe operation of the generator The generator MUST be installed outdoors When working on this equipment remain alert at all times Never work on the equipment when you are physically or mentally fatigued Inspect the generator regularly and contact your nearest Generac Authorized Dealer for parts need ing repair or replacement Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental start up Disconnect the cable from the bat tery 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 con ditions from leaking exhaust gases fuel leakage oil leakage etc ELECTRICAL HAZARDS generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera tion Avoid contact with bare wires terminals con nections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operatin
9. The actual sequence of operation is controlled by sensors and timers on a control logic circuit board as follows A Utility Voltage Dropout Sensor This sensor monitors utility source voltage If utility source voltage drops below about 60 cent of the nominal supply voltage the sensor energizes a 15 second timer Once the timer has expired the engine will crank and start B Engine Warm up Time Delay This mechanism lets the engine warm up for about 10 seconds before the load is transferred to a standby source C Standby Voltage Sensor This sensor monitors generator AC output volt age When the voltage has reached 50 percent of the nominal rated voltage transfer to standby can occur D Utility Voltage Pickup Sensor This sensor monitors utility power supply volt age When that voltage is restored above 80 per cent of the nominal source voltage a retransfer time delay starts timing E Retransfer Time Delay This timer runs for about 15 seconds At end of a 15 second delay circuit board action de energizes transfer relay in the transfer switch Retransfer to utility power source then occurs F Engine Cool down Timer When the load is transferred back to utility power source the engine cool down timer starts timing The timer will run for about one minute and the generator will then shut down 14 Generac Power Systems Inc 3 5 MANUAL TRANSFER OPERATION 3 5 1 TRANSFER TO
10. 17 15 225 224 Section 7 Electrical Data Air cooled 8 5 kW Generator Electrical Schematic Drawing No 0D8501 ELECTRICAL Generac Power Systems Inc C2 6 22 TX C2 5 225A N2 56VA 3 224A 4 225 5 j 224 194 59 CUSTOMER CONNECTIONS N2 N2 13 N1 N1 2 15 17 11 NEUTRAL 23 1 0 gt 22 15 be 33 0 194 5 C 120V 15 POWER WINDING 120V 239 STATOR 15 m 4 cpi sT Q Y 194 d 11 5 225 14 15 224 239 0 240V 14 15 15 loser rM 1 239 13 0 2 1 66 17 13 AN SC SCR Y 56 16 lt lt 16 14 1 1 _ _ 4 om BATTERY SY x NI 12V 0 0 T 0 e L2 BLACK CUSTOMER mMm SUPPLIED um SP1 D 18 C1 5 D IM2 gt 27 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator 0 Compartment Drawing No 0D8445 A Generac Power Systems Inc AD lA cL CO JO Or CO no CO 290 70 31 32 33 34 35 36 37 38 39 40 41 42 QTY 008312 0 6735 067061 0C7062 0C7063 0C7064 0D8333 0C8101A 0C
11. PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser 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 unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Service 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
12. Parts Lists 28 Section 9 Warranty 40 Generac Power Systems Inc 1 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Air cooled 8 5 kW Generator SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted near the unit s installation site Safety should be stressed to all operators and potential operators of this equipment 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 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 fundamental rules or precautions Generac cannot possibly anticipate every possible circumstance that might involve a hazard The warn ings 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 tech nique Generac does not specifically recommend you must satisfy yourself that it is safe for you
13. Section 1 General Information GENERAL Air cooled 8 5 kW Generator INFORMATION Turn off the main gas supply Remove the three carburetor fuel hoses from the outlet ports of the demand regulator 3 Disconnect wire 0 and wire 14 from the gas solenoid located on the top of the demand regu lator 4 Remove the demand regulator from the enclosure by rotating counterclockwise 5 Remove the small jet OD5698A located in the side of the regulator housing and install it into the small threaded hole in the idle circuit port on the regulator 7 Refit the brass hose fitting to the idle circuit port of the regulator Use pipe thread sealant to reseal the threads on the hose fitting 8 Identify both adjustment screws NOTE One adjustment screw can be accessed from the front of the unit and the second can be accessed from the back of the unit Nom 9 The unit has been factory set to run on NG fuel To reset the system to run on LP fuel turn the two adjustment screws 1 2 turn clockwise Use a large screwdriver to make this adjustment 10 The fuel system will now allow the engine to run on LP fuel It may be necessary to make minor adjustments to the preset screw settings to achieve maximum power If you experience prob lems with the unit producing maximum power follow the procedure in Section 2 6 Adjusting the Regulator 1l Reverse procedure steps 1 4 to reinstall the demand regulator Figure 1 2 Deman
14. 02 Printed in U S A
15. 2 GASKET EXHAUST PORT 048031C 2 CLAMP HOSE BAND 1 4 030340 1 33 FT HOSE 1 4 1 0 Generac Power Systems Inc 31 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Engine Drawing 0D8674 C Part 1 2 5 19 20 39 40 47 64 93 140 8 11 12 13 4 5 6 16 16 17 18 7 48 49 50 51 52 53 54 55 56 58 59 60 48 49 50 51 52 53 54 55 56 58 59 60 62 27 28 29 3 32 33 34 35 36 40 72 Generac Power Systems Inc 16 16 17 18 19 20 21 21 22 22 23 24 25 26 27 28 29 30 31 32 33 34 35 QTY 005729 0C3008 090388 0C5372 0C3005 0C3003 0D8067A 071983 0C2981C 045761A 0 5848 021533 071980 004041 0 2983 0C2985A 0C2985B 0D4042 0A7811 0 2977 0 5943 004040 004122 0 2969 003961 002157 0 5313 004123 078699 0 3011 0C3009 003010 093873 005315 0 5998 001667 0 2991 0 2988 6 ech xs um ch gt 165 sak PO no no n5 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator DESCRIPTION ASSEMBLY CRANKCASE HOUSING WITH SLEEVE SEAL 38 I D CRANKSHAFT SCREW TAPTITE M6 1 0 X 12 YC ASSEMBLY BREATHER GASKET BREATHER COVER SEPARATOR OIL BREATHER ASSEMBLY HEAD 1 G amp S RETAI
16. Air cooled 8 5 kW Generator MAINTENANCE 4 15 SERVICE SCHEDULE ATTENTION It is recommended that all service work be performed by your nearest Generac Authorized Dealer SYSTEM COMPONENT PROCEDURE FREQUENCY X Action Inspect Change Clean W Weekly R Replace as Necessary M Monthly Notify Dealer Y Yearly if Repair is Needed FUEL Fuel lines and connections x M LUBRICATION Oil level x M Oil X AFTER BREAK IN AND Y Oil filter X AFTER BREAK IN AND Y COOLING Enclosure louvers X X W BATTERY Remove corrosion X X M ensure dryness Clean and tighten X X M battery terminals Check charge state X R EVERY 6 M Electrolyte level x R EVERY 6 M unsealed batteries only ENGINE AND MOUNTING Air cleaner X R Y Spark plug s X R Y GENERAL CONDITION Vibration Noise Leakage X M Temperature COMPLETE TUNE UP TO BE COMPLETED BY A GENERAC Y AUTHORIZED DEALER Generac Power Systems Inc 21 TROUBLESHOOTING Section 5 Troubleshooting Air cooled 8 5 kW Generator 5 11 TROUBLESHOOTING GUIDE PROBLEM The engine will not crank CAUSE 1 Fuse blown CORRECTION Replace fuse 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defective starter contactor 3 4 Defective starter motor 4 5 Dead Battery 5 Charge or replace battery The en
17. B DESCRIPTION CASTING TWIN REGULATOR HOUSING SOLENOID TWIN REGULATOR GASKET SOLENOID PLUNGER LP REGULATOR ASSEMBLY SPRING SOLENOID PLUNGER WASHER FLAT 46 WASHER LOCK M4 SCREW PPHM 4 0 7 X 10 JET GN 410 ENGINE LP 7KW BARBED STRAIGHT 1 2NPT x 1 2 O RING CHECK VALVE ADJUSTER SCREW TWIN REGULATOR LEVER REGULATOR SUPPORT INLET SEAL SEAL INLET PIN ARM SPRING REGULATOR SPRING REGULATOR 7KW SCREW PFHMS M3 0 5 x 5 SCREW PFHMS M3 0 5 x 5 7KW GASKET DIAPHRAGM COVER TWIN REGULATOR ITEM 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 PART NO 045764 045764 0C6731 0C6067 004706 0C6068 0C4643A 026073 044032 003308 003308 004643 028414A 0D5698A 0C5760B 0C5760C 0C5760D 0C5760E 0D3973 QTY PARTS debe Vers 00 DESCRIPTION SCREW TAPTITE M4X8 BP SCREW TAPTITE M4X8 BP 7KW RIVET POP 118 X 125 SUPPORT DIAPHRAGM DIAPHRAGM TWIN REGULATOR CAP DIAPHRAGM SUPPORT INLET TWIN REGULATOR 11 11 DIA PLUG STANDARD PIPE 1 8 STEEL SQUARE HEAD PIN LIMITED ADJUSTMENT WASHER FLAT M3 X 10mm O D WASHER FLAT X 10mm O D 7KW INLET TWIN REGULATOR NO HOLE NOT SHOWN 7KW BARBED STRAIGHT 1 8 X 1 4 JET IDLE PRIMER PHILLIPS HD JET GT760 CYL 1 NAT GAS JET GT760 CYL 2 NAT GAS JET GT 760 LP CYL 1 JET GT760 LP CYL 2 PLUG EXPANSION 16mm A QUANTITY OF 1 IS BE USED ON 7KW HOME STANDBY Generac
18. Installation 8 1 11 The err rette edit die 8 Section 2 Post Installation Start up and Adjustments 9 2 1 Betore Initial Startup e 9 2 2 Check Transfer Switch Operation 9 2 3 El cirical t eege gg 9 2 4 Generator Tests Under Load 10 2 5 Checking Automatic Operation 11 2 6 Adjusting the Regulator Natural Gas Only 11 2 7 Engine Governor Adjustment 12 2 7 1 Additional Corrosion Protection 12 2 8 Voltage Regulator Adjustment 12 Section 3 Operation 13 3 1 Break in 52 tests 13 3 2 Using the Auto Off Manual Switch 13 3 2L te E Ee 13 3 2 2 Of POSITION 13 3 2 3 Manual Position 13 3 3 Automatic Transfer Operation 13 3 4 Sequence of Automatic Operation 14 Table of Contents SEU Air cooled 8 5 kW Generator CONTENTS 3 5 Manual Transfer Operation 14 3 5 1 Transfer to Generator Power SOUT 14 3 5 2 Transfer Back to Utility 15 3 6 Setting the Exercise Timer 15 3 7 Protection SySUSDS irre rii Ieri 15 3 7 1 Low Oil Pressure
