Home

GE Monogram PSB9240DF Oven User Manual

1.
2. Generac Power Systems Inc lt C2 6 22 lt TX C2 5 225A N2 1 GO 240VAC UTILITY 56VA T N2 GO INPUT 224A al 225 12Vdc 23 TRANSFER 62 RELAY 224 N1 GOIL CUSTOMER CONNECTIONS 13 17 oS 23 gt i 22 ia 33 0 SW1 15A 194 POWER 120V WINDING 120V 239 STATOR 13 17 15 m 44 sA 194 d 11 55 15 239 0 240V 14 15 e 13 RED 0 C2 1 13 sc is 16 mil 14 18 C1 1 ib 0 sc Fs SM 0 0 0 i i BLACK 15 CUSTOMER 0 2 SUPPLIED 18 4 SPI D 18 C1 5 D M2 gt SP2 XXX ELECTRICAL DATA 27 Section 7 Electrical Data ELECTRICAL Air cooled 8 5 kW Generator DATA gt Electrical Schematic 12 Circuit Load Center Drawing No 0E7815 z 9 19 12Vdc TRANSER COIL 3 23 6 23 E1 TS TO 5 9 0 GENERATOR N1A Fo CONTROL PANEL 6 2 60 240VAC N2A F1 OUTPUT N1A 6 1 9 N1 G N1A E1 1 60 BLACK TO GENERATOR EE 48 RED OUTPUT CIRCUIT BREAKER E TETTE NEUTRAL WHITE CONNECTION B NEUTRAL WHITE 240VAC TO RED MAIN 2 MAIN DISTRIBUTION PANEL BLACK MAIN 1 o 6 BLU WHT 20A 120V CIRCUIT 10 o6 QRG 15W 120V CIRCUIT 9 B 20A 120V CIRC
3. 10 5 HBR RA BRAD PARTS Section 8 Exploded Views and Parts Lists Ce Air cooled 8 5 kW Generator GTS Load Center Drawing No 0E7975 B DESCRIPTION BOX GTS LOAD CENTER COVER 12 POSITION GTS LOAD CENTER TRANSFER SWITCH HOME STANDBY 100A 2P 250V COIL UTILITY COIL STANDBY INSULATOR SIDEWALL NOT SHOWN LIMIT SWITCH OPERATION NOT SHOWN SCREW 5 0 8 X 10 SCREW HHTT 1 4 20 X 5 8 LOCK WASHER SPECIAL 1 4 RELAY PANEL 12VDC 10A Q240VAC 12 CIRCUIT LOAD CENTER 125A 240V SCREW HHTT M4 0 7 X 10 RIVET POP 156 X 675 WASHER FLAT 1 4 M6 ZINC PLUG PLASTIC 1 375 HARNESS ADAPTER PLATE SUBPLATE LOAD CENTER TRIM VINYL BLACK 1 8 GP WASHER LOCK 10 SCREW HWHS 6 25 X 3 8 ARM EXTENDER PIN HOLDER CABLE TIE HARNESS GTS TO MAIN PANEL LUG QUICK DISCONNECT NI S 10X45 DEG BRASS TIN 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 SCREW SWAGE 1 4 20 X 1 2 ZINC COVER RELAY amp TERMINAL BLOCK WIRE HARNESS GTS LOAD CENTER NOT SHOWN FOR CLARITY FUSE HOLDER FUSE 5A X BUSS PCB SUPPORT SNAP IN 1 3 8 CIRCUIT BREAKER 20A 1P CIRCUIT BREAKER 20A 2P CIRCUIT BREAKER 15A 1P CIRCUIT BREAKER 30A 2P COVER HARNESS ENTRY HARNESS GTS TO EXT CONN BOX HARNESS GTS TO EXT CONN BOX 8 5KW SCREW PPHM M4 0 7 X 10 SCREW
4. m L ASSEMBLY DIPSTICK WITH HANDLE TUBE DIPSTICK O RING OIL CLR 3 8 X 1 2 SEAL 42 D CRANKSHAFT ASSEMBLY HOUSING COVER WITH SLEEVE SCREW HHFC M10 1 5 X 55 SCREW HHFC M6 1 0 X 25 ASSEMBLY OIL FILL CAP HOOK LIFTING ROCKER COVER WITH OIL FILL GASKET VALVE COVER KEEPER VALVE SPRING RETAINER VALVE SPRING SPRING VALVE SEAL VALVE STEM D7 WASHER VALVE SPRING STUD ROCKER ARM PIVOT NUT HEX M8 1 0 G8 YEL CHR O RING 3 8 X 1 2 ROCKER ARM PLATE PUSH ROD GUIDE SCREW HHFC M8 1 25 X 65 VALVE EXHAUST VALVE INTAKE TAPPET SOLID ASSEMBLY HEAD 42 G amp S PUSHROD 147 GASKET HEAD BARBED ELBOW 90 3 8NPT X 3 8 LOCKTITE KIT GASKET KIT PISTON amp RINGS KIT BREATHER ASSEMBLY KIT GOVERNOR ASSEMBLY KIT HEAD ASSEMBLY CYLINDER 1 KIT HEAD ASSEMBLY CYLINDER 2 KIT OIL RELIEF KIT GEAR COVER Generac Power Systems Inc 37 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Engine Drawing No 0E8774 G Part 2 x A EN ae ds C b MEL LIES 126 38 Generac Power Systems Inc 109 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Engine Drawing No 0E8774 G Part 2 PART NO QTY DESCRIPTION 0C5136A 0C3024 0C3040 0C8127 0D8564A 0D8564B 0D2595 0D4417 003025 0D3083 007292 070185B 075281 0 2094 035461 0C7649 0C9806 0C3026 0C9764 0C3043 0C7
5. NS B P 9 po NP no n ASSEMBLY CRANKCASE HOUSING WITH SLEEVE SEAL 38 1 0 CRANKSHAFT SCREW TAPTITE M6 1 0 X 12 YC ASSEMBLY BREATHER GASKET BREATHER COVER SEPARATOR OIL BREATHER ASSEMBLY HEAD 1 G amp S RETAINER 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 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 ASSEMBLY CONNECTING ROD 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 BUSHING GOVERNOR LOWER PARTS ib ues 00 PART NO QTY DESCRIPTION 0C3971C 0C5305 0C3027 0E9842 065731 003006 080318 093064 008808 0D2723B 002979 086515 0D2274 0D3867 078672 005371 072694 0D3998 0C3027 0D5313 0D6024 0C2976 086516 0C2229 083897 0D8067B 0D9853D 0C2978 043790A 0D4010 004011 004012 004013 0D8675A 0D8675B 0D4015 0D4016 NM CO N po
6. 5 RIVET POP 0 125 X 0 337 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHC M6 1 0 X 12 G8 8 NUT LOCKING FLANGE 6 1 0 SCREW HHTT M8 1 2 X 20 BP SCREW TAPTITE M6 1 0 X 12 YC NUT LOCK TRIC M6 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 SELF ALIGN SCREW M6 HH NUT HEX 8 1 25 G8 YC CABLE 46 RED BATTERY 38 5 NOT SHOWN WASHER FLAT 5 16 ZINC WASHER LOCK 5 16 SCREW TAPTITE M5 0 8 X 10 BP HARNESS ENGINE BUSHING SNAP 5 1000 12 SCREW HHC M8 1 25 X 25 G8 8 RIVET 1 8 X 0 126 0 375 LSH POP L WASH SPECIAL 10 ASSEMBLY BASE C PNL GRND WIRE ASSEMBLY BASE DOOR GROUND WIRE PLUG PLASTIC 1 375 GASKET EXTRUDED TRIM PLATE HOT 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 10 WASHER FLAT M5 NUT HEX 10 32 STEEL FOAM EXHAUST FAN HOUSING WASHER SHAKPROOF EXT 1 4 STEEL NUT HEX M6 1 0 G8 YELLOW CHROME HINGE LIFT OFF TYPE A KNUCKLE PANEL EXHAUST ALIGNMENT GROMMET 38 1 CROSS SLIT WITH HOLE BRACKET REGULATOR MOUNTING SCREW HHC M8 1 25 X 16mm Generac Power Systems Inc 33 Qi Section 8 Exploded Views and Parts Lists gt Air cooled 8 5 kW Generator 06 N Engine amp Alternator Drawing No 0D8446 C 34 Generac Power Systems Inc 32 ITE
7. 1 7 79 9 r t H 1 1613 4 13A 77 13 C2 1 0 i BATTERY CHARGE 66 14 19 WINDING N A AAA 66 C2 2 22 0 e 0 C2 4 uro C2 11 0 55 40 4 X LOP 11 ENGINE RUN BA E WINDING 4 B Sw2 22 AR STATOR WP 15 0 Ny C1 3 ELECTRONIC l 4 C2 10 C2 9 2 3 VOLTAGE 4 4 REGULATOR 0 66A 85 23 162 1 6 86 194 6 4 CB2 0 351 225 a VA 224 SES ET RTT id 66A DPE WINDING STATOR f 122 u 4 5 15A 23 239 66 DIAGRAM KEY di 194 3 23 BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY 1 CIRCUIT BREAKER MAIN OUTPUT 2 CIRCUIT BREAKER ALT EXCITATION 18 D DIODE 7 14 FS FUEL SOLENOID CONTROL 8 66A F1 FUSE 15 PRINTED CIRCUIT 9 239 F2 FUSE 5 BOARD 10 15A HTO HIGH OIL TEMPERATURE SWITCH 7 17 IM1 IGNITION MODULE CYLINDER 1 15 IM2 IGNITION MODULE CYLINDER 2 n LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTER SCR STARTER CONTACTOR RELAY 15 224 SP1 SP2 SPARK PLUGS 16 SW1 AUTO OFF MANUAL SWITCH 17 SW SET EXERCISE SWITCH SM STARTER MOTOR TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC ee Generac Power Systems Inc Section 7 Electrical Data Air cooled 8 5 kW Generator Electrical Schematic Drawing No 0D8501 B
8. SH3NHOO Yr S3 1OH ONILAN HIV zl lt L6PLol uuz oeg TRY k 206 3 3 m 3 j bj 3 p LINN GNNOHV D C 0 9 6 2 RE Soc Jac 23 Generac Power Systems Inc 4 ELECTRICAL DATA Section 7 Electrical Data Air cooled 8 5 kW Generator Wiring Diagram Drawing No 0D8500 B ENGINE WIRING DIAGRAM KEY BA BRUSH ASSEMBLY BCR BATTERY CHARGE RELAY CB1 MAIN OUTPUT BREAKER CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION D DIODE DSW PCB MOUNTED DIP SWITCH FS FUEL SOLENOID F1 FUSE 15 AMP F2 FUSE 5 AMP GRD CONTROL PANEL GROUND HTO HIGH OIL TEMPERATURE SWITCH IC INLINE CONNECTOR ICT INTERCONNECTION TERMINALS IM1 IGNITION MODULE CYLINDER 1 IM2 IGNITION MODULE CYLINDER 2 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY
9. WARNING 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 e Wear full eye protection and protective clothing e Where electrolyte contacts the skin wash it off immediately with water e 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 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 body before touch ing the battery by first touching a grounded metal surface A 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 a
