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Generac 004692-0 manual

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  • Page 1

    PO WER SY STEMS, INC. ® GENERA C POWER SYSTEMS, INC. R R Installation and Owner’ s Man ual Air -cooled, Prepacka g ed A utomatic Standb y Generators Models: 004692-0 (8.5 kW) DEADL Y EXHAUST FUMES. OUTDOOR INST ALLA TION ONL Y!! D ANGER Not intended f or use as Primar y P ower in place of utility or in life- suppor t applications. ! ![...]

  • Page 2

    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[...]

  • Page 3

    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 .....[...]

  • Page 4

    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[...]

  • Page 5

    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[...]

  • Page 6

    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 r egulations. 1.1 U N P ACKING/I NSP ECTION After unpacking, carefully inspect the contents for damage. • This standby generator set has been fa[...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 Section 1 — General Information Air-cooled 8.5 kW Generator 1.4 Y OU R GEN ER A T OR Control P anel Air Filter Exhaust Enclosure 12 V olt Battery Fuel Regulator Oil Filter Oil Dipstick Data Decal Figure 1.1 – 8.5 kW , V -T win GT -990 Engine[...]

  • Page 8

    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[...]

  • Page 9

    Generac ® Pow er Systems, Inc. 7 1 .6 FUE L RE Q UIREME NT S AN D R E COMM EN D A TIONS 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[...]

  • Page 10

    1.9 L OCA TION 1.9.1 GEN ERA T OR 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-[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 amps for 8.5 kW at -17.8º C (0º 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 [...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. 2. T urn OFF all loads connected to the transfer switch terminals T1 and T2. 3. T urn on the utility power supply to the transfer switch using the means provided (such as a utili- ty main line circuit breaker). The transfer switch is now electrically “hot.” Contact with “hot” parts will result in extr eme-[...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 15. Set the Auto/Off/Manual switch to OFF . The engine should shut down. 2.5 CH E CKI NG AUT OMA TIC OP ER A TION T o check the system for proper automatic operation, proceed as follows: 1. Check that the Auto/Off/Manual switch is set to OFF . 2. T urn OFF the utility power supply to the transfer switch, using the[...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. Do not make any unnecessary adjustments. Factory settings are corr ect for most applica- tions. However , when making adjustments, be careful to avoid overspeeding the engine. If this procedure or equipment are not available to you, locate the Generac Dealer nearest you and they can perform the adjustments. NOTE: [...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 Section 3 — Operation Air-cooled 8.5 kW Generator 3.1 B R EAK-I N P ROCEDU R E 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. Set the generator?[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. Section 3 — Operation Air-cooled 8.5 kW Generator 3.4 SE QU ENCE OF AUT OMA TIC OP ER A TION The generator’s control panel houses a control logic circuit board. This board constantly monitors utility power source voltage. Should that voltage drop below a preset level, circuit board action will signal the engin[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 3.5.2 TR ANSFER BA CK T O UTI LIT Y POWER SOURCE When utility power has been restored, you will want to 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. Let the engine run for a minute or [...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. 3.7 .3 OVERCRAN K This feature prevents the generator from damaging itself when it continually attempts to start and anoth- er problem, such as no fuel supply , prevents it from starting . The unit will crank and rest for a preset time limit. Then, it will stop cranking, and the LED on the generator control panel [...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 4.3 CHANGI NG TH E ENGI N E OI L 4.3.1 ENGI N E OIL R EC OM M ENDA TIONS Use oil of American P etroleum Institute (API) Service Class SG, SH or SJ . Use all season SAE 5W -30 Synthetic oil. Organic break -in oil is required before using synthetic oil. NOTE: The unit is supplied with “break-in ” oil. See the ?[...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. Figure 4.4 — 12 kW and 15 kW Engine Air Cleaner 4.6 SP AR K P L UG(S) Reset the spark plug(s) gap or replace the spark plug(s) as necessary . See Section 4.11 (P age 19) for maintenance requirements. 1. Clean the area around the base of the spark plug(s) to keep dirt and debris out of the engine. Clean by scrapi[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 Lead-acid batteries present a risk of fir e because they generate hydrogen gas. The following procedur es are to be followed: • DO NOT SMOKE when near the battery; • DO NOT cause flame or spark in battery area; and • Discharge static electricity from your body befor e touching the battery by first touching a[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. The maximum ambient temperature for your generator is 48.9° C (104° F). 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 O[...]

  • Page 23

    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 your nearest Generac Authorized Dealer . SYSTEM/COMPONENT PROCEDURE FREQUENCY X = Action Inspect Change Clean W = W eekly R = Replace as Necessary M = Monthly * = Noti[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. Section 5 — T roubleshooting Air-cooled 8.5 kW Generator 5.1 TROU B LE SHOO TI NG GUI DE P ROB LEM CAUSE C OR R ECTION 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. Defec[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 Section 6 — Mounting Dimensions Air-cooled 8.5 kW Generator Drawing No. 0D3 7 39-A TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F CBHOM-F TYPE HOM TYPE HOM CBHOM-F CBHOM-F 120/240v 120/240v TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F CBHOM-F TYPE HOM TYPE HOM 120/240v 120/240v CBHOM-F CBHOM-F TYPE HOM TYPE HOM 120/[...]

  • Page 26

    BATTERY CUSTOMER SUPPLIED 12V HTO BLACK 86 LOP 85 IM2 1 - 20 Vac Sense Transformer L.E.D - ALARM INDICATORS 3 - 50 Hz Operation 2 - Remote Not Auto 4 - SPARE 86 RED SM IC PRINTED CIRCUIT BOARD ON - INDICATES 3 2 1 ON DSW 4 CONTROL J2 J1 85 56 12 4 35 18 351 86 14 ENGINE WIRING ICT - INTERCONNECTION TERMINALS TX - TRANSFORMER, 16 Vac 56 VA & 16 [...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 CLOSEST TO BEARING 0 4 STATOR GRD 225 225 14 16 17 15 224 15 17 10 11 12 13 7 8 9 15A 0 66A 3 4 5 61 2 18 14 194 23 4 224 351 13 224A N1 225A CONNECTION MANUAL AUTO 15 15 239 13 15A 13A 17 351 351 SW1 239 0 N1 N2 194 23 UTILITY FROM T/SW UTILITY FROM T/SW TRANSFER RELAY COIL TRANSFER RELAY COIL SWITCH CONTACTOR OU[...]

  • Page 28

    26 Generac ® Pow er Systems, Inc. Section 7 — Electrical Data Air-cooled 8.5 kW Generator Electrical Schematic - Drawing No. 0D850 1 IM1 - IGNITION MODULE, CYLINDER #1 IM2 - IGNITION MODULE, CYLINDER #2 LOP - LOW OIL PRESSURE SWITCH SP1, SP2 - SPARK PLUGS SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TX - TRANSFOR[...]

  • Page 29

    2 15 34 J2 2 1 3 2 1 8 14 16 17 15 11 13 12 10 9 J1 7 5 6 3 4 2 1 15 224 225 0 224A 239 IM2 15A 15 18 SP2 240V IM1 0 15 194 13 17 17 15 23 15 239 SW1 194 15A N1 N2 22 11 23 11 22 11 SP1 44 POWER WINDING 120V 120V 33 NEUTRAL N2 N1 23 CUSTOMER CONNECTIONS 194 0 17 66A 0 SC FS 16 14 BATTERY CUSTOMER SUPPLIED SM 12V SC N2 N1 13 225A 14 225 224 TX 239 5[...]

  • Page 30

    28 Generac ® Pow er Systems, Inc. A A 51 23 36 24 37 49 35 26 47 46 49 2 43 49 43 32 33 50 7 51 4 35 25 51 15 51 48 21 1 67 62 70 59 13 49 42 39 10 3 59 25 35 14 47 54 9 8 27 35 22 51 49 50 51 49 49 11 50 16 17 51 5 47 19 12 6 31 44 47 30 29 28 18 86 41 40 55 57 56 58 52 49 20 52 72 64 65 66 45 71 69 68 71 68 69 38 58 34 73 75 46 74 76 82 78 77 80[...]

  • Page 31

    Generac ® Pow er Systems, Inc. 29 ITEM P AR T NO. QTY . DESCRIPTION 1 0D8312 1 ASSEMBL Y , ENCLOSURE BASE 2 0C6735 2 SUPPOR T , R OOF FOLDING 3 0C7061 1 ENCLOSURE, FRONT 4 0C7062 1 ENCLOSURE, EXHA UST SIDE 5 0C7063 1 ENCLOSURE, SIDE & BA CK 6 0C7064 1 ENCLOSURE, ROOF 7 0D8333 1 P ANEL, AL TERNA TOR DIVIDER 8 0C8101A 1 P ANEL, MUFFLER BO X SIDE[...]

  • Page 32

    30 Generac ® Pow er Systems, Inc. 36 35 36 37 6 34 7 8 21 38 9 3 1 4 5 23 11 24 31 12 25 22 14 20 38 15 30 24 26 32 10 19 16 28 27 17 10 19 32 28 31 32 17 32 31 33 29 28 13 28 39 18 10 40 29 2 42 41 41 Section 8 — Exploded Views and P ar ts Lists Air-cooled 8.5 kW Generator Engine & Alternator – Drawing No. 0D8446[...]

  • Page 33

    Generac ® Pow er Systems, Inc. 31 Section 8 — Exploded Views and P ar ts Lists Air-cooled 8.5 kW Generator Engine & Alternator – Drawing No. 0D8446 ITEM P AR T NO. QTY . DESCRIPTION 1 0C6934 1 AD APTOR, ENGINE 2 0D8062H 1 ST A T OR 3 0D8057H 1 RO TOR 4 0C6043A 1 CARRIER, REAR BEARING 5 0D8274 1 F AN, 12" CUR VED BLADE 6 0D6634A 1 MUFF[...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. 17 15 18 21 22 14 13 12 9 7 8 31 24 3 27 29 28 32 19 23 6 5 65 64 63 62 61 60 59 58 52 51 50 49 48 47 46 45 44 43 57 1 42 41 38 37 36 35 34 33 39 3 3 40 2 3 26 10 4 34 25 11 30 20 66 2, 5, 19, 20, 39, 40, 47, 64, 93, 140 8, 11, 12, 13 67 4, 5, 6 68 16A, 16B, 17, 18 69 7, 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59,[...]

  • Page 35

    Generac ® Pow er Systems, Inc. 33 ITEM P ART NO . QTY . DESCRIPTION 1 0C5729 1 ASSEMBL Y , CRANKCASE HOUSING WITH SLEEVE 2 0C3008 1 SEAL, 38 I.D . CRANKSHAFT 3 090388 8 SCREW , T APTITE M6-1.0 X 12 YC 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER CO VER 6 0C3003 3 SEP ARA T OR, OIL BREA THER 7 0D8067A 1 ASSEMBL Y , HEAD #1 G&S[...]

  • Page 36

    34 Generac ® Pow er Systems, Inc. 112 112 111 108 107 106 105 104 103 102 100 109 99 92 95 96 91 89 90 89 88 86 85 83 84 82 81 130 99 118 114 126 94 93 117 79 78 76 77 75 74 122 125 123 125 119 120 137 136 134 133 132 131 127 129 135 113 101 110 121 112 128 124 124 80 87 98 97 98 97 138 139 115 116 Section 8 — Exploded Views and P ar ts Lists Ai[...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 ITEM P ART NO . QTY . DESCRIPTION 74 0C5136A 2 KNOB, AIR CLEANER 75 0C3024 1 CO VER, AIRBO X NG/LP 76 0C3040 1 PRE-CLEANER, 77 0C8127 1 ELEMENT , AIR CLEANER 78 0D8564A 1 ASSEMBL Y , MIXER/AIRBO X 990 0D8564B 1 ASSEMBL Y , MIXER/AIRBO X 760 79 0D2595 4 SCREW SHOULDER (8MM) M6-1.0 X 18 80 0D4417 4 W ASHER,RUBBER 1/[...]

  • Page 38

    36 Generac ® Pow er Systems, Inc. 21 46 22 37 38 8,32 8,9 27 44 47 10 13 19 14 15 35 25 17 49 14 15 5 34 16 23 36 39 38 45 48 2 28 29 21 17 16 4 6 7 49 23 27 42 12 45 44 20 40 11 1 43 15 35 14 30 29 28 3 28 29 41 24 45 47 31 47 45 31 33 Section 8 — Exploded Views and P ar ts Lists Air-cooled 8.5 kW Generator Control Panel Assembly – Drawing No[...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 ITEM P ART NO . QTY . DESCRIPTION 1 0A9947E 1 CIRCUIT BREAKER 30 X 2 240V SQD QOU230 (7KW) 0A9947G 1 CIRCUIT BREAKER 40 X 2 240V SQD QOU240 (8.5KW) 0A9947F 1 CIRCUIT BREAKER 50 X 2 240V SQD QOU250 (12KW) 0A9947C 1 CIRCUIT BREAKER 60 X 2 240V SQD QOU260 (13KW) 2 0A18010SR V 1 ASSEMBL Y , BA TTER Y CHARGER ENGINE 3 [...]

  • Page 40

    ITEM P AR T NO. QTY . DESCRIPTION 1 0D3086 1 BO X GTS LOAD CENTER 2 0D3092 1 CO VER, 12 POSITION GTS LOAD CENTER 3 0C2237 1 TRANSFER SWITCH HOME ST ANDBY 100A2P250V 4 074908 6 SCREW T APTITE M5-0.8 X 10 BP 5 024912 1 SCREW T APTITE 1/4-20 X 5/8 BP 6 0A1658 1 LOCK W ASHER, SPECIAL-1/4" 7 063617 1 RELA Y P ANEL 12VDC DPDT 10A@240V A C 8 0D3030 1[...]

  • Page 41

    Generac ® Pow er Systems, Inc. 39 ITEM P AR T NO. QTY . DESCRIPTION 1 0D5694 1 CASTING, TWIN REGULA T OR HOUSING 2 0C5765 1 SOLENOID , TWIN REGULA TOR 3 0C4647 1 GASKET , SOLENOID 4 0C4680 1 PLUNGER, LP REGULA T OR ASSEMBL Y 5 0C6070 1 SPRING-SOLENOID , PLUNGER 6 022985 4 WASHER, FLA T #6 7 022264 4 WASHER, LOCK M4 8 075475 4 SCREW PPHM M4-0.7 X 1[...]

  • Page 42

    40 Generac ® Pow er Systems, Inc. CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y ST A TEM ENT Y OUR W AR R ANT Y R IGHT S AN D 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[...]

  • Page 43

    Generac ® Pow er Systems, Inc. 41 EM IS SION CONTROL S YS TEM W AR R 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 P eriod shall begin on the date the new engine or equipment is purchased by/delivere[...]

  • Page 44

    GEN ERAC PO WER SY STEMS "TWO YEAR" S T AN D AR D W AR R ANT Y FOR ® "P REP ACKAGED EMERGENCY AUT OMA TIC ST AN DB Y GEN ER A T ORS" F or a period of two years or 2000 hours of operation from the date of original sale, whichever occurs first, Generac P ower Systems, Inc. (Generac) will, at its option, repair or replace any part[...]