19. LASH 99 040976 4 SCREW SHC 8 1 25 X 20 G12 9 133 003048 1 ROD GOVERNOR CONTROL 100 0C3016A 1 PLATE BACKING GT990 WITH OIL COOL 134 003754 1 ASSEMBLY GOVERNOR LEVER 101 085011 1 INSULATOR ASSEMBLY IGNITION 135 003742 1 SPRING GOVERNOR 102 0C3725B 1 FLYWHEEL ASSEMBLY 136 0C8482 1 ASSEMBLY GOVERNOR ADJUSTER 103 003031 1 FAN NYLON 137 0D2576 1 SCREW SHC M10 1 5 X 70 G10 9 104 003032 1 PLATE FAN 138 0D3743 1 SPRING GOVERNOR IDLE 105 0A5992 2 WASHER SHAKEPROOF INT M8 SS 139 0D3705 1 ASSEMBLY GOVERNOR ADJUSTER 106 051754 2 SCREW HHC M8 1 25 X 12 G8 8 BRACKET 107 003033 1 WASHER 25mm I D 140 0C2993 1 SEAL GOVERNOR SHAFT Generac Power Systems Inc 35 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Control Panel Assembly Drawing No 0D8503 B 36 Generac Power Systems Inc QTY JO n5 11 12 13 14 15 16 17 18 19 20 21 0 9947 0A9947G 0A9947F 0A9947C 0A18010SRV 0830490SRV 0C2174 075210A 0D3062 0D8615 032300 022676 033873 0D5045 023484E 075476 022264 051715 043182 043181 0D8443 054502 0D8438 075235 D m oc c CD IND coo Noe de x Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Control Panel Assembly Drawing No 0D8503 B DESCRIPTION CIRCUIT BREAKER 30 X 2 240V SQD QOU230 7KW CIRCUIT BREAKER 40 X 2 240V SQD 001240 8 5KW CIRCUIT BREAKER
20. Power Systems Inc 39 Section 9 Warranty WARRANTY Air cooled 8 5 kW Generator NOTE This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below 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 utility and lawn and garden equipment 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 for the periods of time listed below provided there has been no abuse neglect unapproved modifi cation 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 and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted If dur ing 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
21. SCREW TAPTITE M6 1X10 YELLOW 0D8564B 1 ASSEMBLY MIXER AIRBOX 760 CHROME 79 0D2595 4 SCREW SHOULDER 8MM M6 1 0 X 18 113 0C9763 4 NUT GROMMET 1 4 PLUG 80 0D4417 4 WASHER RUBBER 1 4 X 1 8 THICK 114 0C3036 1 HOSE BREATHER 81 0C3025 1 SWITCH OIL PRESS 115 0C8919 1 BRACKET STARTER 82 0D3083 1 ASSEMBLY OIL DRAIN HOSE 116 079246 1 SCREW HHC M6 1 0 x 16 WITH LOCK 83 0C7292 1 NIPPLE 3 4 16 UNF WASHER 84 070185 1 FILTER OIL D 69 X 64 LONG 117 0C3018 1 WRAPPER UPPER CYLINDER 1 85 075281 1 SWITCH THERMAL 284F 118 0C3019 1 WRAPPER LOWER CYLINDER 1 86 0C1085 2 SCREW PPHM M3 0 5 X 8 119 0D1142A 1 WRAPPER LOWER CYLINDER 2 87 043182 2 WASHER LOCK M3 120 0D1143 1 WRAPPER UPPER CYLINDER 2 88 035461A 2 BARBED STR 1 4 X 3 8 WITH VIBRA 121 066849B 2 SCREW TAPTITE M5 0 8 X 8 BP SEAL 122 0C3053 1 ASSEMBLY GROUND WIRE 89 040173 4 CLAMP HOSE 45 5 62 62 123 0C3052 2 ASSEMBLY IGNITION COIL 90 0C9806 2 HOSE 3 8 1 D X 6 LONG 124 022097 4 WASHER LOCK M6 1 4 91 0C3026 1 COOLER OIL 125 092079 4 SCREW TAPTITE M6 1 0 X 25 BP 92 0C9764 4 PLASTITE 1 4 15 X 3 4 126 0C3017 1 STARTER 93 0C3043 2 GASKET MANIFOLD PORT 127 0D4529 2 SPARKPLUG 94 0C7694 1 MANIFOLD CYLINDER 2 128 022129 2 WASHER LOCK M8 5 16 95 0C7693 1 MANIFOLD CYLINDER 1 129 061906 2 SCREW HHC M8 1 25 X 85 G8 8 96 003041 2 SLEEVE RUBBER 130 082774 1 KEY WOODRFF 4 X 19D 97 070008 4 WASHER FLAT M8 SS 131 052859 1 NUT HEX LOCK M10 1 50 98 070006 4 WASHER LOCK 8 SSTL 132 008468 1 SPRING ANTI
22. Switch 15 3 7 2 High Temperature Switch 15 3 7 9 e ehe een 16 Oud 55 16 Section 4 Maintenance 16 4 1 FUSE entem et er HER EFI FEES YER RYE 16 4 2 Checking the Engine Oil Level 16 4 3 Changing the Engine Oil 17 4 3 1 Engine Oil Recommendations 17 4 3 2 Oil Change Procedure 17 4 4 Changing the Oil Filter 17 4 5 Changing the Engine Air Cleaner 17 4 6 Spark Plug s eo 18 4 7 Battery 18 4 8 Adjusting Valve 19 4 9 Cooling 42 00 19 4 10 Attention After Submersion 20 4 11 Out of Service Procedure 20 4 11 1 Removal From Service 20 4 11 2 Return t Service eene 20 4 12 Corrosion PrOLeClOl 20 4 15 Service 5Chedwule sis caen irr es 21 Section 5 Troubleshooting 22 5 1 Troubleshooting Guide 22 Section 6 Mounting Dimensions 23 Section 7 Electrical Data 24 Section 8 Exploded Views and
23. Systems Inc 4 7 BATTERY MAINTENANCE The battery should be inspected per the Service Schedule Section 4 11 Page 19 The following pro cedure should be followed for inspection l Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer DIG Do not dispose of the battery a fire The battery is capable of exploding A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or dis connecting battery terminals warninc Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic yN The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing
24. and others You also must make sure the procedure work method or operating technique that you choose does not render the generator unsafe A 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 A 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 0 Parts of the generator are rotating and or hot during operation Exercise care near running generators e Generac Power Systems Inc A GENERAL HAZARDS A For safety reasons Generac recommends that the installation initial start up and mainte nance of this equipment is carried out by a Generac Authorized Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust sys tem must be installed properly in strict compli ance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in noncompli ance with such codes and 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
25. breaker to its OFF or open position Let the engine run at no load for a few minutes to stabilize internal engine generator temperatures 12 Set the generator s Auto Off Manual switch to OFF The engine should shut down NOTE It is important that you do not proceed until you are certain that generator AC voltage and frequen cy are correct and within the stated limits Generally if both AC frequency and voltage are Generac Power Systems Inc Section 2 Post Installation Start up and Adjustments high or low the engine governor requires adjust ment If frequency is correct but voltage is high or low the generator s voltage regulator requires adjustment 2 4 GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied proceed as follows 1 Set generator s main circuit breaker to its OFF or open position 2 Turn OFFall loads connected to the transfer switch terminals T1 and T2 3 Set the generator s Auto Off Manual switch to OFF 4 Turn OFF the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker A A Do not attempt manual transfer switch opera tion until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 5 Manually set the transfer swit
26. 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 the 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 owner shall not be held responsi ble for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such
27. the fuel system Recommended fuels should have a Btu content of at least 1 000 Btus per cubic foot for natural gas or at least 2 520 Btus per cubic foot for LP gas Ask your fuel supplier for the Btu content of your fuel Fuel pressure for both natural gas and liquid propane set ups must be 11 inches to 14 inches of water column 0 6 psi at all load ranges NOTE A seperate gas line and regulator may be needed to assure proper gas pressure 11 14 to the gen erator Low gas pressure can cause hard starting and could affect engine durability 1 7 FUEL CONSUMPTION Nat Gas LP Vapor Full Load 1 98 72 5 1 2 Load Full Load 1 2 Load 114 170 1 33 45 8 Natural gas is in cubic feet per hour LP is in gallons per hour cubic feet per hour warninc amp Gaseous fuels such as natural gas and liquid propane LP gas are highly explosive Even the slightest spark can ignite such fuels and cause an explosion No leakage of fuel is permitted Natural gas which is lighter than air tends to collect in high areas LP gas is heavier than air and tends to settle in low areas 1 8 RECONFIGURING THE FUEL SYSTEM To reconfigure the fuel system from NG to LP follow these steps NOTE The primary regulator for the propane supply is NOT INCLUDED vwith the generator You must sup ply a fuel pressure of 11 to 14 inches of water col umn 0 6 psi to the fuel inlet of the generator
28. timer see Section 3 6 Page 14 This position also is used for remote starting when it is set up 3 2 0 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation Section 5 Operation OPERATION Air cooled 8 5 kW Generator dx 3 2 5 MANUAL POSITION Set the switch to MANUAL to crank and start the engine Transfer to standby power will not occur unless there is a utility failure Figure 3 1 Generator Control Panel Locate your nearest GENERAC dealer at www generac com GENER power systems SYSTEM SET LOW OIL AUTO OFF MAN FUSE HIGH TEMP OVER SPEED OVER CRANK fessi 15A SET FLASHING GREEN LED NO UTILTY SENSE EXERCISE Q 4 FLASHING RED LEDS TIME EXERCISER NOT SET warninc amp With the switch set to AUTO the engine may crank and start at any time without warning Such automatic starting normally occurs when utility power source voltage drops below a pre set level or during the normal exercise cycle To prevent possible injury that might be caused by such sudden starts always set the switch to OFF and remove the fuse before working on or around the generator or transfer switch Then place a Do Not Operate tag on the generator panel and on the transfer switch 3 3 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the trans
