Generac 004692-0 User Manual

POWER SYSTEMS, INC.
®
Installation and
Owner’s Manual
Air-cooled, Prepackaged
Models: 004692-0 (8.5 kW)
DEADLY EXHAUST FUMES.
OUTDOOR INSTALLATION ONLY!!
Not intended for use as Primary Power in place of utility or in life­support applications.
GENERAC
POWER SYSTEMS, INC.
R
R
!
DANGER
!
Generac®Power Systems, Inc.
INTRODUCTION
Thank you for purchasing this model of the Centurion product line by Generac Power Systems Inc. This model is a compact, high performance, air­cooled, engine-driven generator designed to automat­ically supply electrical power to operate critical loads during a utility power failure.
This unit is factory installed in an all-weather, metal enclo­sure that is intended exclusively for outdoor installation. This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).
READ THIS MANUAL THOROUGHLY
If you do not understand any portion of this manual, contact Generac or your nearest Generac Authorized Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or care­lessly. Observe them carefully. Their definitions are as follows:
After this heading, you can read instructions that, if not strictly complied with, will result in personal injury, including serious injury and/or death or property damage.
After this heading, you can read instructions that, if not strictly complied with, may result in personal injury or property damage.
After this heading, you can read instructions that, if not strictly complied with, could result in damage to equipment and/or property.
NOTE:
After this heading, you can read explanatory statements that require special emphasis.
These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict compli­ance with the special instructions while performing the service are essential to preventing accidents.
Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The type of information each indicates follows:
This symbol points out important safety informa­tion that, if not followed, could endanger personal safety and/or property of you and others.
This symbol points out potential explosion hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock hazard.
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 using this equip­ment. We also strongly recommend instructing other users to properly start and operate the unit. This pre­pares them if they need to operate the equipment in an emergency.
CONTENTS
This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views and lists of repair parts, for Centurion model:
• 004692-0 – 8.5 kW NG, 8.5 kW LP, V-twin GT-990 Engine
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safe­ty checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by a Generac Authorized Dealer. Normal maintenance service and replacement of parts are the responsibility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.
Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum. See your Generac Authorized Dealer for service aids and accessories.
HOW TO OBTAIN SERVICE
When your generator requires servicing or repairs, simply contact a Generac Authorized Dealer for assistance. Service technicians are factory-trained and are capable of handling all of your service needs.
When contacting a Generac Authorized Dealer or the factory about parts and service, always supply the complete model number and serial number of your unit as given on its data decal, which is located on your generator. See Figure 1.2 or Figure 1.3 in Section 1.4 (Page 5) for decal location.
Model No. ____________ Serial No. ______________
AUTHORIZED
DEALER LOCATION
To locate the GENERAC AUTHORIZED
DEALER nearest you, please call this number:
1-800-333-1322
DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
DANGER
!
Table of Contents
Air-cooled 8.5 kW Generator
Generac®Power Systems, Inc. 1
Introduction ........................Inside Front Cover
Read This Manual Thoroughly ........................IFC
Contents ..........................................................IFC
Operation and Maintenance ............................IFC
How to Obtain Service ....................................IFC
Authorized Dealer Locator Number ................IFC
Safety Rules ........................................................2
Standards Index ..................................................3
Section 1 – General Information ..................4
1.1 Unpacking/Inspection ....................................4
1.2 Protection Systems ........................................4
1.3 System Set LED ............................................4
1.4 Your Generator ..............................................5
1.5 Specifications ................................................6
1.5.1 Generator ..........................................6
1.5.2 Engine ................................................6
1.6 Fuel Requirements and Recommendations ....7
1.7 Fuel Consumption ........................................7
1.8 Reconfiguring the Fuel System ......................7
1.9 Location ........................................................8
1.9.1 Generator ..........................................8
1.9.2 Transfer Switch ..................................8
1.10 Battery Installation ........................................8
1.11 The Battery ....................................................8
Section 2 – Post Installation Start-up
and Adjustments ........................9
2.1 Before Initial Startup ....................................9
2.2 Check Transfer Switch Operation..................9
2.3 Electrical Checks ..........................................9
2.4 Generator Tests Under Load ......................10
2.5 Checking Automatic Operation ....................11
2.6 Adjusting the Regulator (Natural Gas Only) ..11
2.7 Engine Governor Adjustment ......................12
2.7.1 Additional Corrosion Protection ......12
2.8 Voltage Regulator Adjustment ......................12