10. 86 194 18 66A 15A 15 225 17 16 15 14 13 12111 10 9 8 7 6 5 4 312 L E D ALARM INDICATORS 224 Section 7 Electrical Data Air cooled 8 5 kW Generator ELECTRICAL Wiring Diagram 8 5 kW Drawing No 0D8500 B lt DATA lt 225 224A CONTROL PANEL BOX 224 225A 224A 225A a CLOSEST TO BEARING BCR T CB2 BA sss sh Aa
11. 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 switch 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 Setthe 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 1 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
12. 1 Fuse blown CORRECTION Replace fuse 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defective starter contactor 9 4 Defective starter motor 4 5 Dead Battery 5 Charge or replace battery The engine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel solenoid FS 2 7 3 Open 14 wire from 92 7 engine control board 4 Defective spark plug s 4 Clean re gap or replace plug s 5 Valve Lash o Reset Valve Lash The engine starts hard 1 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 3 Fuelregulator not set 3 Set fuel regulator 4 Fuel pressure incorrect 4 Confirm fuel pressure to regulator is 11 14 water column 0 4 0 5 psi for LP and 5 7 water colum 0 18 0 25 psi for natural gas The AUTO OFF MANUAL switch 1 Defective switch 42 is set to but the engine 2 AUTO OFF MANUAL switch 2 5 continues to run wired incorrectly 3 Defective control board Oa 9 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 2 There is no transfer to 1 Defective transfer switch coil l e standby after utility 2 Defective transfer relay 2575 source failure 3 Transfer relay circuit open ium 4 Defective control logic board 2 Unit
13. NOTE The rocker arm jam nut must be held in place as the pivot ball stud is turned 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 Install new valve cover gasket Re attach the valve cover MAINTENANCE S Section 4 Maintenance Air cooled 8 5 kW Generator Figure 4 6 Valve Clearance Adjustment Rocker Pivot Ball Arm Jam Nut Start all four screws before tightening or it will not be possible 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 49 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 Figure 4 7 Cooling Vent Locations AIR OUTLET j j U PCO ttt t AIR INTAKE caution The exhaust from this product gets extremely f hot and remains hot after shutdown High g
14. co ub 4O o 4 7 9 13 66 35 162 0 225B 225B T 224B 224B i Ss 6 11 66 8 lt 14 2 55 0 7 22 0 11 6 66A H 11 22 5 lt 77 66 66 225 13A s 5 0 11 4 4 3 N 77 2 6 44 224 1 lt 162 162 al VOLTAGE REGULATOR 0 66A 0 0 66A 33 4 55 N2 22 N1 13 13 225 13 351 224 194 23 4 N2 23 N1 i 351 44 13 11 13A 851 194 22 13 ad 23 194 N1 0 eiie 13 ii F2 F1 239 CB1 B 17 13 239 15 17 SS e U U V I 0 225 Swi 15 5 p 224 taj S p swe 240V GENERATOR E AUTO OUTPUT TO TRANSFER 2 m _ SWITCH CONTACTOR 5 4 2 CUSTOMER MANUAL CONNECTION Generac Power Systems Inc 25 Section 7 Electrical Data Air cooled 8 5 kW Generator ELECTRICAL DATA Electrical Schematic Drawing No 0D8501 B 11 22 225A 3 225A 2 224A l BATTERY 225B F2 225 gt 224 13A 13 e 13A i i F1 224
15. 0E4494 0E7890 023484E 075476 0 6480 0C1085 0D8443 054502 053623 0E7870 0E7871 075235 A aA O PARTS Ce LISTS Control Panel Assembly Drawing No 0E7974 F O ITEM_ PART NO QTY DESCRIPTION CIRCUIT BREAKER 30A X 2P 240V 7KW 22 0D5240 1 SWITCH SPST ON ON N O CIRCUIT BREAKER 40A X 2P 240V 23 0D9784 6 NUT HEX LOCK M3 0 5 NYLON INSERT 8 5KW 0D9784 4 NUT HEX LOCK M3 0 5 NYLON INSERT CIRCUIT BREAKER 45A X 2P 240V 7KW 11KW 24 008502 1 NEUTRAL CONNECTOR CIRCUIT BREAKER 50A X 2P 240V 26 0D8441 1 HARNESS CONTROL PANEL NOT 12KW SHOWN CIRCUIT BREAKER 60A X 2P 240V 0E0120 1 HARNESS CONTROL PANEL WIRE NOT 13KW SHOWN 7KW CIRCUIT BREAKER 70A X 2P 240V 27 074908 4 SCREW TAPTITE M5 0 8 x 10 BP 15KW 29 082025 6 NUT HEX LOCK M5 0 8 NYLON INSERT ASSEMBLY BATTERY CHARGER 30 063910 1 TRANSFORMER ENGINE 31 022507 2 SCREW HHC 1 4 20 x 1 2 ASSEMBLY POTTED REGULATOR 32 099727 1 FUSE 5A X AGC5 RELAY 12V 25A SPST 33 046689 1 BLOCK TERMINAL STRIP 20A 4 X 6 X BLOCK 1 POSITION 1100V HEX STAND OFF 16 32 x 3 8 34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC ASSEMBLY HOME STANDBY 35 075475 4 SCREW PPHM 4 0 7 x 10mm CONTROLLER 36 043180 2 WASHER FLAT M4 ASSEMBLY HOME STANDBY 37 0D8439 1 COVER CONTROL PANEL COMPONENT CONTROLLER 7KW 0 0119 1 COVER CONTROL PANEL COMPONENT HOLDER FUSE 7KW FUSE 15AMP X AGC15 38 092036 8 SCREW PPHMS LW 46 32 x 1 4 SWITCH ROCKER DPDT ON
16. 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 eo Generac Power Systems Inc 4 11 2 RETURN TO SERVICE To return the 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 2 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 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 WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery oee Specifications Section 1 5 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 The generator is now ready for service NOTE If the battery was dead or disconnected the exer cise timer must be reset 4 12 CORROSION
17. A 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 5 AUTOMATIC TRANSFER OPERATION To select automatic operation do the following 1 Make sure the transfer switch main contacts are set to their UTILITY position i e loads connect ed to the UTILITY power source Figure 3 2 2 Be sure that normal UTILITY power source volt age is available to transfer switch terminal lugs N1 and N2 3 Set the generator s 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 Section 3 4 Sequence of Automatic Operation 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 p
18. Figure 2 3 Figure 2 3 V twin Engine Governor Adjustment Idle Spring Governor ww QD Shaft O te ae Q AT Go EUM _ No Load Idle Governor Clamp Bolt Adjustment Screw 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 o Remove load stop engine loosen the idle adjust screw and reconnect the idle spring 6 Using a 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 The governor is now set Figure 2 4 Full Load Speed Adjust Screw Full Load Speed Adjust Screw 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 The access panel on top of the control panel must be removed to adjust the voltage regulator NOTE The voltage regulator is housed above the genera tor s control p
19. do nothing that might ren der the system unsafe or in noncompliance 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 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 physically or mentally fatigued Inspect the generator regularly and contact the 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
20. e Wear full eye protection and protective clothing e 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 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 e Discharge static electricity from body before touch ing the battery by first touching a grounded metal surface A 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 or sparking may occur at the battery posts as the cables are attached and cause an explosion Generac Power Systems Inc s POST CED INSTALLATION START UP ADJUSTMENTS Air cooled 8 5 kW Generator 2 1 BEFORE INITIAL START UP
21. 0C3048 0D3754 0D3742 0C8482 0 0486 0D3743 0D3705 0C2993 045771 0D6147 0 8152 1338 1 HOUSING BLOWER NG COOLER GUARD FAN SCREW TAPTITE M6 1X10 YELLOW CHROME NUT GROMMET 1 4 PLUG HOSE BREATHER WASHER FLAT 5 16 8 ZINC WASHER LOCK M8 5 16 WRAPPER UPPER CYLINDER 1 WRAPPER LOWER CYLINDER 1 WRAPPER LOWER CYLINDER 2 WRAPPER UPPER CYLINDER 2 SCREW TAPTITE M5 0 8 X 8 ZP ASSEMBLY GROUND WIRE ASSY IGN COIL W DIODE NO ADV WASHER LOCK M6 1 4 SCREW TAPTITE M6 1 0 X 25 BP STARTER SPARKPLUG WASHER LOCK M8 5 16 SCREW HHC 8 1 25 X 85 G8 8 KEY WOODRFF 4 X 19D NUT HEX LOCK M10 1 50 SPRING ANTI LASH ROD GOVERNOR CONTROL ASSEMBLY GOVERNOR LEVER SPRING GOVERNOR ASSEMBLY GOVERNOR ADJUSTER SCREW SHC M10 1 5 X 75 010 9 SPRING GOVERNOR IDLE ASSEMBLY GOVERNOR ADJUSTER BRACKET SEAL GOVERNOR SHAFT NUT HEX M8 1 25 G8 SCREW HHFC M6 1 0 X 10mm O RING 0 49 1 0 X 0 07 THICK ASSY IGN COIL W DIODE NO ADV Generac Power Systems Inc 39 i us Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Control Panel Assembly Drawing 0 7974 g 40 Generac Power Systems Inc ITEM NOD Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator PART NO QTY DESCRIPTION 0 7886 0 7886 0 78860 0 7886 0 7886 0 78860 0 1801 083049 0C2174 075210A 0D3062 0D8615 0D8615A 032300 022676
22. Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to 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
23. 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 dipstick 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 2 CHECK TRANSFER SWITCH OPERATION Refer to Section 3 5 of the owner s manual for man ual operation procedures WARNING 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 2 Turn OFFall loads connected to the transfer switch terminals T1 and T2 3 Turn on the U
24. Drawing No 0E7687 lt DATA 1 Nea LEGEND ATS AUTUMATIC TRANSFER SWITCH CUIL amp RECTIFIER Ce GENERATUR CHIL amp RECTIFIER FI Fe 3A 600V FUSE LC CIRCUIT BREAKER CLUADSD N NEUTRAL TR TRANSFER RELAY TS TERMINAL STRIP XA XB LIMIT SWITCHES LILI zZ lt lt Y O LJ Z LIL U L a Generac Power Systems Inc 31 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Enclosure Drawing No 0 0100 32 Generac Power Systems Inc ITEM CONDOR WD Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Compartment Drawing 0 0100 PART NO QTY DESCRIPTION 0D8312 066735 0 0063 0C7062 OF0066 0 9873 008333 0C8101A 0C8101B 0C8283 0C8284A 0C8284B 0C8284C 0C8285 0C8899A 0D1128 0 4244 0D2538A 0D1839 0D1840 0D2425 002588 0D2676 0D2677 0D2979B 0D2979C 0D2979D 0 4245 0 4245 0 4245 0D3057D 0D3059A 0D3059B 0E2874 0D7176 0D3059D 003059 0C7781A 0D3037 0D2537 0D2538 0D3037A 0A2115 022097 022473 cl cl cl cc cl cl 24 oo R ASSEMBLY ENCLOSURE BASE SUPPORT ROOF FOLDING ENCLOSURE FRONT ENCLOSURE EXHAUST SIDE ENCLOSURE SIDE amp BACK ENCLOSURE ROOF PANEL ALTERNATOR DIVIDER PANEL MU
25. OFF ON 39 045770 2 SCREW HHC M5 0 8 x10mm CIRCUIT BREAKER MOUNTING 40 0 7866 1 COVER CONTROL PANEL BRACKET 0E7867 1 COVER CONTROL PANEL 7KW SNAP BUSHING 41 0D3700 8 NUT FLANGE 6 1 0 NYLOK SCREW PPHM 4 0 7 x 16mm 42 0912970069 1 ASSEMBLY ROOF DOOR GROUND WIRE NUT HEX LOCK M4 0 7 NYLON INSERT 43 0E2874 1 SCREW HHTR 1 4 20 X 3 4 SCREW PPHM M3 0 5 X 8mm 44 0A1658 2 WASHER LOCK SPECIAL 1 4 DECAL CONTROL PANEL NOT SHOWN 45 022473 3 WASHER FLAT 1 4 M6 CIRCUIT BREAKER 3 X 1 ETA 46 500 P 46 038750 1 SCREW HHC M6 1 0 x 30mm CIRCUIT BREAKER 2 5 X 1 ETA 46 500 P 4T 022097 3 WASHER LOCK M6 1 4 7KW 48 049813 1 NUT HEX M6 1 0 CONTROL PANEL BOTTOM 49 031879 6 WASHER FLAT 4 CONTROL PANEL BOTTOM 7KW 031879 4 WASHER FLAT 4 7KW SCREW HHC 5 0 8 x 30mm 50 023897 2 WASHER FLAT 10 Generac Power Systems Inc 41 SS MAX Wi X 557 MI ESA Z 1 14 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator GTS Load Center Drawing No 0E7975 B 42 Generac Power Systems Inc PART NO 0D3086 0D3092 0C2237 077220 077220A 082574 084464 074908 024912 0A1658 063617 0E7889 0A1495 0A1661 022473 055450 0D4684 0E7900 056326 022152 064526 0 6155 063378 003094 074138 036933 077033 048850 028739 0 2110 003191 003088 073591 073590 040213 0 7888 0 7888 0 7888 0 7888 003320 0D3093 0D8597 075475 0A7215 0 6193
26. Reconfiguring the Fuel System 7 E 8 1 10 1 Generator ou suka u d te Nd unius 8 1 10 2 Transfer Switch 8 1 11 Battery Installation eese 8 L2 The BINE u uuu 9 Section 2 Post Installation Start up and Adjustments 10 2 1 Before Initial Startup 10 2 2 Check Transfer Switch Operation 10 2 0 Electrical CHeeRkS 10 2 4 Generator Tests Under Load 11 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 13 2 8 Voltage Regulator Adjustment 13 Section 3 Operation 13 3 1 Break in Procedure 15 3 2 Using the AUTO OFF MANUAL Switch 13 3 2 1 Auto Position 13 Table of Contents Air cooled 8 5 kW Generator TABLE OF CONTENTS 2 22 OM POSION ctr tier ober 14 3 2 3 Manual Position 14 3 9 Automatic Transfer Operation 14 3 4 Sequence of Automatic Operation 14 3 5 Manual T
27. SP1 SP2 SPARK PLUGS SW1 AUTO OFF MANUAL SWITCH SW2 SET EXERCISE SWITCH SM STARTER MOTOR TB INSULATED TERMINAL BLOCK TX TRANSFORMER 16 Vac 56 VA amp 16 Vac 1 VA DUAL SEC SP1 SP2 BLACK IM1 FS BATTERY C CHARGER 2 225B 224B 13A 13A 225B 224B 14 14 1 0 6 86 5 gt 4 85 86 RED BATTERY 12V SM CUSTOMER SUPPLIED ed Generac Power Systems Inc SC 13 2 18 13 13 gt 1 C1 16 16 SCR 351 351 0 14 56 56 86 T J2 J1 CONTROL PRINTED CIRCUIT BOARD DSW 1234 tle ON INDICATES 1 20 Vac Sense Transformer Remote Not Auto 50 Hz Operation SPARE A o N 1
28. consumes large 1 Break in procedure 7 amounts of oil not followed see Section 2 1 Contact the nearest Generac Authorized Dealer for assistance ee Generac Power Systems Inc gt ELECTRICAL DATA lt SSHONI SHSLAWITIIN NI SNOISNAWIG NAWANIW 2 5 coa L 00 uug9Z HV3H 341 LHDIY LNOHJ 34 1441 Gw jkun m A m c M Lap del p 7 E I S SvI 2621 rz 29 wloQ 99 e sc P 4 wu 2 1 i x Z O Eel O O 92 LA bo C 092 0 j I 5 6 9 lt 2 2 E f s S i E 4 3 S Lm j 4 5 ole o SS399Y HO4 SAOWAY EM JE 5 Q S31OH SS320V 318VO 3 I lt 4 c G3HINO4H NANIOD H31VM _ JO AHNSSAYd SVO Zv 66 LL Loez 709 og LAINI 1314 LdN b A zov ZZLL idOOH 4HL LJ LON qariadns 41 HOLIMS H3JSNVHL 78 0
29. is not connected to the unit or if it is below 168 volts AC then the System Set light will flash rapidly This indicates that if the AUTO OFF MANUAL switch is placed in the Auto position the generator 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 17 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 9 for instructions on reconfiguration of 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 the fuel supplier for the Btu content of the fuel Required fuel pressure for natural gas is 5 inches to 7 inches water colum 0 18 to 0 25 psi and for liquid propane 11 inches to 14 inches of water column 0 4 to O 5 psi NOTE Any piping used to connect the generator to the fuel supply should be of adequ
30. is present or in place of utility power where utility power service does not normally exist Steel enclosures that are rusting due to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised 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 oollision theft vandalism riot or wars nuclear holocaust fire freez ing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replace ment of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses e Living or travel ex
31. switch must effectively isolate the electrical system from the utility dis tribution system when the generator is operat ing NEC 700 701 and 702 Failure to isolate an electrical system by such means will result in damage to the generator and also may 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 a loss or damage is discovered after delivery sepa rate 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 pres ent to monitor engine conditions For that reason the engine is equipped with the following systems that protect it against potentially damaging conditions 3 Overcrank 4 Overspeed 1 Low Oil Pressure Sensor 2 High Temperature Sensor e Generac Power Systems Inc Section 1 General Information There are LED readouts on the control panel to noti fy personnel that one of these faults has occurred 1 5 NEC REQUIREMENT FOR ARC FAULT CIRCUIT INTERRUPTION BREAKER FOR BEDROOM