29. 30 31 32 33 34 35 36 37 38 39 40 41 42 PART NO QTY 036933 077033 048850 028739 038150 003191 003088 073591 073590 040213B 0C8037 0D3190 0C8036 0C8035 0D3320 0D3093 0D3926 022264 0A7215 0A2110 075475 0D3094 rS 39 DESCRIPTION SCREW PPHM 10 32 X 3 8 LUG SLDLSS 1 0 14X9 16 AL CU BLOCK TERMINAL 20A 5 X 6 X 1100V TIE WRAP 3 9 X 10 NAT L UL WASHER FLAT 8 ZINC COVER RELAY amp TERM BLOCK WIRE HARNESS GTS LOAD CENTER NOT SHOWN FOR CLARITY FUSE HOLDER ASSEMBLY FUSE 5A X BUSS HLDR73591 PCB SUPPORT SNAP IN 1 3 8 CIRCT BRK 20 X 1 HOM120 CIRCT BRK 20 X 2 HOM220 CIRCT BRK 15 X 1 HOM115 CIRCT BRK 30 X 2 HOM230 COVER HARNESS ENTRY HARNESS GTS TO EXT CONN BOX 10KW 12KW 13KW HARNESS GTS TO EXT CONN BOX 14KW 15KW 16KW WASHER LOCK M4 SCREW SW 1 4 20X5 8 N WA JS500 SCREW SWAGE 1 4 20 X 1 2 ZINC SCREW PPHM M4 0 7 X 10 HARNESS GTS TO MAIN PANEL JO chef CO C gt 005694 005765 004647 004680 0 6070 022985 022264 075475 0 5760 0C6606 097934 004645 0 5761 0C5968 0C6066 005759 005764 0C5764A 070728 070728 0C6069 0C5762 QTY 1 1 1 1 1 4 4 4 ho A 2 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Regulator Drawing No 0D8720
30. 50 X 2 240V SQD QOU250 12KW CIRCUIT BREAKER 60 X 2 240V SQD 900260 13KW ASSEMBLY BATTERY CHARGER ENGINE ASSEMBLY POTTED REGULATOR RELAY 12V 25A SPST BLOCK 1 POSITION HEX STAND OFF 46 32 x 3 8 ASSEMBLY HOME STANDBY CONTROLLER HOLDER FUSE FUSE 15AMP X AGC15 SWITCH ROCKER DIN RAIL SNAP BUSHING SB 687 8 SCREW PPHM M4 0 7 x 16mm WASHER LOCK M4 NUT HEX M4 0 7 WASHER LOCK M3 SCREW PHM M3 0 5 x 10mm DECAL CONTROL PANEL NOT SHOWN CIRCUIT BREAKER 3 X 1 ETA 46 500 P CONTROL PANEL BOTTOM SCREW HHC M5 0 8 x 30mm PARTS debe Vers 00 QTY DESCRIPTION 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 43 44 45 46 47 48 49 005240 051714 008502 041661 008441 074908 049226 051716 0 3910 022507 099727 046689 063617 075475 022985 008439 092036 045770 0 7171 003700 042311 0A1658 022473 038750 022097 049813 031879 AR a SWITCH SPDT ON MOM ON NUT HEX M3 0 5 NEUTRAL ISOLATOR RIVET POP 156 X 160 164 20 HARNESS CONTROL PANEL WIRE NOT SHOWN SCREW TAPTITE M5 0 8 x 10 BP WASHER LOCK M5 NUT HEX M5 0 8 TRANSFORMER SCREW 1 4 20 x 1 2 FUSE 5A X AGC5 TERMINAL STRIP RELAY PANEL 12VDC DPDT 10A 240VAC SCREW PPHM M4 0 7 x 10mm WASHER FLAT 6 COVER CONTROL PANEL COMPONENT SCREW PPHMS LW 6 32 x 1 4 SCR
31. 8101B 0C8283 0C8284A 0C8284B 0C8284C 0C8285 0C8899A 0D1128 0D1605 0D2538A 0D1839 0D1840 0D2425 0D2588 0D2676 0D2677 0D2979B 0D2979C 0D2979D 0D3057A 0D3057B 0D3057C 0D3057D 0D3059A 0D3059B 0A2311 0D7176 0D3059D 0D3059E 0C7781 0D3037 0D2537 0D2538 0D3037A I mE usd Wy cA X BI IX cA E o k Lech NS Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Compartment Drawing No 0D8445 A DESCRIPTION ASSEMBLY ENCLOSURE BASE SUPPORT ROOF FOLDING ENCLOSURE FRONT ENCLOSURE EXHAUST SIDE ENCLOSURE SIDE amp BACK ENCLOSURE ROOF PANEL ALTERNATOR DIVIDER PANEL MUFFLER BOX SIDE COVER MUFFLER BOX GASKET DOOR SEAL FOAM BACK ENCLOSURE FOAM ROOF ENCLOSURE FOAM FRONT ENCLOSURE BRACKET BATTERY SUPPORT PAD 24 48 WITH MOUNTING HOLES PANEL ENGINE DIVIDER BAFFLE INTAKE HINGE LIFT OFF TYPE B KNUCKLE BRACKET TOP SUPPORT BRACKET BOTTOM SUPPORT DUCT BASE AIR GASKET FRONT DIVIDER COVER FRONT EXHAUST ENCLOSURE COVER BACK EXHAUST ENCLOSURE CLOTH HARDWARE 266 7mm x 146mm CLOTH HARDWARE 543mm x 146mm CLOTH HARDWARE 266 7mm x 387 4mm FOAM FRONT INTAKE BAFFLE FOAM TOP INTAKE BAFFLE FOAM BACK INTAKE BAFFLE FOAM BACK ENCL STRIP FOAM EXHAUST SIDE ENCLOSURE END FOAM EXHAUST SIDE ENCLOSURE FRONT SCREW SWAGE 1 4 20 X 1 WASHER SELF LOCKING FOAM FRONT EXHAUST ENCLOSURE CO
32. 9 C co Section 8 Exploded Views and Parts Lists i Lem Air cooled 8 5 kW Generator Engine amp Alternator Drawing No 0D8446 0 DESCRIPTION 0C6934 1 ADAPTOR ENGINE 0D8062H 1 STATOR 0D8057H 1 ROTOR 0C6043A 1 CARRIER REAR BEARING 0D8274 1 FAN 12 CURVED BLADE 0D6634A 1 MUFFLER 0D3220 1 TAIL PIPE MUFFLER 008314 1 PANEL MUFFLER BASE 056482 1 BEARING 1 1811 2 8346 0C3168 3 5 16 SPECIAL LOCK WASHER 008313 1 BOLT IHCS 3 8 24 x 14 2 0D1846 4 BOLT IHCS 8 1 25 x 345mm 0C7038 1 BRACKET ALTERNATOR MOUNTING 0D1647 1 DUCT ALTERNATOR AIR 0D2558 1 GASKET ALTERNATOR AIR DUCT 0C7038A 1 BRACKET ENGINE MOUNTING 0C7758 4 RUBBER MOUNT 0388050 00 1 CABLE 6 48 BLACK BATTERY 0C2417A 1 EARTH STRAP 3 8X 3 8 082121C 1 CLIP J VYNL COAT 0 625 ID 066386 1 ASSEMBLY BRUSH HOLDER 029451 1 8 FT TAPE ELEC UL FOAM 1 8 X 1 2 049451 1 WASHER FLAT 406ID X 1 6200 022237 5 WASHER LOCK 3 8 022511 4 SCREW HHC 3 8 16 X 1 1 4 G5 022131 4 WASHER FLAT 3 8 ZINC 039288 4 SCREW HHC 8 1 25 x 55 G8 8 022145 14 WASHER FLAT 5 16 ZINC 049820 4 NUT LOCK HEX M8 1 25 NYL INSERT 045756 2 SCREW TAPTITE M6 1 0X10 YC 022129 10 WASHER LOCK 8 5 16 022259 8 NUT HEX 5 16 18 STEEL 059637 2 SCREW TAPTITE 3 8 16 X 3 4 CZ 083512 4 SCREW TAPTITE 8 1 25 16 YC 074994 2 83 FT HOSE RES 1 2 LP GAS 057822 4 CLAMP HOSE 8 53 1 00 052858 4 NUT LOCK M8 002824 3 SCREW TAP R 10 32 x 9 16 025145 1 U BOLT 5 16 18 X 1 25 WITH SADDLE 004138
33. A F2 FUSE 5 AMP CONTROL PANEL GROUND o HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR 0 ICT INTERCONNECTION TERMINALS IM1 IGNITION MODULE CYLINDER IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR 5 SCR STARTER CONTACTOR RELAY SP1 SP2 SPARK PLUGS 14 SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH Z TB INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Vac 56 amp 16 Vac 1 VA DUAL SEC IC IS e D SP1 0 6 o 18 5 14 85 4 86 gt 3 gt L 1352 13 D 1 16 SP2 16 SCR 13 18 85 a A B HTO qe e 351 0 5 14 0 85 16 56 13 86 86 2 3 4 5 E J2 0 CONTROL PRINTED CIRCUIT BOARD BLACK RER DSW 1234 umm ON INDICATES SM 1 20 Vac Sense Transformer 2 Remote Not Auto 3 50 Hz Operation 4 SPARE 5 L E D ALARM INDICATORS ea Generac Power Systems Inc Section 7 Electrical Data Air cooled 8 5 kW Generator Wiring Diagram 8 5 kW Drawing 008500 ELECTRICAL DATA
34. EAL VALVE STEM 07 52 005371 4 WASHER VALVE SPRING 53 005326 4 NUT JAM ROCKER ARM 54 006023 4 STUD ROCKER ARM 8 1 0 x 57mm 55 005354 4 PIVOT ROCKER ARM 56 005313 4 ROCKER ARM 57 006024 2 PLATE PUSH ROD GUIDE 58 062976 12 SCREW HHFC 8 1 25 X 65 59 086516 2 VALVE EXHAUST 60 002229 2 VALVE INTAKE 61 083897 4 TAPPET SOLID 62 0080678 1 ASSEMBLY HEAD 42 G amp S 63 0883960 4 PUSHROD 144 6 64 002978 2 GASKET HEAD 65 043790 1 BARBED ELBOW 90 3 8NPT X 3 8 LOCKTITE 66 004010 1 KIT GASKET 67 0D4011 1 KIT PISTON amp RINGS 68 004012 1 KIT BREATHER ASSEMBLY 69 004013 1 KIT GOVERNOR ASSEMBLY 70 008675 1 KIT HEAD ASSEMBLY CYLINDER 1 71 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2 72 004015 1 KIT OIL RELIEF 73 004016 1 GEAR COVER Generac Power Systems Inc 33 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator 0 Engine Drawing No 0D8674 C Part 2 34 Generac Power Systems Inc Section 8 Exploded Views and Parts Lists i Lem Air cooled 8 5 kW Generator Engine Drawing No 0D8674 C Part 2 0 PARTNO QTY DESCRIPTION PART QTY DESCRIPTION 74 0 5136 2 KNOB AIR CLEANER 108 0C3034 1 NUT HEX M24 75 003024 1 COVER AIRBOX NG LP 109 008549 1 SNORKEL AIR INTAKE 76 003040 1 PRE CLEANER 110 0C3022A 1 HOUSING BLOWER NG COOLER 77 0 8127 1 ELEMENT AIR CLEANER 111 0D1131 1 GUARD FAN 78 0D8564A 1 ASSEMBLY MIXER AIRBOX 990 112 045756 27
35. EW HHC M5 0 8 x10mm COVER CONTROL PANEL NUT FLANGE M6 1 0 NYLOCK SCREW SWAGE 1 4 20 x 1 LOCKWASHER SPECIAL 1 4 WASHER FLAT 1 4 SCREW HHC M6 1 0 x 30mm WASHER LOCK M6 1 4 NUT HEX M6 1 0 WASHER FLAT 4 Generac Power Systems Inc 37 age QTY OC 11 12 13 14 15 16 17 18 19 21 LISTS 0D3086 0D3092 0C2237 074908 024912 041658 063617 0D3030 041495 0 1661 022473 055450 025034 004684 003319 056326 022152 087680 077441 063378 074138 zx a NS AE sk Ef et EE gt Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator GTS Load Center Drawing No 0D3996 C DESCRIPTION BOX GTS LOAD CENTER COVER 12 POSITION GTS LOAD CENTER TRANSFER SWITCH HOME STANDBY 100A2P250V SCREW TAPTITE M5 0 8 X 10 BP SCREW TAPTITE 1 4 20 X 5 8 BP LOCK WASHER SPECIAL 1 4 RELAY PANEL 12VDC 10A 240VAC BASE MOUNTING 6 POLE 125A 240V SCREW TAPTITE M4 0 7X10 BP RIVET POP 156 X 160 164 20 WASHER FLAT 1 4 ZINC PLUG HEYMAN DP1375 10KW 12KW 13KW PLUG STEEL 1 0625 STMPSN 3811 14KW 15KW 16KW HARNESS ADAPTER PLATE PANEL SUB BREAKER BASE TRIM VINYL BLACK 1 8GP WASHER LOCK 10 NUT WING M6 1 0 HANDLE TRANSFER SWITCH HOME STANDBY HOLDER CABLE TIE LUG DIS NI S 10X45 DEG BRIT 38 Generac Power Systems Inc ITEM 22 23 24 25 26 27 28 29
36. GENERAG POW ER SYSTEMS INC Installation and Owner s Manual Air cooled Prepackaged Automatic Standby Generators Models 004692 0 8 5 kW T SS SS GE by GENERAC Es 2 Not intended for use as Primary Power place of utility or support applications DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY INTRODUCTION Thank you for purchasing this model of the Centurion product line by Generac Power Systems Inc This model is a compact high performance air cooled engine driven generator designed to automat ically supply electrical power to operate critical loads during a utility power failure This unit is factory installed in an all weather metal enclo sure that is intended exclusively for outdoor installation This generator will operate using either vapor withdrawn liquid propane LP or natural gas NG READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual contact Generac or your nearest Generac Authorized Dealer for starting operating and servicing procedures 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 care lessly Observe them carefully Their defi
37. GENERATOR POWER SOURCE To start the generator and activate the transfer switch manually proceed as follows 1 Set the generator s Auto Off Manual switch to OFF 2 Set the generators main circuit breaker to its OFF or open position 3 Turn OFF the utility power supply to the transfer switch using the means provided such as a utility main line circuit breaker DIG A Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock 4 Use the manual transfer handle inside the trans fer switch to move the main contacts to their Standby position i e loads connected to the standby power source Figure 3 2 Figure 3 2 Manual Transfer Switch Operation LOAD CONNECTED TO UTILITY POWER SOURCE LOAD CONNECTED TO STANDBY POWER SOURCE MANUAL TRANSFER HANDLE TRANSFER SWITCH OPERATING LEVER 5 To crank and start the engine set the Auto Off Manual switch to MANUAL 6 Let the engine stabilize and warm up for a few minutes 7 Setthe generator s main circuit breaker to its ON or closed position The standby power source now powers the loads 5 5 2 TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored you will want to transfer back to that source and shut down the generat
38. NER PISTON PIN 20 ROCKER COVER NO OIL FILL STUD M8 1 25 10MM X 30 G5 ZINC PISTON HC SET PISTON RING 90MM PIN PISTON D20 ASSEMBLY CAMSHAFT amp GEAR SHAFT GOVERNOR ROLLER BEARING GOVERNOR PLATE ROLLER BEARING GOVERNOR ASSEMBLY GOVERNOR GEAR SPOOL GOVERNOR MACHINED 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 SLEEVE SEAMED DOWEL 10 DIA COVER OIL RELIEF SPRING OIL RELIEF BALL 1 2D OIL RELIEF WASHER LOCK RIB M6 GEROTOR OUTER CLAMP OIL TUBE ARM GOVERNOR E RING GOVERNOR ARM THRUST WASHER GOVERNOR ITEM PARTS 50 LISTS Engine Drawing No 0D8674 C Part 1 0 PART NO DESCRIPTION 36 002992 1 BUSHING GOVERNOR LOWER 37 0 3971 1 ASSEMBLY DIPSTICK WITH HANDLE 38 005305 1 TUBE DIPSTICK 39 003027 1 O RING OIL CLR 3 8 X 1 2 40 0 3007 1 SEAL 42 1 0 CRANKSHAFT 41 005731 1 ASSEMBLY HOUSING COVER WITH SLEEVE 42 0 3006 9 SCREW HHFC M10 1 5 X 55 43 0 8566 8 SCREW HHFC 6 1 0 X 20 44 093064 1 ASSEMBLY OIL FILL CAP 45 0 8808 2 HOOK LIFTING 46 0D2723B 1 COVER WITH OIL FILL 47 0 2979 2 GASKET VALVE COVER 48 086515 8 KEEPER VALVE SPRING 49 002274 4 RETAINER VALVE SPRING 50 003867 4 SPRING VALVE 51 078672 2 S
39. P SB 1000 12 SCREW 8 1 25 X 25 8 8 RIVET 1 8 X 0 126 0 375 LSH L WASH SPECIAL 10 ASSEMBLY BASE C PNL WIRE ASSEMBLY BASE DOOR GROUND WIRE PLUG PLASTIC 1 375 GASKET CLIP ON SELF GRIPPING PLATE GROMMET 2 75 X 1 16 EXTERNAL CONNECTION BOX POWER BLOCK HARNESS GENERATOR TO EXTERNAL CONNECTION BOX SCREW PPHM 10 32 X 1 WASHER LOCK 410 WASHER FLAT 10 ZINC NUT HEX 10 32 STEEL FOAM EXHAUST FAN HOUSING WASHER SHAKPROOF EXT 1 4 STEEL NUT HEX 6 1 0 G8 YELLOW CHROME HINGE LIFT OFF TYPE A KNUCKLE TEMS INCLUDED IN KIT 0D3057 Generac Power Systems Inc 29 i Lem Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator 0 Engine amp Alternator Drawing 008446 DON 4 k f d Ww Q 8 gt p NM NN UNS RN lt a m N 2 SN NN N NN NC VN N N XG a e o A N N AN S VAS NN y a s dar Cu Ss x ST FAK XZ e wa X Z di gt N Y ANN JQ A Wy S E S Generac Power Systems Inc JO Om gt E PS ho Om O1 P CO CO O1 CO n
40. VER FOAM BACK EXHAUST ENCLOSURE COVER DOOR PAWL LATCH QUARTER TURN LOCKING HINGE LIFT OFF TYPE A PIN HINGE LIFT OFF TYPE B PIN LATCH QUARTER TURN NON LOCKING ITEM 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 er 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 QTY 0 2115 022097 022473 036261 047411 043116 003700 083512 090388 092120 001606 003167 0A3328 055414 092079 041658 0C3906 045771 0388040AJ0 022145 022129 074908 0D2346 023484F 043107 0A7836 0A8475 0912970069 0912970070 055450 0D2023 0D3701 0D3472 0C8742 0C8911 0D8442 036937 022152 023897 022158 0D3059C 026850 049813 0D2537A NOT SHOWN RNS ks CJ k 6 C 2 op op PARTS Qa ae 00 DESCRIPTION WASHER NYLON 250 WASHER LOCK 6 1 4 WASHER FLAT 14 ZINC RIVET POP 125 X 129 133 30 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHC M6 1 0 X 12 G8 8 NUT LOCKING FLANGE M6 1 0 SCREW TAPTITE M8 1 25 X 16 BP SCREW TAPTITE M6 1 0 X 12 YC NUT LOCK TRIC 6 X 1 0 Y ZNC HOUSING FAN GASKET BATTERY HOLD DOWN PLUG PLASTIC 0 593 LUG SLDLSS 2 8X17 64 CU SCREW TAPTITE M6 1 0X25 BP L WASH SPECIAL 4 SELF ALIGN SCREW M6 HH NUT HEX 8 1 25 G8 CABLE 6 RED BATTERY 38 5 WASHER FLAT 5 16 ZINC WASHER LOCK 5 16 SCREW TAPTITE M5 0 8 X 10 BP HARNESS ENGINE BUSHING SNA
41. ac Authorized Dealer or the factory about parts and service always supply the complete model number and serial number of your unit as given on its data decal which is located on your generator See Figure 1 2 or Figure 1 3 in Section 1 4 Page 5 for decal location Model No Serial No AUTHORIZED DEALER LOCATION To locate the GENERAC AUTHORIZED DEALER nearest you please call this number 1 800 333 1322 DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER Introduction Inside Front Cover Read This Manual Thoroughly IFC COMENTS IFC Operation and Maintenance IFC How to Obtain Service IFC Authorized Dealer Locator Number IFC E WT 2 Standards Index iusso reet SNO S 3 Section 1 General Information 4 l l Unpacking Inspection ere 4 1 2 Protection Systems nnns nna 4 1 3 System Set LED eicere ror 4 Lt Your Generator 5 1 5 Specifications iicet c cernere tH 6 1 5 1 Generator 6 1 9 2 eege 6 1 6 Fuel Requirements and Recommendations 7 1 7 Fuel Consumption 5 ene 7 1 8 Reconfiguring the Fuel System 7 1 9 LocatiOh error xn Enni 8 1 9 1 Generator 8 1 9 2 Transfer Switch eise ees 8 1 10 Battery
42. acement of Regulator XO FS SS SM 500406060600 550606006060 V i Q 55006900 M d 50496096060 55000600006 PISS 505060500096 00400006 05060506006 SS SS lt gt 7 Turn utility power to the main distribution panel back on This can be done by switching the serv ice main breaker to the on or closed position Allow the generator to shut down Generac Power Systems Inc 11 POST c INSTALLATION START UP ADJUSTMENTS Air cooled 8 5 kW Generator caution Do not make any unnecessary adjustments Factory settings are correct for most applica tions However when making adjustments be careful to avoid overspeeding the engine If this procedure or equipment are not available to you locate the Generac Dealer nearest you and they can perform the adjustments NOTE A service fee may be charged for this adjustment 2 ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are correspondingly high or low adjust the engine governor as follows l Loosen governor clamp bolt 2 Completely remove the idle spring 3 With governor arm at wide open throttle position rotate governor shaft fully clockwise Tighten clamp bolt to 84 inch pounds 4 Start unit and apply full load Use full load speed adjust screw Figure 2 4 to adjust frequency to 58 Hz 5 Remove load stop engi
43. at for 45 seconds Approximately 90 seconds total 3 74 OVERSPEED This feature protects the generator from damage by shutting it down if it happens to run faster than the preset limit This protection also prevents the gener ator from supplying an output that could potentially damage appliances connected to the generator cir cuit Contact your nearest Generac Authorized Dealer if this failure occurs 41 FUSE The generator panel s 15 amp fuse Figure 4 1 pro tects the DC control circuit against overload The fuse is wired in series with the battery output lead to the panel If the fuse element has melted open you can not crank or start the engine You should replace the fuse using only an identical 15 amp replacement The generator panel s 5 amp fuse protects the battery charge circuit against overload If the fuse element has melted open you will not have battery charging capability You should replace the fuse using only an identical 5 amp replacement To remove fuse push cap down and rotate counterclockwise 16 Generac Power Systems Inc Figure 4 1 Generator Control Panel FUSE AUTO Locate your nearest dealer at www generac com GENER AC row systems inc SYSTEM SET LOW OIL FUSE HIGH TEMP OVER SPEED Ki OVER 15 FLASHING GREEN LED NO UTILITY SENSE EXERCISE Q 4 FLASHING RED TIME EXERCISER NOT SET
44. aximum ambient temperature for your generator is 48 9 C 104 F 4 10 ATTENTION AFTER SUBMERSION If the generator has been submerged in water it MUST NOT be started and operated Following any submersion in water have Generac Authorized Dealer thoroughly clean and dry the generator 4 11 OUT OF SERVICE PROCEDURE 4 11 1 REMOVAL FROM SERVICE If you cannot exercise the generator every seven days and it is to be out of service longer than 90 days pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 Once the unit has shut down it will signal a low oil fault 4 Set the Auto Off Manual switch to OFF and turn off the utility power to the transfer switch 5 While the engine is still warm from running drain the oil completely Refill the crankcase with oil See Engine Oil Recommendations Section 4 3 1 Page 17 6 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase 7 Remove the spark plug s and spray fogging agent into the spark plug s threaded openings Reinstall and tighten the spark plug s 8 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor 9 Clean and wipe the entire generator 20 Generac Power Systems Inc 4 11 2 RETURN TO SERVICE To return the
45. ay result in injury or death to utility power workers due to backfeed of electrical energy If any loss or damage is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix his or her signature under the consignor s memo of loss or damage If you note loss or damage after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not in evidence at the time of delivery but is discovered later 1 2 PROTECTION SYSTEMS Unlike an automobile engine the generator may have to run for long periods of time with no operator present to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions 1 Low Oil Pressure Sensor 3 Overcrank 2 High Temperature Sensor 4 Overspeed There are LED readouts on the control panel to noti fy you that one of these faults has occurred 4 Generac Power Systems Inc Section 1 General Information 1 5 SYSTEM SET LED The System Set LED is lit when all of the following conditions are true 1 The Auto Off Manual switch is set to the AUTO position 2 The utility voltage being supplied to the unit is being sensed by the PCB If the utility sense volt age is not connected to the unit or if it is below 168 volts AC then the system s
46. ch to the STANDBY position i e load terminals connected to the generator s E1 E2 terminals The transfer switch operating lever should be down 6 Set the generator s Auto Off Manual switch to MANUAL The engine should crank and start immediately 7 Let the engine stabilize and warm up for a few minutes 8 Set the generator s main circuit breaker to its ON or closed position Loads are now powered by the standby generator 9 Turn ON electrical loads connected to transfer switch terminals Tl and T2 Apply an electrical load equal to the full rated wattage amperage capacity of the installed generator 10 Connect an accurate AC voltmeter and a frequen cy meter across terminal lugs 1 and E2 Voltage should be greater than 230 volts frequency should be greater than 58 Hertz 11 Let the generator run at full rated load for 20 30 minutes Listen for unusual noises vibration or other indications of abnormal operation Check for oil leaks evidence of overheating etc 12 When testing under load is complete turn OFF electrical loads 13 Set the generator s main circuit breaker to its OFF or open position 14 Let the engine run at no load for a few minutes Section 2 Post Installation Start up and Adjustments 15 Set the Auto Off Manual switch to OFF The engine should shut down 2 5 CHECKING AUTOMATIC OPERATION check the system for proper automatic operation proceed as follows 1 Check that the Aut
47. chedule A negative ground system is used Battery connections are shown on the wiring diagrams Make sure the battery is correctly connect ed and terminals are tight Observe battery polarity when connecting the battery to the generator set DIG Do not dispose of the battery a fire The battery is capable of exploding A A battery presents a risk of electrical shock and high short circuit current The following precautions are to be observed when working on batteries Remove watches rings or other metal objects e Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery and Disconnect charging source prior to connecting or dis connecting battery terminals warninc amp A Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic A The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a soluti
48. ction 4 Maintenance Air cooled 8 5 kW Generator Figure 4 6 Valve Clearance Adjustment Rocker Pivot Ball Arm Jam Nut Install new valve cover gasket Re attach the valve cover 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 Re attach the spark plug wire to the spark plug Repeat the process for the other cylinder 4 9 COOLING SYSTEM Air inlet and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to quickly shut down See Figure 4 7 for vent locations Figure 4 7 Cooling Vent Locations AIR OUTLET j j d H lt ttt t AIR INTAKE The exhaust from this product gets extremely N hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system Generac Power Systems Inc 19 MAINTENANCE Section 4 Maintenance Air cooled 8 5 kW Generator The m
49. d Regulator FUEL HOSE BRASS HOSE Ki FITTING BRASS HOSE B FITTING zu Ae 4 KENN IDLE CIRCUIT PORT SMALL FUEL JET ADI REGULATOR NEA HOUSING PORT ADJUSTER SCREWS Generac Power Systems Inc 7 Air cooled 8 5 kW Generator 1 9 LOCATION 1 91 GENERATOR Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air is always available Consider these factors Install the unit where air inlet and outlet openings will not become obstructed by leaves grass snow etc If prevailing winds will cause blowing or drift ing you may need to consider using a windbreak to protect the unit Install the generator on high ground where water levels will not rise and endanger it Allow sufficient room on all sides of the generator for maintenance and servicing A good rule is to allow 3 feet of space on all sides Where strong prevailing winds blow from one direction face the generator air inlet openings to the prevailing winds Install the generator as close as possible to the fuel supply to reduce the length of piping Install the generator as close as possible to the transfer switch HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DIS TANCE 1 9 2 TRANSFER SWITCH The transfer switch shipped with this generator is rated 100 amps maximum at 120 240 volts AC single phase The enclosure of the transfer switch is NEMA 1 This t
50. dby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 Generac Power Systems Inc 41 Section 9 Warranty WARRANTY Air cooled 8 5 kW Generator GENERAC POWER SYSTEMS TWO YEAR STANDARD WARRANTY FOR PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years or 2000 hours of operation from the date of original sale whichever occurs first Generac Power Systems Inc 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 under normal use and service in accor dance with the warranty schedule set forth below 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 war ranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac prepackaged emergency automatic standby generators sold and rated for use in Standby applications WARRANTY SCHEDULE YEARS ONE and TWO 100 one hundred percent transferable coverage on Labor and Part s listed proof of purchase and maintenance is required Engine All Components Alternator All Components Transfer System All Components warranty expense allowances are subject to the conditions de
51. don t have the proper tools please contact your Generac Authorized Dealer for service assistance This is a very important step to insure the longest life for your engine To adjusting valve clearance Make sure the engine is at room temperature 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 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 MAINTENANCE Se
52. 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 owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may 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 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped a Breather connection tube 2 Air Induction System including a Intake pipe manifold b Air cleaner Generac engine types covered by this warranty statement include the following 1 Prepackaged Stan
53. ended that the following Break in Procedure be completed to ensure correct generator operation in the future 1 Set the generator s Auto Off Manual switch to AUTO 2 Turn OFF the utility power supply to the transfer switch using the means provided such as a utili ty main line circuit breaker 3 The unit will start and the transfer switch will transfer to standby 4 Using the transfer switch s built in emergency load center turn on circuits to load the generator to approximately 2596 rated load and run the unit for one hour Run the unit for one hour at 5096 rated load Run the unit for one hour at 75 rated load Run the unit for one hour at 10096 rated load Turn ON the utility power supply to the transfer switch which will allow the transfer switch to transfer back to utility power The unit will con tinue to run for one minute and then shut down 9 Allow the unit to cool 10 Drain the oil and remove the oil filter Replace the oil filter according to Section 4 4 Changing the Oil Filter Page 16 Replace the oil with synthet ic oil as recommended in Section 4 3 Changing the Engine Oil Page 15 11 The generator is now ready for service 3 2 USING THE AUTO OFF MANUAL SWITCH FIGURE 3 1 3 2 1 AUTO POSITION Selecting this switch position activates fully automatic system operation It also allows you to start and exercise the engine every seven days with the setting of the exer cise
54. et light will flash rapidly This indicates that if the Auto Off Manual switch is placed in the Auto position the genera tor will start 3 The Not In Auto dip switch is set to the OFF position on the control board 4 No alarms are present for example low oil pres sure high temperature etc Section 1 General Information x GENERAL Air cooled 8 5 kW Generator INFORMATION 1 4 YOUR GENERATOR Figure 1 1 8 5 kW V Twin GT 990 Engine Data Control Decal Panel Air Filter Oil Dipstick Exhaust Enclosure 2 Fuel Regulator i O Vr 12 Volt Battery Oil Filter Generac Bower Systems Inc 5 Section 1 General Information INFORMATION Air cooled 8 5 kW Generator GENERAL 1 5 SPECIFICATIONS 1 5 1 GENERATOR Model 004692 Rated Max Continuous Power Capacity Watts 8 500 NG 8 500 LP Rated Voltage 120 240 Rated Max Continuous Load Current Amps 120 Volts 70 8 NG 70 8 LP 240 Volts 35 4 NG 35 4 LP Main Line Circuit Breaker 40 Amp Phase 1 Number of Rotor Poles 2 Rated AC Frequency 60 Hz Power Factor 1 Battery Requirement Group 26 26R 12 Volts and 550 Cold cranking Amperes Minimum Weight 470 Pounds Output Sound Level 68 db A Normal Operating Range 20 F 28 8 C to 104 F 40 C Maximum wattage and current are subject to and limited by such factors as fuel Btu conte
55. ety of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE available same as Item 1 Generac Power Systems Inc 3 Air cooled 8 5 kW Generator Only qualified electricians or contractors should attempt such installations which must comply strictly with applicable codes standards and regulations 1 1 UNPACKING INSPECTION After unpacking carefully inspect the contents for damage This standby generator set has been factory sup plied with a weather protective enclosure that is intended for outdoor installation only This standby generator set is packaged with an automatic transfer switch with built in load center The combination transfer switch and load center is pre wired with a 2 foot and 30 foot conduit Circuit breakers for emergency circuit connections are included This UL listed NEMA 1 2 pole switch is rated at 100 AC amperes at 250 volts maximum This transfer switch is for indoor use only A warninc A If this generator is used to power electrical load circuits normally powered by a utility power source you are required by code to install a trans fer switch The transfer switch must effectively iso late the electrical system from the utility distribu tion system when the generator is operating NEC 700 701 and 702 Failure to isolate an electrical system by such means will result in damage to the generator and also m
56. fer switch main contacts are set to their Utility position 1 loads connected to the utility power source Figure 3 2 Page 14 2 Be sure that normal utility power source voltage is available to transfer switch terminal lugs N1 and N2 3 Set the generators Auto Off Manual switch to AUTO 4 Set the generator s main circuit breaker to its ON or closed position With the preceding steps complete the generator will start automatically when utility source voltage drops below a preset level After the unit starts loads are transferred to the standby power source Refer to Sequence of Automatic Operation Page 14 Generac Power Systems Inc 13 OPERATION Section 3 Operation Ty Air cooled 8 5 kW Generator 3 4 SEQUENCE OF AUTOMATIC OPERATION The generator s control panel houses a control logic circuit board This board constantly monitors utility power source voltage Should that voltage drop below a preset level circuit board action will signal the engine to crank and start After the engine starts the circuit board signals the transfer switch to activate and connect load circuits to the standby power sup ply load terminal lugs T1 T2 connect to terminal lugs E1 E2 Upon restoration of utility source voltage above a pre set level generator circuit board action signals the transfer switch to transfer loads back to that power supply After retransfer the engine is signalled to shut down
57. fined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Guardian generators that utilize non Generac replacement parts Any Generac Guardian generators used as rental or trailer mounted applications Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation 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 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 defecti
58. g the generator If you must work around an operating unit stand on an insu lated dry surface to reduce shock hazard 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 After installing this home standby electrical sys tem the generator may crank and start at any time without warning When this occurs load circuits are transferred to the STANDBY generator power source To prevent possible injury if such a start and transfer occur always set the generator s Auto Off Manual switch to its OFF position before working on equipment and remove the fuse In case of accident caused by electric shock imme diately 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 nonconducting 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 Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com pone
59. gine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel solenoid FS 2 3 Open 14 wire from 3 engine control board 4 Defective spark plug s 4 Clean re gap or replace plug s 5 Valve Lash 5 Reset Valve Lash The engine starts hard l Air cleaner 1 Check replace air cleaner and runs rough plugged or damaged 2 Defective spark plug s 2 Clean re gap or replace plug s Fuel regulator not set 3 Set fuel regulator 4 Fuel pressure incorrect 4 Confirm fuel pressure to generator is 11 14 WC 0 6 PSI The Auto Off Manual switch l Defective switch pt is set to OFE but the engine Auto Off Manual switch 2 continues to run wired incorrectly 3 Defective control board 3 There is no AC output from 1 Main line circuit breaker open 1 Reset circuit breaker the generator to ON or closed 2 Generator internal failure 2577 There is no transfer to 1 Defective transfer switch coil l standby after utility 2 Defective transfer relay 2 source failure 3 Transfer relay circuit open 3 4 Defective control logic board 4 Unit consumes large l Break in procedure ls t amounts of oil not followed see Section 2 1 Contact your nearest Generac Authorized Dealer for assistance ee Generac Power Systems Inc Section 6 Mounting Dimensions Air cooled 8 5 kW Generator ELECTRICAL Drawing No 0D3739 A K DATA I
60. hall con tinue 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 war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine man ufacturer s application for certification c The ECS Warranty only pertains 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
61. horoughly understand all instructions before using this equip ment We also strongly recommend instructing other users to properly start and operate the unit This pre pares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for Centurion model 004692 0 8 5 kW NG 8 5 kW LP V twin GT 990 Engine OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safe ty checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Authorized Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum See your Generac Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When your generator requires servicing or repairs simply contact a Generac Authorized Dealer for assistance Service technicians are factory trained and are capable of handling all of your service needs When contacting a Gener
62. il pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added The Auto Off Manual switch must then be turned to OFF and then back to AUTO 3 72 HIGH TEMPERATURE SWITCH This switch s Figure 3 3 contacts close if the tem perature should exceed approximately 140 C 2849 F initiating an engine shutdown Your generator will automatically restart and the LED on the generator control panel will reset once the temperature has returned to a safe operating level Figure 3 3 Low Oil Pressure and High Temperature Switches Low Oil Switch High Temp Switch Generac Power Systems Inc 15 MAINTENANCE 2 09 Section 4 Maintenance Air cooled 8 5 kW Generator 5 75 OVERCRANK This feature prevents the generator from damaging itself when it continually attempts to start and anoth er problem such as no fuel supply prevents it from starting The unit will crank and rest for a preset time limit Then it will stop cranking and the LED on the generator control panel will light indicating an over crank failure The Auto Off Manual switch will need to be set to OFF and then back to AUTO to reset the generator control board NOTE If the fault is not repaired the overcrank feature will continue to activate 3 7 3 1 Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repe
63. liquid propane LP gas are extremely EXPLOSIVE Install the fuel supply system according to applica ble fuel gas codes Before placing the home stand by electric system into service fuel system lines must be properly purged and leak tested according to applicable code After installation you must inspect the fuel system periodically for leaks No leakage is permitted STANDARDS INDEX In the absence of pertinent standards codes regula tions and laws the published information listed below may be used as installation guide for this equipment 1 No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 No 76 ESSENTIAL ELECTRICAL SYS TEMS FOR HEALTH CARE FACILITIES avail able same as Item 1 NFPA No 54 NATIONAL FUEL GAS CODE available same as Item 1 NFPA No 58 AMERICAN NATIONAL STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS available same as Item 1 NFPA No 70 NFPA HANDBOOK OF NATIONAL ELECTRIC CODE available same as Item 1 Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOR available from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 3634 INSTALLATION AND MAINTE NANCE OF FARM STANDBY ELECTRICAL SYS TEMS available from the American Soci
64. ne loosen the idle adjust screw and reconnect the idle spring 6 Using your hand push the governor arm to the closed throttle position Make sure the idle spring does not stretch at all 7 Restart the unit 8 Slowly turn the idle adjust screw to adjust the no load idle frequency to 63 63 5 Hz 9 The governor is now set Figure 2 4 Full Load Speed Adjust Screw Full Load Speed Adjust Screw Generac Power Systems Inc Section 2 Post Installation Start up and Adjustments 2 7 1 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack ets with corrosion inhibiting spray such as WD 40 or a comparable product 2 8 VOLTAGE REGULATOR ADJUSTMENT With the frequency between 62 63 Hertz slowly turn the slotted potentiometer Figure 2 5 until line volt age reads 244 252 volts NOTE You must remove the access panel on top of the control panel to adjust the voltage regulator Figure 2 5 Voltage Adjustment Potentiometer KI D D D NOTE The voltage regulator is housed above the genera tor s control panel The regulator maintains a volt age in direct proportion to frequency at a 2 to 1 ratio For example at 62 Hertz line to neutral voltage will be 124 volts 3 1 BREAK IN PROCEDURE Once the unit has been installed and all electrical checks have been made it is strongly recomm
65. nitions are as follows After this heading you can read instructions that if not strictly complied with will result in personal injury including serious injury and or death or property damage WARNING amp After this heading you can read instructions that if not strictly complied with may result in personal injury or property damage caution 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 compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of you and others This symbol points out potential explosion hazard This symbol points out potential fire hazard A This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator is responsible for proper and safe use of the equipment We strongly recommend that the operator read this Owner s Manual and t
66. not occur during the exercise cycle A switch on the control panel see Figure 3 1 Page 13 allows you to select the day and time for system exercise To select the desired day and time of day you must perform the following sequence at that time 1 Verify that the Auto Off Manual switch is set to AUTO 2 Hold down the Set Exercise Time Switch until the generator starts approximately 10 seconds and then release During this time all the red LEDs on the control panel will flash to indicate board is resetting itself Section 3 Operation OPERATION Air cooled 8 5 kW Generator uu 3 The generator will start and run for approximately 12 minutes and then shut down on its own The exerciser will then be set to run at that time of day every week NOTE The exerciser will only work in the AUTO mode and will not work correctly unless this procedure is performed The exerciser will need to be reset every time the 12 volt battery is disconnected and then reconnected The exerciser WILL NOT work if dip switch 2 on the controller printed circuit board Remote Not Auto is ON If the exerciser is not set using the Set Exercise Time Switch the generator will automatically exercise 7 days after the battery connection was made 3 7 PROTECTION SYSTEMS 5 71 LOW OIL PRESSURE SWITCH This switch Figure 3 3 has normally closed contacts that are held open by engine oil pressure during crank ing and operating Should o
67. nt ambient temperature altitude engine power and condition etc Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent for each 6 C 10 F above 16 C 60 F ambient temperature 1 5 2 ENGINE Model 004692 Type of Engine GT 990 Number of Cylinders 2 Rated Horsepower 26 3 600 rpm Displacement 992cc Cylinder Block Aluminum w Cast Iron Sleeve Valve Arrangement Overhead Valves Ignition System Solid state w Magneto Recommended Spark Plug RC12YC Spark Plug Gap 0 50 mm 0 020 inch Compression Ratio 9 5 1 Starter 12 Vdc Oil Capacity Including Filter Approx 1 7 Qts Recommended Oil Filter Generac Part 70185 Recommended Air Filter Generac Part 0C8127 Operating RPM 3 600 6 Generac Power Systems Inc 1 6 FUEL REQUIREMENTS AND RECOMMENDATIONS With LP gas use only the vapor withdrawal system This type of system uses the vapors formed above the liquid fuel in the storage tank The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper proof dual fuel systems The unit will run on natural gas or LP gas but it has been factory set to run on natural gas Should the primary fuel need to be changed to LP gas the fuel system needs to be reconfigured See Section 1 8 Page 7 for instructions on reconfigura tion of
68. nts causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation 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 installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Air cooled 8 5 kW Generator 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 extin guisher properly charged and be familiar with its use If you have any question pertaining to fire extinguishers consult your local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gaseous fluids such as natural gas and
69. o Off Manual switch is set to OFF 2 Turn OFF the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker 3 Manually set the transfer switch to the UTILITY position i e load terminals connected to the util ity power source side 4 Turn ON the utility power supply to the transfer switch using the means provided such as a util ity main line circuit breaker 5 Setthe Auto Off Manual switch to AUTO The sys tem is now ready for automatic operation 6 Turn OFF the utility power supply to the transfer switch With the Auto Off Manual switch at AUTO the engine should crank and start when the utility source power is turned OFF After starting the transfer switch should connect load circuits to the standby side Let the system go through its entire automatic sequence of operation With the generator running and loads powered by generator AC output turn ON the utility power sup ply to the transfer switch The following should occur After about six seconds the switch should transfer loads back to the utility power source About one minute after retransfer the engine should shut down 2 6 ADJUSTING THE REGULATOR NATURAL GAS ONLY Although the generator has been factory set to pro vide maximum power it may be necessary in some areas to adjust this setting Because natural gas has different BTU or power content across the country the engine may not pe
70. on of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried Lead acid batteries present a risk of fire f because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from your body before touching the battery by first touching a grounded metal surface POST C INSTALLATION START UP ADJUSTMENTS Air cooled 8 5 kW Generator Be sure the Auto Off Manual switch is set to the OFF position before connecting the battery cables If the switch is set to AUTO or MANUAL the generator can crank and start as soon as the battery cables are connected Be sure the utility power supply is turned off 5 or sparking may occur at the battery posts as you attach the cables and cause an explosion 2 1 BEFORE INITIAL START UP Before starting complete the following 1 Setthe generator s Auto Off Manual switch to the OFF position 2 Turn OFF the utility power supply to the transfer switch using the means provided such as the utility main line circuit breaker 3 Turn OFFall loads connected to the tranfer switch terminals T1 and T2 4 Check the engine crankcase oil level and if nec essary fill to the dip
71. or This can be accomplished as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Let the engine run for a minute or two at no load to stabilize the internal temperatures 3 Set the generators Auto Off Manual switch to its OFF or open position The engine should shut down 4 Check that utility power supply to the transfer switch is turned OFF A Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off Failure to turn off all power voltage supplies may result in extremely hazardous and possibly fatal electrical shock 5 Use the manual transfer handle inside the trans fer switch to move the main contacts back to their Utility position i e loads connected to the util ity power source Figure 3 2 on page 14 6 Turn ON the utility power supply to the transfer switch using the means provided 7 Set the system to automatic operation as outlined in Automatic Transfer Operation Section 3 3 Page 13 3 6 SETTING THE EXERCISE TIMER Your generator is equipped with an exercise timer Once it is set the generator will start and exercise once every seven days on the day of the week and at the time of day you complete the following sequence During this exercise period the unit runs for approx imately 12 minutes and then shuts down Transfer of loads to the generator output does
72. rform as designed If you experience engine problems at high or full load conditions follow these steps It will require a fre quency meter to perform this procedure 1 Turn off utility power to the main distribution panel in the house This can be done by switching the service main breaker to the off or open posi tion 2 POST Ce INSTALLATION START UP ADJUSTMENTS Air cooled 8 5 kW Generator 2 Allow the generator to start Before loading the generator confirm that the no load frequency with the roof open and door off is set at 63 63 5 Hz Transfer load to emergency circuits 3 Turn on appliances lights pumps etc that are on the emergency circuits in an attempt to fully load the generator Be cautious not to overload the generator Use the following chart as a guide Unit 120 Volts 240 Volts 8 5 kW 70 8 amps 35 4 amps 4 When full load has been achieved Connect a fre quency meter to the output lugs of the generator s main line circuit breaker 5 The fuel regulator is fitted with two adjustment screws While watching the frequency meter slowly turn the adjustment screws clockwise or counterclockwise one at a time until the highest frequency is read on the meter Figures 2 1 and 2 2 Figure 2 1 Dual Fuel Regulators 6 When the highest frequency is reached maximum power has been set From this point turn both adjustment screws 1 4 turn clockwise The regu lator is now set Figure 2 2 Pl
73. rt the engine before it has been properly serviced with the recom mended oil may result in an engine failure 4 3 2 OIL CHANGE PROCEDURE To change the oil proceed as follows 1 Run the engine until it is thoroughly warmed up then shut OFF the engine 2 Immediately after the engine shuts OFF pull the oil drain hose Figure 4 3 free of its retaining clip Remove the cap from the hose and drain the oil into a suitable container MAINTENANCE Air cooled 8 5 kW Generator Figure 4 3 Oil Drain Hose and Filter Filter 3 After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip 4 Refill with the proper recommended oil see Section 4 3 1 See Section 1 5 2 Page 6 for oil capacities 4 4 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 With the oil drained remove the old oil filter by turning it counterclockwise 2 Applya light coating of clean engine oil to the gas ket of the new filter See Section 1 5 1 Page 6 for recommended filter 3 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn Figure 4 3 4 Refill with the proper recommended oil see Section 4 3 1 See Section 1 5 2 Page 6 for oil capacities 5 Start the engine and check for leaks 4 5 CHANGING THE ENGINE AIR CLEANER 4 5 1 8 5 KW GENERATORS
74. ry cable from frame ground to the battery post indicated by a nega tive NEG or NOTE Damage will result if battery connections are made in reverse Figure 1 5 Battery Cable Connections BLACK LEAD ae FROM FRAME Bn cc RED LEAD FROM STARTER CONTACTOR RED BLACK NOTE Your generator is equipped with a battery trickle charger that is active when your unit is set up for automatic operation With the battery installed and utility power source voltage available to the transfer switch the battery receives a trickle charge while the engine is not running to prevent self discharge The trickle charger is designed to help extend the life of your battery by maintaining the battery when the unit is not running The trickle charge feature cannot be used to recharge a discharged battery 1 11 THE BATTERY Servicing of the battery is to be performed or super vised by personnel knowledgeable of batteries and the required precautions Keep unauthorized person nel away from batteries When replacing the battery use the following type of battery Group 26 26R 12VDC 550 cold cranking Section 2 Post Installation Start up and Adjustments amps for 8 5 kW at 17 8 C 0 F minimum When using a maintenance free battery it is not necessary to check the specific gravity or electrolyte level Have these procedures performed at the intervals specified in the Service S
75. stick FULL mark with the recommended oil Do not fill above the FULL mark 5 Check the fuel supply Gaseous fuel lines must have been properly purged and leak tested in accordance with applicable fuel gas codes fuel shutoff valves in the fuel supply lines must be open caution Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 2 0 CHECK TRANSFER SWITCH OPERATION Refer to Section 3 5 Page 13 of the owner s manual for manual operation procedures wanNING amp A Do not attempt manual transfer switch opera tion until all power voltage supplies to the transfer switch have been positively turned off Failure to turn off all power voltage supplies will result in extremely hazardous and possibly fatal electrical shock 2 5 ELECTRICAL CHECKS Complete electrical checks as follows 1 Set the generator s main circuit breaker to its OFF or open position Generac Power Systems Inc 9 POST gt INSTALLATION START UP ADJUSTMENTS Air cooled 8 5 kW Generator 2 Turn OFFall loads connected to the transfer switch terminals T1 and T2 3 Turn on the utility power supply to the transfer switch using the means provided such as a utili ty main line circuit breaker DIG A The transfer switch is now electrically hot Contact with hot parts will result in extreme ly hazardous and possibl
76. unit to service after storage proceed as follows 1 Verify that utility power is turned off and that the Auto Off Manual switch is set to OFF Check the tag on the engine for oil viscosity and classification Verify that the correct recommend ed oil is used in the engine see Section 4 3 1 Page 17 If necessary drain and refill with the proper oil 3 Check the state of the battery Fill all cells of unsealed batteries to the proper level with dis tilled water DO NOT USE TAP WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery See Specifications Section 1 5 Page 6 for type and size 4 Clean and wipe the entire generator 5 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 6 Open the fuel shutoff valve 7 Start the unit by moving the Auto Off Manual switch to MANUAL Allow the unit to warm up thoroughly 8 Stop the unit and set the Auto Off Manual switch to AUTO 9 Turn on the utility power to the transfer switch 10 Your generator is now ready for service NOTE If the battery was dead or disconnected you must reset the exercise timer 4 12 CORROSION PROTECTION Periodically wash and wax the enclosure using auto motive type products Frequent washing is recom mended in a salt water coastal area Spray engine linkages with a light oil such as WD 40 Section 4 Maintenance
77. ve 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 conse quential 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 SYSTEMI INC BOX 297 WHITEWATER WI 531 90 Part OD8444 Revision O 04 03
78. y fatal electrical shock Proceed with caution 4 Use an accurate AC voltmeter to check utility power source voltage across transfer switch ter minals N1 2 Nominal line to line voltage should be 240 volts AC 5 Check utility power source voltage across termi nals N1 and the transfer switch neutral lug then across terminal N2 and neutral Nominal line to neutral voltage should be 120 volts AC 6 When certain that utility supply voltage is com patible with transfer switch and load circuit rat ings turn OFF the utility power supply to the transfer switch 7 On the generator panel set the Auto Off Manual switch to MANUAL The engine should crank and start 8 Let the engine warm up for about five minutes to allow internal temperatures to stabilize Then set the generator s main circuit breaker to its ON or closed position DIG A A Proceed with caution Generator power voltage is now supplied to the transfer switch Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock 9 Connect an accurate AC voltmeter and a frequen cy meter across transfer switch terminal lugs E1 and E2 Voltage should be 242 252 volts fre quency should read about 61 63 Hertz 10 Connect the AC voltmeter test leads across termi nal lug El and neutral then across E2 and neu tral In both cases voltage reading should be 121 126 volts AC 11 Set the generator s main circuit
79. ype of enclosure is intended for indoor use only Follow these rules Install the transfer switch indoors on firm stur dy supporting structure To prevent switch distortion level the switch if necessary This can be done by placing washers between the switch enclosure and mounting sur face Never install the switch where water or any corro sive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and cor rosive vapors 1 10 BATTERY INSTALLATION Fill the battery with the proper electrolyte fluid if nec essary and have the battery fully charged before installing it Before installing and connecting the battery complete the following steps 1 Set the generator s Auto Off Manual switch to OFF 2 Turn off utility power supply to the transfer switch 8 Generac Power Systems Inc Section 1 General Information If the Auto Off Manual switch is not set to its OFF position the generator can crank and start as soon as the battery cables are connected If the utility power supply is not turned off sparking can occur at the battery posts and cause an explosion Battery cables were factory connected at the genera tor Figure 1 5 Connect cables to battery posts as follows 3 Connect the red battery cable from starter con tactor to the battery post indicated by a positive POS or 4 Connect the black batte

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