Section 3 – Operation ....................................13
3.1 Break-in Procedure......................................13
3.2 Using the Auto/Off/Manual Switch ..............13
3.2.1 “Auto” Position ..................................13
3.2.2 “Off” Position....................................13
3.2.3 “Manual” Position ............................13
3.3 Automatic Transfer Operation ....................13
3.4 Sequence of Automatic Operation................14
3.5 Manual Transfer Operation ........................14
3.5.1 Transfer to Generator
Power Source......................................14
3.5.2 Transfer Back to Utility
Power Source......................................15
3.6 Setting the Exercise Timer ..........................15
3.7 Protection Systems ......................................15
3.7.1 Low Oil Pressure Switch ..................15
3.7.2 High Temperature Switch ................15
3.7.3 Overcrank ........................................16
3.7.4 Overspeed ........................................16
Section 4 – Maintenance ..............................16
4.1 Fuse ............................................................16
4.2 Checking the Engine Oil Level ....................16
4.3 Changing the Engine Oil ..............................17
4.3.1 Engine Oil Recommendations ..........17
4.3.2 Oil Change Procedure ......................17
4.4 Changing the Oil Filter ................................17
4.5 Changing the Engine Air Cleaner ................17
4.6 Spark Plug(s) ..............................................18
4.7 Battery Maintenance....................................18
4.8 Adjusting Valve Clearance ............................19
4.9 Cooling System............................................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
4.13 Service Schedule ........................................21
Section 5 – Troubleshooting ........................22
5.1 Troubleshooting Guide ................................22
Section 6 – Mounting Dimensions..............23
Section 7 – Electrical Data ............................24
Section 8 – Exploded Views and
Parts Lists....................................28
Section 9 – Warranty......................................40
2 Generac®Power 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 follow simple and fundamental rules or precautions.
Generac cannot possibly anticipate every possible circumstance that might involve a hazard. The warn­ings in this manual, and on tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating tech­nique Generac does not specifically recommend, you must satisfy yourself that it is safe for you and others. You also must make sure the procedure, work method or operating technique that you choose does not render the generator unsafe.
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.
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.
GENERAL HAZAR
DS
• 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 monox­ide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust sys­tem must be installed properly, in strict compli­ance with applicable codes and standards. Following installation, you must do nothing that might render 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 venti­lating air is critical to correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seri­ously affect safe operation of the generator. The generator MUST be installed outdoors.
• When working on this equipment, remain alert at all times. Never work on the equipment when you are physically or mentally fatigued.
• Inspect the generator regularly, and contact your nearest Generac Authorized Dealer for parts need­ing repair or replacement.
• Before performing any maintenance on the genera­tor, disconnect its battery cables to prevent acci­dental start up. Disconnect the cable from the bat­tery 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 con­ditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
!
!
!
IMPORTANT SAFETY INSTRUCTIONS
Air-cooled 8.5 kW Generator
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted near the unit’s installation site. Safety should be stressed to all operators and potential operators of this equipment.
!
!
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.
WARNING:
!
!
!
!
DANGER
!
Generac®Power Systems, Inc. 3
ELECTRICAL HAZARDS
• 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 opera­tion. Avoid contact with bare wires, terminals, con­nections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If you must work 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 sys­tem, 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, imme­diately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.
• Never wear jewelry when working on this equip­ment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving com­ponents 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 installa­tion, do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes, standards, laws and regu­lations.
• 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 extin­guisher properly charged and be familiar with its use. If you have any question pertaining to fire extinguishers, consult your local fire department.
EXPL
OSION HAZARDS
• Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no com­bustible materials are left in the generator com­partment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surround­ing 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 applica­ble fuel-gas codes. Before placing the home stand­by electric system into service, fuel system lines must be properly purged and leak tested according to applicable code. After installation, you must inspect the fuel system periodically for leaks. No leakage is permitted.
STANDARDS INDEX
In the absence of pertinent standards, codes, regula­tions and laws, the published information listed below may be used as installation guide for this equipment.
1. NFPA No. 37, STATIONARY COMBUSTION
ENGINES AND GAS TURBINES, available from the National Fire Protection Association, 470 Atlantic Avenue, Boston, MA 02210.
2. NFPA No. 76A, ESSENTIAL ELECTRICAL SYS-
TEMS FOR HEALTH CARE FACILITIES, avail­able same as Item 1.
3. NFPA No. 54, NATIONAL FUEL GAS CODE,
available same as Item 1.
4. NFPA No. 58, AMERICAN NATIONAL STANDARD
FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GAS, available same as Item 1.
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL
ELECTRIC CODE, available same as Item 1.
6. Article X, NATIONAL BUILDING CODE, available
from the American Insurance Association, 85 John Street, New York, N.Y. 10038.
7. AGRICULTURAL WIRING HANDBOOK, available
from the Food and Energy Council, 909 University Avenue, Columbia, MO 65201.
8. ASAE EP-3634, INSTALLATION AND MAINTE-
NANCE OF FARM STANDBY ELECTRICAL SYS­TEMS, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.
IMPORTANT SAFETY INSTRUCTIONS
Air-cooled 8.5 kW Generator
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 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents for damage.
• This standby generator set has been factory sup­plied 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.
If this generator is used to power electrical load circuits normally powered by a utility power source, you are required by code to install a trans­fer switch. The transfer switch must effectively iso­late the electrical system from the utility distribu­tion system when the generator is operating (NEC 700, 701, and 702). Failure to isolate an electrical system by such means will result in damage to the generator and also 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 you note loss or damage after delivery, separate the damaged materials and contact the carrier for claim procedures.
“Concealed damage” is understood to mean damage to the contents of a package that is not in evidence at the time of delivery, but is discovered later.
1.2 PROTECTION SYSTEMS
Unlike an automobile engine, the generator may have to run for long periods of time with no operator present to monitor engine conditions. For that reason, the engine is equipped with the following systems that protect it against potentially damaging conditions:
1. Low Oil Pressure Sensor 3. Overcrank
2. High Temperature Sensor 4. Overspeed
There are LED readouts on the control panel to noti­fy you that one of these faults has occurred.
1.3 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 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 pres­sure, high temperature, etc.
4 Generac®Power Systems, Inc.
Generac®Power Systems, Inc. 5
Section 1 General Information
Air-cooled 8.5 kW Generator
1.4 YOUR GENERATOR
Figure 1.1 – 8.5 kW, V-Twin GT-990 Engine
Exhaust Enclosure
Oil Dipstick
Air Filter
Oil Filter
Data Decal
Control Panel
Fuel Regulator
12 Volt Battery
6 Generac®Power Systems, Inc.
Section 1 General Information
Air-cooled 8.5 kW Generator
1.5 SPECIFICATIONS
1.5.1 GENERATOR
Model 004692
Rated Max. Continuous Power Capacity (Watts*) 8,500 NG/8,500 LP Rated Voltage 120/240 Rated Max. Continuous Load Current (Amps)
120 Volts 70.8 NG/70.8 LP
240 Volts 35.4 NG/35.4 LP Main Line Circuit Breaker 40 Amp Phase 1 Number of Rotor Poles 2 Rated AC Frequency 60 Hz Power Factor 1 Battery Requirement Group 26/26R
12 Volts and
550 Cold-cranking
Amperes Minimum
Weight 470 Pounds
Output Sound Level 68 db (A) Normal Operating Range -20°F (28.8°C to 104°F (40°C)
* Maximum wattage and current are subject to and limited by such factors as fuel Btu 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 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
Generac®Power Systems, Inc. 7
1.6 FUEL REQUIREMENTS AND RECOMMENDATIONS
With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed
above the liquid fuel in the storage tank.
The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper-proof dual fuel systems. The unit will run on natural gas or LP gas, but it has been factory set to run on natural gas. Should the primary fuel need to be changed to LP gas, the fuel system needs to be reconfigured. See Section 1.8 (Page 7) for instructions on 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 your fuel supplier for the Btu content of your fuel.
Fuel pressure for both natural gas and liquid propane set ups must be 11 inches to 14 inches of
water column (0.6 psi) at all load ranges.
NOTE:
A seperate gas line and regulator may be needed to assure proper gas pressure (11-14”) to the gen­erator. Low gas pressure can cause hard starting and could affect engine durability.
1.7 FUEL CONSUMPTION
*Natural gas is in cubic feet per hour. **LP is in gallons per hour/cubic feet per hour.
Gaseous fuels such as natural gas and liquid propane (LP) gas are highly explosive. Even the slightest spark can ignite such fuels and cause an explosion. No leakage of fuel is permitted. Natural gas, which is lighter than air, tends to collect in high areas. LP gas is heavier than air and tends to settle in low areas.
1.8 RECONFIGURING THE FUEL SYSTEM
To reconfigure the fuel system from NG to LP, follow these steps:
NOTE:
The primary regulator for the propane supply is NOT INCLUDED with the generator. You must sup­ply a fuel pressure of 11 to 14 inches of water col­umn (0.6 psi) to the fuel inlet of the generator.
1. Turn off the main gas supply.
2. Remove the three carburetor fuel hoses from the outlet ports of the demand regulator.
3. Disconnect wire #0 and wire #14 from the gas solenoid located on the top of the demand regu­lator.
4. Remove the demand regulator from the enclosure by rotating counterclockwise.
5. Remove the small jet (0D5698A) located in the side of the regulator housing and install it into the small threaded hole in the idle circuit port on the regulator.
7. Refit the brass hose fitting to the idle circuit port of the regulator. Use pipe thread sealant to reseal the threads on the hose fitting.
8. Identify both adjustment screws.
NOTE:
One adjustment screw can be accessed from the front of the unit and the second can be accessed from the back of the unit.
9. The unit has been factory set to run on NG fuel. To reset the system to run on LP fuel, turn the two adjustment screws 1/2 turn clockwise. Use a large screwdriver to make this adjustment.
10. The fuel system will now allow the engine to run on LP fuel. It may be necessary to make minor adjustments to the preset screw settings to achieve maximum power. If you experience prob­lems with the unit producing maximum power, follow the procedure in Section 2.6, “Adjusting the Regulator”.
11. Reverse procedure steps 1-4 to reinstall the demand regulator.
Figure 1.2 – Demand Regulator
Section 1 General Information
Air-cooled 8.5 kW Generator
Model # Nat. Gas (*) LP Vapor (**)
1/2 Load Full Load 1/2 Load Full Load
004692-0 114 170 1.33/45.8 1.98/72.5
IDLE CIRCUIT
PORT
FUEL HOSE
BRASS HOSE FITTING
O U T
PRESSURE
1
TAP
1/8 NPT
BRASS HOSE
FITTING
ADJUSTER SCREWS
SMALL FUEL JET
REGULATOR HOUSING PORT
1.9 LOCATION
1.9.1 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 drift­ing, you may need to consider using a windbreak to protect the unit.
• Install the generator on high ground where water levels will not rise and endanger it.
• Allow sufficient room on all sides of the generator for maintenance and servicing. A good rule is to allow 3 feet of space on all sides.
• Where strong prevailing winds blow from one direction, face the generator air inlet openings to the prevailing winds.
• Install the generator as close as possible to the fuel supply, to reduce the length of piping.
• Install the generator as close as possible to the transfer switch. HOWEVER, REMEMBER THAT LAWS OR CODES MAY REGULATE THE DIS­TANCE.
1.9.2 TRANSFER SWITCH
The transfer switch shipped with this generator is rated 100 amps maximum at 120/240 volts AC single phase. The enclosure of the transfer switch is NEMA
1. This type of enclosure is intended for indoor use only. Follow these rules:
• Install the transfer switch indoors on a firm, stur­dy supporting structure.
• To prevent switch distortion, level the switch if necessary. This can be done by placing washers between the switch enclosure and mounting sur­face.
• Never install the switch where water or any corro­sive substance might drip onto the enclosure.
• Protect the switch at all times against excessive moisture, dust, dirt, lint, construction grit and cor­rosive vapors.
1.10 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if nec­essary and have the battery fully charged before installing it.
Before installing and connecting the battery, complete the following steps:
1. Set the generator's Auto/Off/Manual switch to
OFF.
2. Turn off utility power supply to the transfer
switch.
If the Auto/Off/Manual switch is not set to its OFF position, the generator can crank and start as soon as the battery cables are connected. If the utility power supply is not turned off, sparking can occur at the battery posts and cause an explosion.
Battery cables were factory connected at the genera­tor (Figure 1.5). Connect cables to battery posts as follows:
3. Connect the red battery cable (from starter con­tactor) 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 nega­tive, NEG or (—).
NOTE:
Damage will result if battery connections are made in reverse.
Figure 1.5 – Battery Cable Connections
NOTE:
Your generator is equipped with a battery trickle charger that is active when your unit is set up for automatic operation. With the battery installed and utility power source voltage available to the transfer switch, the battery receives a trickle charge while the engine is not running, to prevent self-discharge. The trickle charger is designed to help extend the life of your battery by maintaining the battery when the unit is not running. The trickle charge feature cannot be used to recharge a discharged battery.
1.11 THE BATTERY
Servicing of the battery is to be performed or super­vised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized person­nel away from batteries.
When replacing the battery, use the following type of battery: Group 26/26R 12VDC, 550 cold-cranking
Section 1 General Information
Air-cooled 8.5 kW Generator
8 Generac®Power Systems, Inc.
DANGER
Generac®Power 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 the wiring diagrams. Make sure the battery is correctly connect­ed and terminals are tight. Observe battery polarity when connecting the battery to the generator set.
Do not dispose of the battery in a fire. The battery is capable of exploding.
A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when working on batteries:
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the battery; and
• Disconnect charging source prior to connecting or dis-
connecting battery terminals.
Do not open or mutilate the battery. Released electrolyte has been known to be harmful to the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek medical attention; and
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicar­bonate 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 because they generate hydrogen gas. The following procedures are to be followed:
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area; and
• Discharge static electricity from your body before
touching the battery by first touching a grounded metal surface.
Be sure the Auto/Off/Manual switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.
Be sure the utility power supply is turned off, or sparking may occur at the battery posts as you attach the cables and cause an explosion.
2.1 BEFORE INITIAL START-UP
Before starting, complete the following:
1. Set the 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 OFF all loads connected to the tranfer switch terminals T1 and T2.
4. Check the engine crankcase oil level and, if nec­essary, 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. All fuel shutoff valves in the fuel supply lines must be open.
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 (Page 13), of the owner’s manual for manual operation procedures.
Do not attempt manual transfer switch opera­tion 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.
2.3 ELECTRICAL CHECKS
Complete electrical checks as follows:
1. Set the generator's main circuit breaker to its OFF (or open) position.
Section 2 Post Installation Start-up and Adjustments
Air-cooled 8.5 kW Generator
DANGER
!
!
!
!
10 Generac®Power Systems, Inc.
2. Turn OFF all loads connected to the transfer switch terminals T1 and T2.
3. Turn on the utility power supply to the transfer switch using the means provided (such as a utili­ty main line circuit breaker).
The transfer switch is now electrically “hot.” Contact with “hot” parts will result in extreme­ly hazardous and possibly fatal electrical shock. Proceed with caution.
4. Use an accurate AC voltmeter to check utility power source voltage across transfer switch ter­minals N1 and N2. Nominal line-to-line voltage should be 240 volts AC.
5. Check utility power source voltage across termi­nals N1 and the transfer switch neutral lug; then across terminal N2 and neutral. Nominal line-to­neutral voltage should be 120 volts AC.
6. When certain that utility supply voltage is com­patible with transfer switch and load circuit rat­ings, turn OFF the utility power supply to the transfer switch.
7. On the generator panel, set the Auto/Off/Manual switch to MANUAL. The engine should crank and start.
8. Let the engine warm up for about five minutes to allow internal temperatures to stabilize. Then, set the generator’s main circuit breaker to its ON (or closed) position.
Proceed with caution! Generator power voltage is now supplied to the transfer switch. Contact with live transfer switch parts will result in dangerous and possibly fatal electrical shock.
9. Connect an accurate AC voltmeter and a frequen­cy meter across transfer switch terminal lugs E1 and E2. Voltage should be 242-252 volts; fre­quency should read about 61-63 Hertz.
10. Connect the AC voltmeter test leads across termi­nal lug E1 and neutral; then across E2 and neu­tral. In both cases, voltage reading should be 121­126 volts AC.
11. Set the generator’s main circuit breaker to its OFF (or open) position. