Generac 004692-2 manual

GENERA C POWER SYSTEMS, INC. R R Installation and Owner’ s Man ual Air -cooled, Prepac kaged A utomatic Standb y Generator s Models: 004692-2 (8.5 kW) DEADL Y EXHAUST FUMES. OUTDOOR INST ALLA TION ONL Y!! D ANGER CENTURION CENTURION C E N T U R I O N ® Not intended f or use as Primary P ower in place of utility or in life-support applications. ![...]

Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the Centurion product line by Generac P ower 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 f[...]

T able of Cont ents Air-cooled 8.5 kW Generator Generac ® Pow er Systems, Inc. 1 Introduction ........................Inside Front Cover Read This Manual Thoroughly ........................IFC Contents ..........................................................IFC Operation and Maintenance ............................IFC How to Obtain Service .....[...]

2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to fo[...]

Generac ® Pow er Systems, Inc. 3 ELE CTR ICAL HA Z AR DS • All generators covered by this manual produce dangerous electrical voltages and can cause fatal electrical shock. Utility power delivers extremely high and dangerous voltages to the transfer switch as does the standby generator when it is in opera- tion. A void contact with bare wires, t[...]

Section 1 — General Information Air-cooled 8.5 kW Generator Only qualified electricians or contractors should attempt such installations, which must comply strictly with applicable codes, standards and regulations. 1.1 U N P ACKING/I NSP ECTION After unpacking, carefully inspect the contents for damage. • This standby generator set has been fac[...]

Generac ® Pow er Systems, Inc. 5 Section 1 — General Information Air-cooled 8.5 kW Generator 1.4 TH E GEN ER A T OR Control Pa n e l Air Filter Exhaust Enclosure Battery Compar tment Fuel Inlet Oil Filter Oil Dipstick Data Decal Fuel Regulator Figure 1.1 – 8.5 kW , V -T win GT -990/760 Engine[...]

6 Generac ® Pow er Systems, Inc. Section 1 — General Information Air-cooled 8.5 kW Generator 1.5 SP E CI F ICA TIONS 1.5.1 GEN ERA T OR Model 004692 Rated Max. Continuous P ower Capacity (W atts*) 8,500 NG/8,500 LP Rated V oltage 120/240 Rated Max. Continuous Load Current (Amps) 120 V olts 70.8 NG/70.8 LP 240 V olts 35.4 NG/35.4 LP Main Line Cir[...]

Generac ® Pow er Systems, Inc. 7 1.6 S Y STEM SE T LED The “System Set ” LED is lit when all of the following conditions are true: 1. The A UTO/OFF/MANUAL switch is set to the A UTO position. 2. The UTILITY voltage being supplied to the unit is being sensed by the PCB. If the UTILITY sense voltage is not connected to the unit or if it is below[...]

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 th[...]

Generac ® Pow er Systems, Inc. 9 Figure 1.5 – Battery Cable Connections NOTE: The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation. W ith the battery installed and utility power source voltage available to the transfer switch, the battery receives a trickle charge while the engin[...]

10 Generac ® Pow er Systems, Inc. 2.1 B EFOR E I N ITIAL S T ART -U P Before starting, complete the following: 1. Set the generator's A UTO/OFF/MANUAL switch to the OFF position. 2. T urn OFF the utility power supply to the transfer switch using the means provided (such as the utility main line circuit breaker). 3. T urn OFF all loads connect[...]

Generac ® Pow er Systems, Inc. 11 2.4 GEN ER A T OR TES TS UN DER L O AD T o 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. T urn OFF all loads connected to the transfer switch terminals T1 and T2. 3. Set the generator's A UTO/OFF/MANU AL sw[...]

12 Generac ® Pow er Systems, Inc. 3. T urn 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: 4. When full load has been achieved. Connect a fre- quency meter to the output lugs of the generator’s main l[...]

Generac ® Pow er Systems, Inc. 13 Section 3 — Operation Air-cooled 8.5 kW Generator Figure 2.4 — Full Load Speed Adjust Screw 2.7 .1 ADDITIONAL C ORROSION P RO TECTION P eriodically spray all engine linkage parts and brack- ets with corrosion inhibiting spray such as WD -40 or a comparable product. 2.8 V OL T A GE R E GU L A T OR ADJ US TM ENT[...]

14 Generac ® Pow er Systems, Inc. Section 3 — Operation Air-cooled 8.5 kW Generator 3.2.2 “OF F” POSITION This switch position shuts down the engine. This position also prevents automatic operation. 3.2.3 “MAN U AL ” POSITION Set the switch to Manual to crank and start the engine. Transfer to standby power will not occur unless there is [...]

Generac ® Pow er Systems, Inc. 15 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 extr emely hazardous and possibly fatal electrical shock. 4. Use the manual transfer handle inside the trans- fer swit[...]

16 Generac ® Pow er Systems, Inc. 3.7 P RO TECTION S YS TEMS 3.7 .1 L OW OIL P RESSUR E SWIT CH 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 rest[...]

Generac ® Pow er Systems, Inc. 17 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 “F ull” mark. If nec- essary , add oil to the “F ull” mark only . DO NOT FILL ABOVE THE “FULL ” MARK. Never operate the engine with the oil level below the [...]

18 Generac ® Pow er Systems, Inc. 5. Install the cover . T urn 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 . Figure 4.4 — V -twin Engine Air Cleaner 4.6 SP AR K P L UG(S) Reset the spark plug(s) gap or replace the s[...]

Generac ® Pow er Systems, Inc. 19 • DO NOT SMOKE when near the battery; • DO NOT cause flame or spark in battery area; and • Discharge static electricity from body befor e touch- ing the battery by first touching a grounded metal surface. Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If t[...]

20 Generac ® Pow er Systems, Inc. 4.1 0 A TTENTION AF TER S U B M ERSION If the generator has been submerged in water , it must not be started and operated. F ollowing any submersion in water , have a Generac Authorized Dealer thoroughly clean and dry the generator . 4.1 1 OUT OF SERVICE P ROCEDU R E 4.1 1.1 REMOV AL F ROM SERVICE If the generator[...]

Generac ® Pow er Systems, Inc. 21 Section 4 — Maintenance Air-cooled 8.5 kW Generator 4.1 3 SERVICE S CH EDU LE A TTENTION: 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 = W eekly R = Replace as Necessary M = Monthly * = Notif[...]

22 Generac ® Pow er Systems, Inc. Section 5 — T roubleshooting Air-cooled 8.5 kW Generator 5.1 TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION The engine will not crank. 1. F use blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary . 3. Defective starter contactor 3. * 4. Def[...]

Generac ® Pow er Systems, Inc. 23 Section 6 — Mounting Dimensions Air-cooled 8.5 kW Generator Drawing No. 0D3 7 3 9-B T M6PEM-T M6P M6PEM PE REAR VIEW L EFT S IDE VIEW TRANSFER SWITCH R I G HT S IDE VIEW F R O NT VIEW AIR NTAKE ( IF SUPPLIED ) " D O N O T LIFT BY THE R OO F" L IFTIN G H O LE S 4- CO RNER S Ø 3 0.2mm [ Ø 1 .19" ][...]

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA ( DUAL SEC. ) 0 CUS T O MER SU PPLIE D BLA CK BATTERY 12V L OP HT O 0 S P 2 S P 1 IM2 86 85 IM1 D D DIA G RAM KE Y D S W - P C B M OU NTED DIP S WIT CH CB2 - CIRCUIT BREAKER , ALTERNATOR EXCITATIO N C B1 - MAIN OU TP U T BREAKE R B C R - BATTERY C HAR G E RELA Y HT O - HI G H O IL TEMPERAT U RE S WIT[...]

Generac ® Pow er Systems, Inc. 25 C L OS E S T T O BEARIN G G R D 0 4 S TAT OR 1 94 224 224 22 5 1 5 224 17 4 22 5 224B 22 5 0 0 OU TP U T T O TRAN S FE R 22 22 MAN U A L F2 0 1 5A 66A 2 39 1 3 1 5 1 3 1 3 0 F1 1 5 17 17 V O LTA GE RE GU LAT OR 1 5A 2 3 1 3 351 1 3 1 3 1 3A 13 13 0 0 N2 N1 351 0 66A 4 1 62 0 4 6 0 4 1 62 6 2 39 A U T O S W 1 1 1 b[...]

26 Generac ® Pow er Systems, Inc. Section 7 — Electrical Data Air-cooled 8.5 kW Generator Electrical Schematic - Drawing No. 0D850 1-B IM1 - IGNITION MODULE , CYLINDER # 1 IM2 - IGNITION MODULE , CYLINDER # 2 L O P - L O W O IL PRE SSU RE S WIT CH SP1 , SP2 - SPARK PLUG S S W1 - A U T O / O FF / MAN U AL S WIT CH S W2 - S ET EXER C I S E S WIT C[...]

2 39 IM2 1 5 1 8 S P 2 24 0V IM1 0 1 94 17 1 5 2 3 1 5 2 39 S W 1 1 94 1 5A 22 11 2 3 11 22 11 S P 1 44 WINDIN G 12 0V 12 0V 33 NEUTRAL N2 N1 2 3 CUS T O ME R CO NNE C TI O N S 1 94 0 0 SC F S 1 6 14 BATTERY CUS T O ME R SU PPLIE D SM 12V SC N2 N1 1 3 TX 56 V A 1VA C 2- 6 C 2- 5 C B 1 ( STATOR ) 14 RED BLA CK C 2- 1 C 1- 1 C 1- 5 0 0 D D SCR 1 6 1 [...]

NE U TRA L CO NNE C TI ON IN S IDE S WIT CH N O C1 N C N C C2 VR2 N O TR 1 94 2 3 1 7 4 7 9 3 6 9 F2 CO NNE C TI ON 1 5 A / 12 0 V C IR CU IT 9 2 0 A / 12 0 V C IR CU IT 1 0 BLACK ( MAIN 1 ) 2 0 A / 12 0 V C IR CU IT 6 1 5 A / 12 0 V C IR CU IT 1 2 30 A / 24 0 V C IR CU IT 1 2 0 A / 24 0 V C IR CU IT 2 1 5 A / 12 0 V C IR CU IT 5 1 5 A / 12 0 V C I[...]

Generac ® Pow er Systems, Inc. 29 F1 B N2A B N2A B E2 E2 C2 T1 T2 T2 T1 N2A N O XB N O B 2 05 B XA N C 12 6 N C 7 7 N1A E1 12 6 1 N1A E1 9 9 2 05 N1A 4 3 6 2 3 TR 1 94 N1A E1 N2A E2 E2 E1 E 2 N2A N1A E1 2 3 1 94 N1A F2 CO NNE C TI ON 30 A / 24 0 V C IR CU IT 3 1 5 A / 12 0 V C IR CU IT 4 1 5 A / 12 0 V C IR CU IT 8 1 5 A / 12 0 V C IR CU IT 7 1 5 [...]

30 Generac ® Pow er Systems, Inc. Section 7 — Electrical Data Air-cooled 8.5 kW Generator Wiring Diagram - 1 2 Circuit Load Center - Drawing No. 0E7 68 7[...]

Generac ® Pow er Systems, Inc. 31 Section 7 — Electrical Data Air-cooled 8.5 kW Generator Wiring Diagram - 1 2 Circuit Load Center - Drawing No. 0E7 68 7[...]

32 Generac ® Pow er Systems, Inc. 68 1 35 53 52 2 0 2 4 9 43 49 4 43 37 2 5 33 36 32 35 83 2 6 44 7 9 77 74 35 4 9 82 80 8 51 46 80 85 81 72 1 8 86 5 7 6 4 8 39 60 62 63 50 21 1 5 5 1 71 69 42 1 0 35 11 4 9 51 9 4 9 50 72 44 7 3 52 41 5 57 27 62 56 1 1 9 A 4 0 1 2 71 59 64 50 38 34 22 89 68 1 6 69 1 4 1 3 54 47 55 7 5 4 9 30 17 3 59 25 2 9 2 8 Sec[...]

Generac ® Pow er Systems, Inc. 33 ITEM P ART NO . QTY . DESCRIPTION 1 0D8312 1 ASS E M B LY, E N CLO S U R E B AS E 2 0C6735 2 S UPPO R T, R OOF FOLDI N G 3 0F0063 1 E N CLO S U R E, F R O N T 4 0C7062 1 E N CLO S U R E, EXH A U S T S IDE 5 0F0066 1 E N CLO S U R E, S IDE & B A CK 6 0E9873 1 E N CLO S U R E, R OOF 7 0D8333 1 P AN EL, A LT E RN[...]

34 Generac ® Pow er Systems, Inc. 29 36 3 4 11 2 5 24 38 21 7 13 33 12 38 17 3 2 3 1 28 3 1 20 19 10 17 15 3 2 16 2 22 39 9 8 6 3 7 14 3 40 1 3 2 25 10 30 19 28 27 28 3 2 3 1 41 10 18 35 36 29 42 36 36 5 Section 8 — Exploded Views and P arts Lists Air-cooled 8.5 kW Generator Engine & Alternator – Drawing No. 0D8446-C[...]

Generac ® Pow er Systems, Inc. 35 Section 8 — Exploded Views and P arts Lists Air-cooled 8.5 kW Generator Engine & Alternator – Drawing No. 0D8446-C ITEM P AR T NO . QTY . DESCRIPTION 1 0C6934 1 A D A PT O R , E N GI N E 2 0D8062H 1 S T A TO R 3 0D8057H 1 R OTO R 4 0C6043 A 1C ARR IE R , R E AR BE AR I N G 5 0D8274 1 F AN , 12" CU R V[...]

36 Generac ® Pow er Systems, Inc. 1 4 3 53 46 48 47 49 50 5 1 5 2 40 38 42 45 4 4 43 29 143 3 7 26 3 24 1 4 0 3 2 35 55 33 36 20 5 7 58 59 61 6 0 6 4 6 2 63 65 1 2 6 3, 32 , 33 , 34 , 35 , 36 , 40 , 72 2 7 , 28 , 2 9 2, 5 , 19 , 20 , 39 , 40 , 47 , 64 , 93 , 140 16B 56 54 23 25 30 16 A 3 4 3 4 15 16 A 17 18 22 71 73 72 66 8 1 4 13 12 1 0 7 9 4 5 S[...]

Generac ® Pow er Systems, Inc. 37 ITEM P ART NO . QTY . DESCRIPTION 1 0C5729 1 ASS E M BL Y , C RAN KC AS E HOU S I N G W ITH S LEEVE 2 0E9843 1 S E A L, 38 I.D . C RAN K S H A FT 3 090388 3 S C R E W , T A PTITE M 6-1.0 X 12 YC 4 0C5372 1 ASS E M B LY, B R E A THE R 5 0C3005 1 G AS KET , B R E A THE R CO VE R 6 0E3372B 3 S EP ARA TO R , OIL B R E[...]

38 Generac ® Pow er Systems, Inc. 1 112 8 11 0 1 33 91 84 88 86 89 85 90 89 74 80 83 81 7 9 11 102 99 92 1 01 11 3 112 105 1 07 1 08 103 111 1 09 12 5 123 , 14 5 96 95 14 3 1 30 114 7 5 7 8 77 7 6 99 11 8 8 97 121 124 124 11 9 122 12 5 1 37 12 0 127 12 6 11 5 11 6 1 36 1 38 32 142 2 9 1 34 1 39 1 35 Section 8 — Exploded Views and P arts Lists Ai[...]

Generac ® Pow er Systems, Inc. 39 ITEM P ART NO . QTY . DESCRIPTION 74 0C5136 A 2K N OB, A I R CLE AN E R 75 0C3024 1 CO VE R , A I R BO X N G/LP 76 0C3040 1 P R E-CLE AN E R , 77 0C8127 1 ELE M E N T, A I R CLE AN E R 78 0D8564 A 1 ASS E M B LY, M IXE R / A I R BO X 990 0D8564B 1 ASS E M B LY, M IXE R / A I R BO X 760 79 0D2595 4 S C R E W S HOUL[...]

40 Generac ® Pow er Systems, Inc. 31 19 3 7 38 22 8, 9 27 45 46 44 48 47 10 3 49 35 13 1 7 5 21 35 23 49 29 21 17 4 2 38 6 7 33 2 20 27 15 40 41 39 45 44 43 1 30 15 11 47 45 24 45 47 49 Section 8 — Exploded Views and P arts Lists Air-cooled 8.5 kW Generator Control Panel Assembly – Drawing No. 0E7 97 4-F[...]

Generac ® Pow er Systems, Inc. 41 ITEM P ART NO . QTY . DESCRIPTION 1 0E7886 A 1C I R CUIT B R E A KE R 30 A X 2P 240V (7K W ) 0E7886C 1 CI R CUIT B R E A KE R 40 A X 2P 240V (8.5K W ) 0E7886D 1 CI R CUIT B R E A KE R 45 A X 2P 240V (11K W ) 0E7886E 1 CI R CUIT B R E A KE R 50 A X 2P 240V (12K W ) 0E7886F 1 CI R CUIT B R E A KE R 60 A X 2P 240V (1[...]

17 2 0 1 8 4 0 14 24 1 0 1 9 1 37 2 6 21 8 34 38 32 34 38 33 2 3 9 1 3 1 5 36 27 30 12 22 3B 22 16 3A 31 7 9 1 6 3 6 1 1 5 2 39 42 Generac ® Pow er Systems, Inc. Section 8 — Exploded Views and P arts Lists Air-cooled 8.5 kW Generator GT S Load Center – Drawing No. 0E7 97 3-B[...]

Generac ® Pow er Systems, Inc. 43 ITEM P AR T NO . QTY . DESCRIPTION 1 0D3086 1 BO X GT S LO A D CE N TE R 2 0D3092 1 CO VE R , 12 PO S ITIO N GT S LO A D CE N TE R 3 0C2237 1 T RANS FE R SW ITCH HO M E S T AN DBY 100 A 2P 250V 3 A 077220 1 COIL UTILITY 3B 077220 A 1 COIL S T AN DBY 3C 082574 1 I NS UL A TO R - S IDE WA LL ( N OT S HO WN ) 3D 0844[...]

44 Generac ® Pow er Systems, Inc. Section 8 — Exploded Views and P arts Lists Air-cooled 8.5 kW Generator Regulator – Drawing No. 0D8 7 2 0-D 17 12 2 8 11 2 0 1 0 32 2 5 24 1 9 2 3 22 22 1 5 2 6 14 1 3 1 6 2 9 1 8 8 2 8 12 1 0 11 27 31 4 5 3 2 1 0 17 1 2 6 1 5 14 6 7 1 6 1 3 37 1 9 9 30 21 2 5 2 0 24 2 9 1 8 2 3 11 12 2 8[...]

Generac ® Pow er Systems, Inc. 45 ITEM P AR T NO . QTY . DESCRIPTION 1 0D5694 1 C AS TI N G, T W I N R EGUL A TO R HOU S I N G 2 0F3154 1 S OLE N OID COIL, 12VDC 3 0C4647 1 G AS KET , S OLE N OID 4 0D4166 1 PLU N GE R , LP R EGUL A TO R ASS E M BL Y 5 0C6070 1 S P R I N G- S OLE N OID , PLU N GE R 6 043180 4 WA S HE R , FL A T M 4 7 022264 4 WA S [...]

46 Generac ® Pow er Systems, Inc. Section 9 — Notes Air-cooled 8.5 kW Generator[...]

Generac ® Pow er Systems, Inc. 47 Section 9 — Notes Air-cooled 8.5 kW Generator[...]

48 Generac ® Pow er Systems, Inc. CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y S T A TEM ENT Y OUR W AR R ANTY R IGHTS AND OB LIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine. * In California, new utility , and lawn and g[...]

Generac ® Pow er Systems, Inc. 49 EM IS SION CONTROL S Y S TEM W ARR ANT Y Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS W arranty Period shall begin on the date the new engine or equipment is purchased by/delivered[...]

Part No. 0F0091 Revision B (11/15/04) Printed in U.S.A. Section 1 0 – W arranty Air-cooled 8.5 kW Generator GENER AC PO WER SY S TEMS "T W O YEAR" LI MITED WARRANT Y FOR CENTU R ION "PR EP ACKAGED EMERGENCY AUT OMA TIC ST AN DBY GENERA T ORS" F or a period of two years from the date of original sale, Generac P ower S ystems, I[...]