32. turned with a long flat blade screwdriver 13 To adjust the system to run on LP fuel turn BOTH adjuster screws 1 2 TURN CLOCKWISE The system should now be set for maximum power and best perfomance DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE SET PINS FROM THE REGULATOR HOUSING THIS WILL VOID THE WARRANTY 14 may be necessary to make minor adjustments to the preset adjustment screw settings to achieve maximum power particularly at higher altitudes If experiencing problems with the unit producing maximum power follow the procedure in Section 2 6 Adjusting the Fuel Regulator 1 10 LOCATION 1 10 1 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 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 three 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 Inst
33. 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 operating the generator If work must be done around an operating unit stand on an insulated 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 vic
34. 038 AGRICULTURAL WIRING HANDBOOK 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 Society 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 A 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 WARNING A If this generator is used to power electrical load circuits normally powered by a utility power source it is required by code to install a trans fer switch The transfer
35. 16 X 3 4 BP SCREW 5 16 18X3 4 HH THD ROLL HOSE RES 1 2 LP GAS CLAMP HOSE 8 53 1 00 NUT HEX W TOOTH WSHR 8 1 25 SCREW TAP R 10 32 x 9 16 U BOLT 5 16 18 X 1 25 WITH SADDLE GASKET EXHAUST PORT CLAMP HOSE BAND 1 4 HOSE 1 4 0 CLAMP HOSE BAND 1 4 HOSE 1 4 0 Generac Power Systems Inc LISTS OG 35 LISTS an Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator KO Engine Drawing No 0E8774 G Part 1 64 68 JA Y VERG LL ZA P 2 A A 49 50 51 52 53 54 56 57 58 59 60 62 9 19 20 39 40 47 64 93 140 48 47 66 2 lt CO L y IN A 27 _ KY NW Q l Um S 7 5 en cO jamal 51 SK Uh ae da A find XL arcs i VAS SR U LO LR ra YY ki A P IL F a C lt 41 4 36 Generac Power Systems Inc Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Engine Drawing No 0E8774 G Part 1 PART NO QTY DESCRIPTION 0C5729 0 9843 090388 0 5372 0C3005 0E3372B 0D8067A 071983 0C2981C 045761A 0 2985 021533 0 1466 004041 0C2983 0C2985A 0C2985B 0D4042 0A7811 0C2977 0C5943 0E4357E 0E3223 0D2157 0 6098 0D4123A 078699E 0C3011 0C3009 0C3010 093873 0C5315 0C5998 0D1667 0C2991 0C2988 0C2992
36. 26 26R 12VDC 5295 cold cranking 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 Schedule 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 A Do not dispose of the battery in 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 Section 1 General Information P ENERAL Air cooled 8 5 kW Generator INFORMATION Remove watches rings or other metal objects e Use tools with insulated handles e Wear rubber gloves and boots e Do not lay tools or metal parts on top of the battery and e Disconnect charging source prior to connecting or dis connecting battery terminals WARNING amp 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
37. 5 1 for recom mended 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 for oil capaci ties 5 Start the engine and check for leaks 4 5 CHANGING THE ENGINE AIR CLEANER 4 5 1 8 5 KW GENERATORS oee Figure 1 1 for the location of the air cleaner Use the following procedure 1 Turn the two screws counterclockwise to loosen Figure 4 4 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 Generac Power Systems Inc 17 MAINTENANCE 5 Install the cover Turn the two cover screws clock wise to tighten See the Service Schedule Section 4 11 for air cleaner maintenance See Section 1 5 1 for air filter replacement part number Section 4 Maintenance Air cooled 8 5 kW Generator Figure 4 4 V twin 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 for mainte nance 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 sp
38. 694 0C7693 0C3041A 070008 070006 040976 0C3016A 0E4997 0C3725B 0C3031 0C3032 0A5992 051754 0C3033 0C3034 0C8549A HB B KNOB AIR CLEANER COVER AIRBOX NG LP PRE CLEANER ELEMENT AIR CLEANER ASSEMBLY MIXER AIRBOX 990 ASSEMBLY MIXER AIRBOX 760 SCREW SHOULDER 8MM M6 1 0 X 18 WASHER RUBBER 1 4 X 1 8 THICK SWITCH OIL PRESS ASSEMBLY OIL DRAIN HOSE NIPPLE 3 4 16 UNF OIL FILTER SWITCH THERMAL 284F SCREW M3 0 5 X 6 SEMS BARBED STR 1 4NPT X 3 8 WITH VIBRA SEAL CLAMP HOSE 38 87 HOSE 3 8 1 0 6 LONG COOLER OIL PLASTITE 1 4 15 X 3 4 GASKET MANIFOLD PORT MANIFOLD CYLINDER 2 MANIFOLD CYLINDER 1 SLEEVE RUBBER WASHER FLAT M8 SS WASHER LOCK M8 SSTL SCREW SHC 8 1 25 X 20 612 9 PLATE BACKING WITH OIL COOLER GROUND WIRE CONNECTOR FLYWHEEL ASSEMBLY FAN NYLON PLATE FAN WASHER SHAKEPROOF INT 8 55 SCREW HHC 8 1 25 X 12 G8 8 WASHER 25mm 1 0 NUT HEX M24 SNORKEL AIR INTAKE ITEM 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 142 143 144 145 PARTS ib ues 00 PART NO QTY DESCRIPTION 0C3022A 001131 045756 0 9763 0 3036 022145 022129 003018 003019 0D1142A 0D1143 0 6043 1177 OF1338B 022097 092079 0E4271 0D4529 022129 061906 082774 0E5343 0C8468
39. CENTURION Installation and Owner s Manual Air cooled Prepackaged Automatic Standby Generators Models 004692 2 8 5 kW dO ARARALR V VV V VV VIT E CENTURION This manual should remain with the unit Not intended for use as Primary Power in place of utility or T in life support applications N A 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 any portion of this manual is not understood contact the 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 per sonnel to special instruction about a particular oper ation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their defini tion
40. FFLER BOX SIDE COVER MUFFLER BOX GASKET DOOR SEAL FOAM BACK ENCLOSURE FOAM ROOF ENCLOSURE FOAM FRONT ENCLOSURE BRACKET BATTERY SUPPORT PAD 24 X48 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 HHTR 1 4 20 X 3 4 WASHER SELF LOCKING FOAM FRONT EXHAUST ENCLOSURE COVER 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 WASHER NYLON 250 WASHER LOCK M6 1 4 WASHER FLAT 14 ZINC PARTS qea 00 PART NO QTY DESCRIPTION 0710 047411 043116 0D3700 0D4662 090388 092120 0D1606 0D3167 0A3328 055414 092079 0A1658 003906 045771 0388040AJ0 022145 022129 074908 0D2346 023484F 043107 0A7836 0A8475 0912970069 0912970070 055450 0E5968 0D3701 0D3472 008742 008911 0D8442 036937 022152 051713 022158 0D3059C 026850 049813 0D2537A 0E4321 0E1330A 0 9692 042907 14 14
41. 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 Standby Generator 2 Auxiliary Power Unit APU Generator 3 Standby Generator Part 2 Generac Power Systems Inc 49 Section 10 Warranty WARRANTY Air cooled 8 5 kW Generator GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR CENTURION PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale 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 accordance with the warranty schedule set forth below Any equipment that the pur chaser owner claims to be defective must be examined by the neares
42. GRY 15 120 CIRCUIT 7 ATS AUTOMATIC TRANSFER SWITCH C1 UTILITY COIL amp RECTIFIER o PNK 154 120V CIRCUIT 8 C2 GENERATOR COIL amp RECTIFIER F1 F2 5A 600V FUSE LC CIRCUIT BREAKER LOADS TR TRANSFER RELAY LC TS TERMINAL STRIP XA XB LIMIT SWITCHES Generac Power Systems Inc 29 Il gt IBI KE D Y per 138 333338 1102912 3018 gt LN LN LAMAN JHM N LVS3N39 01 g NIY 13NVd NN I NIVW gt NOTLNEIALSIC waln3N NIVN OL m S MIA LHM MIA n18 ANd u 2 S e 5 c yg 9 9 s B em DS 5 5 Ele m 858 TE elg 3 2 LINDAI AOv2 V02 8 59 86 IHM MTA 1109319 0 2 902 v n 118 9 1 0 12 AO2I VO2 uja E 8 11195419 021 902 2 5 D LHM R18 01 1102412 021 902 ss 5 I LHM SNO 21 1102312 AOSI VGI Sos 1 9 z o fae IT 11020412 AOSI VSI n EC 90 6 LINONIO AOSI VSI 2 ASQ 89 4 1103313 AOSI VGI G LIROMIO 021 961 LHMZN8I LHM N38 1119419 AOv2 V0E nag T 1102812 0 2 906 30 Generac Power Systems Inc Section 7 Electrical Data Air cooled 8 5 kW Generator cs ELECTRICAL Wiring Diagram 12 Circuit Load Center
43. M CONDO WP PART NO QTY 0C6934 0D8062H 0D8057H 0C6043A 0D8274 0D6634A 0D3220 0D8314 056482 0C3168 0D8313 0D1846 0C7038 0D1647 0D2558 0C7038A 0C7758 0388050AD0 0 2417 0821216 066386 029451 1 8 049451 1 022237 022511 022131 039288 022145 14 049820 4 045756 2 022129 10 022259 8 059637 2 004662 4 074994 057822 4 0 0462 4 3 1 2 2 3 c P CO c c 0C2824 025145 0C4138 048031C 030340 1 3 048031C 2 030340 1 33 FT PARTS Section 8 Exploded Views and Parts Lists Ce Air cooled 8 5 kW Generator Engine amp Alternator Drawing No 0D8446 C DESCRIPTION ADAPTOR ENGINE STATOR ROTOR CARRIER REAR BEARING FAN 12 CURVED BLADE MUFFLER TAIL PIPE MUFFLER PANEL MUFFLER BASE BEARING 1 1811 2 8346 5 16 SPECIAL LOCK WASHER BOLT HHCS 3 8 24 x 14 2 BOLT 5 M8 1 25 x 345mm BRACKET ALTERNATOR MOUNTING DUCT ALTERNATOR AIR GASKET ALTERNATOR AIR DUCT BRACKET ENGINE MOUNTING RUBBER MOUNT CABLE 6 48 BLACK BATTERY EARTH STRAP 3 8X 3 8 CLIP J VYNL COAT 0 625 ID ASSEMBLY BRUSH HOLDER TAPE ELEC UL FOAM 1 8 X 1 2 WASHER FLAT 406ID X 1 6200 WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 1 4 G5 WASHER FLAT 3 8 ZINC SCREW HHC 8 1 25 x 55 08 8 WASHER FLAT 5 16 ZINC NUT LOCK HEX 8 1 25 NYL INSERT SCREW TAPTITE M6 1 0X10 BP WASHER LOCK M8 5 16 NUT HEX 5 16 18 STEEL SCREW TAPTITE 3 8
44. 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 4 15 SERVICE SCHEDULE Section 4 Maintenance Air cooled 8 5 kW Generator MAINTENANCE 2 0 ATTENTION It is recommended that all service work be performed by the 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 6M Electrolyte level X R EVERY 6M 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 1 TROUBLESHOOTING GUIDE PROBLEM The engine will not crank CAUSE
45. RECOMMENDATIONS Use oil of American Petroleum Institute API Service Class SG SH or SJ Use all season SAE 5W 30 oynthetic oil Organic break in oil is required before using synthetic oil NOTE The unit is supplied with break in oil See the Procedure Section 3 1 for the first required oil change A caution amp Any attempt to crank or start the engine before A 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 MAINTENANCE S Section 4 Maintenance Air cooled 8 5 kW Generator 2 Immediately after the engine shuts OFE 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 3 After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip 4 with the proper recommended oil see Section 4 3 1 See Section 1 5 2 for oil capaci ties Figure 4 3 Oil Drain Hose and Filter Oil Drain Hose O LA Oil Filter 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 Apply a light coating of clean engine oil to the gas ket of the new filter See Section 1
46. REGULATOR SCREW TAPTITE M4X8 BP 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 PLUG STANDARD PIPE 1 8 STEEL SQUARE HEAD 7KW PIN LIMITED ADJUSTMENT WASHER FLAT 3 X 10mm O D PLUG STANDARD PIPE 1 2 STEEL SQUARE HEAD 7KW BARBED STRAIGHT 1 8 NPT X 1 4 JET IDLE PRIMER PHILLIPS HD V TWIN ONLY PLUG EXPANSION 16mm A QUANTITY OF 1 1 TO BE USED ON 7KW HOME STANDBY LISTS age Generac Power Systems Inc 45 NOTES Section 9 Notes Air cooled 8 5 kW Generator 46 Generac Power Systems Inc Section 9 Notes NOTES Air cooled 8 5 kW Generator Generac Power Systems Inc 47 Section 10 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 neg
47. S The 2002 National Electric Code NEC introduced a requirement for new construction This new require ment indicates the need for Arc Fault Circuit Interrupters to be used to protect the complete branch circuit that feeds a dwelling bedroom The actual NEC requirement is indicated below 1 3 1 SECTION 210 12 ARC FAULT CIRCUIT INTERRUPTER PROTECTION 1 Definition An arc fault circuit interrupter is a device intended to provide protection from the effects of arc faults by recognizing characteristics unique to arcing and by functioning to de ener gize the circuit when an arc fault is detected 2 Dwelling Unit Bedrooms All branch circuits that supply 125 volt single phase 15 and 20 ampere outlets installed in dwelling unit bedrooms shall be protected by an arc fault circuit interrupter listed to provide protection of the entire branch circuit Section 210 12 requires that AFCI protection be pro vided on branch circuits that supply outlets recepta cle lighting etc in dwelling bedrooms The require ment is limited to 15 and 20 ampere 125 volt cir cuits There is no prohibition against providing AFCI protection on other circuits or in locations other than bedrooms Because circuits are often shared between a bedroom and other areas such as closets and hall ways providing AFCI protection on the complete cir cuit would comply with 210 12 If during the installation of the Guardian Home Standby system the decision
48. SW 1 4 20 X 5 8 WITH WASHER BRACKET ARM EXTENDER Generac Power Systems Inc LISTS OG 43 us Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator KO Regulator Drawing No 0D8720 D u av AN M G 10 Ad Generac Power Svstems Inc ITEM CONDO WP co 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 37 PART NO 0D5694 0 3154 004647 0D4166 0C6070 043180 022264 075475 0C5760E 0C6606 097934 0 4645 0 5761 0 5968 0 6066 0C5759 0C5764 0C5764A 070728 0C6069 0C5762 045764 0C6731 0C6067 0C4706 0C6068 0C4643A 026073 026073 0A4032 0D3308 024310 028414A 0D5698A 0D3973 QTY RD FS F RO D D Q S Q PRP A Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Regulator Drawing No 0D8720 D DESCRIPTION CASTING TWIN REGULATOR HOUSING SOLENOID COIL 12VDC GASKET SOLENOID PLUNGER LP REGULATOR ASSEMBLY SPRING SOLENOID PLUNGER WASHER FLAT M4 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 PIVOT ARM SPRING REGULATOR SPRING REGULATOR 7KW SCREW PFHMS M3 0 5 x 5 GASKET DIAPHRAGM COVER TWIN
49. TILITY power supply to the trans fer switch using the means provided such as a utility main line circuit breaker INTI A A The transfer switch is now electrically hot Contact with hot parts will result in extreme ly hazardous and possibly fatal electrical shock Proceed with caution 10 Generac Power Systems Inc Section 2 Post Installation Start up and Adjustments 4 Use an accurate AC voltmeter to check UTILITY power source voltage across transfer switch ter minals N1 and N2 Nominal line to line voltage should be 240 volts AC 5 Check UTILITY power source voltage across ter minals 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 MAN UAL 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 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 volt
50. UIT 6 o6 VIO 15A 120V CIRCUIT 5 6 YEL 20A 40V CIRCUIT 2 T gt EE BRN 30A 240V CIRCUIT 1 dL CIRCUIT O BRNWHT B30A 240V CIRCUIT 3 CONNECTION Mi o YEL IWHT 20A 240V CIRCUIT 4 15A 120V CIRCUIT 7 LEGEND o PNK 20 120 CIRCUIT 8 ATS AUTOMATIC TRANSFER SWITCH C1 UTILITY COIL amp RECTIFIER 5 6 VIOWHT 15A 120V CIRCUIT 11 C2 GENERATOR COIL amp RECTIFIER F1 F2 5A 600V FUSE TR TRANSFER RELAY TS TERMINAL STRIP LC XA XB LIMIT SWITCHES ee Generac Power Systems Inc Section 7 Electrical Data Air cooled 8 5 kW Generator U ELECTRICAL Electrical Schematic 12 Circuit Load Center Drawing No 0E7815 lt 14 19 12Vdc TRANSER COIL 23 2 60 23 E1 TS TO 5 9 0 GENERATOR N1A Fo CONTROL PANEL OO 69 240VAC xa FI OUTPUT N1A 6 1 9 N N1A E1 1 60 BLACK TO GENERATOR E oo RED OUTPUT CIRCUIT BREAKER E TETUER NEUTRAL WHITE CONNECTION B INSIDE SWITCH NEUTRAL WHITE 240VAC TO RED MAIN 2 MAIN DISTRIBUTION PANEL BLACK MAIN 1 B 15A 120V CIRCUIT 6 6 VIO 15A 20V CIRCUIT 5 20M 120V CIRCUIT 2 ____ 6 30A 240V CIRCUIT 1 CUSTOMER ES CIRCUIT 6 BRN WHT 30A 240V CIRCUIT 3 o YLW WHT 15A 120V CIRCUIT 4 LEGEND 6
51. all the generator as close as possible to the transfer switch HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DIS TANCE 8 Generac Power Systems Inc Section 1 General Information 1 10 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 l This type of enclosure is intended for indoor use only Follow these rules nstall the transfer switch indoors on a firm stur dy supporting structure To prevent switch distortion level the switch if nec essary This can be done by placing washers between the switch enclosure and mounting surface 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 11 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 Setthe generator s AUTO OFF MANUAL switch to 2 Turn off utility power supply to the transfer switch A 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 connect ed If the utility power supply is not turned off sparki
52. anel 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 Figure 2 5 Voltage Adjustment Potentiometer Section 5 Operation OPERATION Air cooled 8 5 kW Generator J gt 5 1 PROCEDURE Once the unit has been installed and all electrical checks have been made it is strongly recommended that the following Break in Procedure be completed to ensure correct generator operation in the future 1 Setthe generator s AUTO OFF MANUAL switch to AUTO 2 Turn OFF the UTILITY power supply to the trans fer switch using the means provided such as a utility main line circuit breaker 3 The unit will start and the transfer switch will transfer to standby 4 Using the transfer switch s builtin emergency load center turn on circuits to load the generator to approximately 25 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 100 rated load Turn ON the UTILITY power supply to the trans fer switch which will allow the transfer switch to transfer back to UTILITY power The unit will continue to run for one minute and then shut down 9 Allow the unit t
53. ark plug s and check the condi tion Replace the spark plug s if worn or if reuse is questionable See Section 4 11 for recom mended 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 gt lt wd SN 18 Generac Power Systems Inc 4 7 BATTERY MAINTENANCE The battery should be inspected per the Service ochedule Section 4 11 The following procedure should be followed for inspection 1 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 DX A Do not dispose of the battery in 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 e Remove watches rings or other metal objects e Use tools with insulated handles e Wear rubber gloves and boots e Do not lay tools or metal parts on top of the battery and e Disconnect charging source prior to connecting or dis connecting battery terminals
54. at no load for a few minutes 15 Set the AUTO OFF MANUAL switch to OFE The engine should shut down POST CED INSTALLATION START UP ADJUSTMENTS Air cooled 8 5 kW Generator 2 5 CHECKING AUTOMATIC OPERATION To check the system for proper automatic operation proceed as follows 1 Check that the AUTO OFF MANUAL switch is set to OFF 2 Turn OFF the UTILITY power supply to the trans fer switch using the means provided such as a UTILITY main line circuit breaker 3 Manually set the transfer switch to the UTILITY position i e load terminals connected to the UTILITY power source side 4 Turn ON the UTILITY power supply to the trans fer switch using the means provided such as a UTILITY main line circuit breaker 5 Set the AUTO OFF MANUAL switch to AUTO The system is now ready for automatic operation 6 Turn OFF the UTILITY power supply to the trans fer 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 supply 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 retran
55. ate size to ensure the fuel pressure NEVER drops below 4 inches water colum for natural gas or 10 inches water col umn for liquid propane for all load ranges 1 8 FUEL CONSUMPTION Nat Gas LP Vapor 1 2Load FullLoad 1 2Load Full Load 1 33 45 8 1 98 72 5 Natural gas is in cubic feet per hour LP is in gallons per hour cubic feet per hour Section 1 General Information GENERAL Air cooled 8 5 kW Generator INFORMATION WARNING amp Gaseous fuels such as natural gas and liquid A 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 9 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 with the generator A fuel pres sure of 11 to 14 inches of water column 0 4 to 0 5 psi to the fuel inlet of the generator MUST BE SUPPLIED 1 Turn off the gas supply if connected 2 Open the roof and remove the door 3 Remove the battery if installed 4 Remove the engine air in baffle located on the left hand side of the battery compartment Two M6 screws are located on top of the baffle and two MO screws are located on the inside of the
56. baffle towards the back 5 Remove the small hose clamp and hose from the fuel regulator It may be necessary to pry the hose off of the brass fitting using a screwdriver to gen tly lift up the hose edge 6 Remove the small brass hose fitting from the reg ulator casting 7 Place the small fuel jet thread side first into the threaded hole originally occupied by the brass hose fitting Figure 1 4 8 Using a short No 2 Phillips screw driver thread the small fuel jet into the regulator casting Do not over tighten Figure 1 4 Demand Regulator OUTLET PORTS FUEL HOSE BRASS HOSE pee FITTING BRASS HOSE PORT bi PRESSURE FITTING 1 8 ADJUSTER SCREWS at A SMALL FUEL JET REGULATOR HOUSING PORT Generac Power Svstems Inc 7 GENERAL Air cooled 8 5 kW Generator INFORMATION 9 Apply thread sealant to the threads of the hose fit ting and replace it into the regulator body 10 Re attach the small hose and hose clamp and tighten as necessary 11 Replace the engine air in baffle using the four M6 Screws 12 Identify both brass adjustment screws on the reg ulator 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 enclosure by removing the plastic hole plug The screw can be
57. 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 Generac Power Systems Inc 15 MAINTENANCE Section 4 Maintenance Air cooled 8 5 kW Generator 5 7 SYSTEMS 3 7 1 LOW OIL PRESSURE SWITCH This switch Figure 3 3 has normally closed contacts that are held open by engine oil pressure during cranking and operating Should oil 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 The 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 5 1 5 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 i
58. ement at 17 8 C O F Group 26 26R 12 Volts and 525 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 content 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 990 760 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 Svstems Inc 1 66 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 voltage
59. ey 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 1 800 555 1522 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe 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 purchase
60. frequency is read on the meter Figures 2 1 and 2 2 Figure 2 1 Dual Fuel Regulators Adjustment Screw Both Sides Set Pin Both Sides 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 Placement of Regulator MAMMA RAI DOO NN ROGO 9 AM NARRA ij om a LL RY ji A XXX AWANA DAR ARN 7 Turn UTILITY power to the main distribution panel back on This can be done by switching the service main breaker to the on or closed position Allow the generator to shut down 12 Generac Power Systems Inc Section 2 Post Installation Start up and Adjustments INSTALLATION ETAR UP Air cooled 8 5 kW Generator ADJUSTMENTS 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 locate the nearest Generac Dealer and they can per form the adjustments NOTE A service fee may be charged for this adjustment 2 7 ENGINE GOVERNOR ADJUSTMENT If both AC frequency and voltage are correspondingly high or low adjust the engine governor as follows 1 Loosen governor clamp bolt
61. g 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 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 5 5 MANUAL TRANSFER OPERATION 5 5 1 TRANSFER TO GENERATOR POWER SOURCE To start the generator and activate the transfer switch manually proceed as follows 1 Set the generators AUTO OFF MANUAL switch to OFF 2 Set the generator s 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 DYE 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 o 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 mi
62. ing 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 2 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 the generator ensures a minimum number of problems and keep operating expenses at a minimum See a Generac Authorized Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the 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 service needs When contacting a Generac Authorized Dealer about parts and service always supply the c
63. is made to provide back up power to a bedroom branch circuit then the cir cuit breaker in the Guardian Transfer Switch should be replaced with an Arc Fault Circuit Interrupter It is most important that breakers only be switched like for like For instance if replacing a 15A breaker it MUST be replaced with a 15A AFCI breaker Likewise a 20A breaker MUST be replaced with a 20A AFCI These AFCI breakers are available at the nearest hardware store Siemens Item Q115AF Q120AF Description 15A Single Pole AFCI 20A Single Pole AFCI Section 1 General Information GENERAL Air cooled 8 5 kW Generator INFORMATION 1 4 THE GENERATOR Figure 1 1 8 5 kW V Twin GT 990 760 Engine Data Control Decal Panel Oil Dipstick Air Filter Exhaust Enclosure Fuel Regulator L il al Fuel Inlet a 1 gt Ji W das ad UT o Oil Filter Battery Compartment Generac Power Systems Inc 5 GENERAL INFORMATION Air cooled 8 5 kW Generator 1 5 SPECIFICATIONS 1 5 1 GENERATOR Section 1 General Information 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 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 Requir
64. lect 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 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 gr
65. meter 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 E1 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 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 not to proceed until certain that generator AC voltage and frequency are correct and within the stated limits Generally if both AC frequency and voltage are high or low the engine governor requires adjustment If frequency is cor rect but voltage is high or low the generator s voltage regulator requires adjustment Section 2 Post Installation Start up and Adjustments 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 generators AUTO OFF MANUAL switch to OFF 4 Turn OFF the UTILITY power supply to the trans fer switch using the means provided such as a utility main line circuit breaker A
66. ng 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 battery 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 FROM FRAME _ _ FROM STARTER CONTACTOR 0 a es LLI zz BATTERY BLACK NOTE The generator is equipped with a battery trickle charger that is active when the 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 the battery by maintaining the battery when the unit is not running The trickle charge feature cannot be used to recharge a discharged battery 1 12 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
67. nutes 7 Set the generator s main circuit breaker to its ON or closed position The standby power source now powers the loads 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 5 2 TRANSFER BACK TO UTILITY POWER SOURCE When utility power has been restored transfer back to that source and shut down the generator This can be accomplished as follows 1 Set the generator s main circuit breaker to its OFF or open position 2 Letthe engine run for a minute or two at no load to stabilize the internal temperatures 3 Set the generator s 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 Section 3 Operation OPERATION Air cooled 8 5 kW Generator J gt INTI 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 UTILITY power source Figure 3 2 6 Turn ON the UTILITY power supply to the trans fer swi
68. o cool 10 Drain the oil and remove the oil filter Replace the oil filter according to Section 4 4 Changing the Oil Filter Replace the oil with synthetic oil as recommended in Section 4 3 Changing the Engine Oil 11 The generator is now ready for service 3 2 USING THE AUTO OFF MANUAL SWITCH FIGURE 3 1 5 2 1 AUTO POSITION se el Selecting this switch position activates fully automat ic system operation It also permits starting and exer cising the engine every seven days with the setting of the exercise timer see Section 3 6 This position also is used for remote starting when it is set up Figure 3 1 Generator Control Panel FUSE Locate your neares t GENERAC dealer at www generac com GENER AC power systems Inc 5A AUTO OFF MAN SYSTEM SET LOW OIL FUSE HIGH TEMP OVER SPEED OVER CRANK 15A SET FLASHING GREEN LED NO UTILITY SENSE EXERCISE 5 EDS OO 4 FLA SN RED L DS TIME ERCISER NOT SET Generac Power Systems Inc 13 OPERATION Section 3 Operation IX Air cooled 8 5 kW Generator 3 2 2 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation 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 WARNING
69. ocedure work method or operating tech nique Generac does not specifically recommend sat isfy yourself that it is safe for others Also make sure the procedure work method or operating technique choosen does not render the generator unsafe DX A 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 Parts of the generator are rotating and or hot during operation Exercise care near running generators e Generac Power Systems Inc operation be copied and posted near the unit s installation site Safety should be stressed to A all operators and potential operators of this equipment A GENERAL HAZARDS For safety reasons Generac recommends that the installation initial start up and maintenance 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
70. 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 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
71. omplete model number and serial number of the unit as given on its data decal which is located on the generator See Figure 1 2 or Figure 1 3 in Section 1 4 for decal loca tion Model No Serial No AUTHORIZED DEALER LOCATION To locate the nearest GENERAC AUTHORIZED DEALER 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 E IFC Operation and Maintenance IFC How to Obtain Service IFC Authorized Dealer Locator Number IFC Safety Rules 2 Standards Section 1 General Information 4 Unpackino Inspection uuu ua 4 1 2 Proleelion riii ih 4 1 3 Requirement for Arc Fault Circuit Interruption Breaker for Bedrooms 4 1 3 1 Section 210 12 Arc Fault Circuit Interrupter Protection 4 1 4 The Generator 5 1 2 bio 6 lol AQCWELALOL kies 6 IN MOS c 6 LO oy Stemi Sel LED ERE 1 7 Fuel Requirements and Recommendations 7 1 8 Fuel Consumption T 1 9
72. penses 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 Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc Overnight freight costs for replacement part s Overtime labor e Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Revision 10 01 04 Part No OFOO91 Revision B 11 15 04 Printed in U S A
73. r owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 48 Generac Power Systems Inc Section 10 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 shall 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
74. ransfer Operation 14 3 5 1 Transfer to Generator Power S0uUrCE deut 14 3 5 2 Transfer Back to Utility POWELL 15 3 6 Setting the Exercise Timer 15 3 7 Protection Systems 16 3 7 1 Low Oil Pressure Switch 16 3 7 2 High Temperature Switch 16 Deb OVEVCE AN TP 16 VNPT MEOS cS MM 16 Section 4 Maintenance 16 PUSO ON 16 4 2 Checking the Engine Oil Level 16 4 3 Changing the Engine 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 5 1 8 5kW Generators 17 430 18 4 7 Battery Maintenance 18 4 8 Adjusting Valve Clearance 19 kud 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 to Service 20 4 12 Corrosion Protection 20 TIS Service Schedule 21 Section 5 Troubleshooting 22 5 1 Trouble
75. rass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system A The maximum ambient temperature for the generator is 48 9 C 104 F Generac Power Systems Inc 19 MAINTENANCE S O Section 4 Maintenance Air cooled 8 5 kW Generator 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 a Generac Authorized Dealer thoroughly clean and dry the generator 4 11 OUT OF SERVICE PROCEDURE 4 11 1 REMOVAL FROM SERVICE If the generator cannot be exercised 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 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 o 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 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
76. reset 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 14 Generac Power Systems Inc 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 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 per 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 voltage When that voltage is restored above 80 percent of the nominal source voltage a retrans fer time delay starts timin
77. s the battery cables are connected Be sure the utility power supply is turned off or sparking may occur at the battery posts as the cables are attached and cause an explosion 4 8 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation adjust the valve clearance in the engine Important If feeling uncomfortable about doing this procedure or the proper tools are not available please contact the Generac Authorized Dealer for service assistance This is a very important step to insure the longest life for the 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
78. s are as follows INTI A After this heading 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 read instructions that if not strictly complied with may result in personal injury or property damage caution amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading 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 A This symbol points out important safety informa tion that if not followed could endanger personal safety and or property of 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 thoroughly understand all instructions before us
79. sfer 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 perform as designed If experiencing 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 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 Generac Power Systems Inc 11 POST 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 o 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
80. shooting Guide 22 Section 6 Mounting Dimensions 23 Section 7 Electrical Data 24 Section 8 Exploded Views and Parts Lists 32 Section 9 Notes 46 Section 10 Warranty 48 Generac Power Systems Inc SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Air cooled 8 5 kW Generator SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe 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 otudy these SAFETY RULES carefully before instaling operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precau tions 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 using a pr
81. t Generac Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Centurion 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 main tenance is required Engine All Components Alternator All Components Transfer System All Components Steel enclosures are warranted against rusting for the first year of ownership only Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty Nicks srapes dents or scratches to the painted enclosure should be repaired promptly by the owner All warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies Procedures and Flat Rate Manual THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Centurion generators that utilize non Generac replacement parts Generac Centurion generators utilizing non Generac transfer switches Repairs performed by individuals other than Centurion Generac authorized dealers Any Generac Centurion generators used as rental or trailer mounted applications Air cooled units used for prime power in place of existing utility power where utility power
82. t 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 16 Generac Power Systems Inc 3 7 3 1 Approximate Crank Cycle Times 15 seconds ON 7 seconds OFF 7 seconds ON 7 seconds OFF Repeat 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 the nearest Generac Authorized Dealer if this failure occurs 4 1 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 the engine will not crank or start 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 battery charging capabilities will not be possible Replace the fuse using only an iden tical 5 amp replacement To remove fuse push cap do
83. tch using the means provided 7 Set the system to automatic operation as outlined in Automatic Transfer Operation Section 3 3 3 6 SETTING THE EXERCISE TIMER The 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 the following sequence is completed During this exercise period the unit runs for approx imately 12 minutes and then shuts down Transfer of loads to the generator output does not occur during the exercise cycle A switch on the control panel see Figure 3 1 permits selection of the day and time for system exercise To select the desired day and time of day the following sequence must be performed 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 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
84. tely 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 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 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 l NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES available from the National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 NFPA No 76A 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 10
85. tim 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 ponents 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 there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immedia
86. wn and rotate counterclockwise Figure 4 1 Generator Control Panel FUSE Locate your neares t GENERAC dealer at www generac com GENERACG i POWER SYSTEMS INC AUTO OFF MAN SYSTEM SET LOW OIL FUSE HIGH TEMP OVER SPEED OVER CRANK 15A SET FLASHING GREEN LED EXERCISE 4 FLA SUNG RED LEDS TIME EXERCISER NOT SET 4 2 CHECKING THE ENGINE OIL LEVEL For oil capacities see Specifications Section 1 5 For engine oil recommendations see Section 4 3 1 To check the engine oil level proceed as follows Figure 4 2 l 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 FULL 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 origi nal position Figure 4 2 Oil Dipstick and Fill 8 5 kW Cil Dipstick Cil Fill 4 5 CHANGING THE ENGINE OIL 4 51 ENGINE OIL

GE Monogram PSB9240DF Oven User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents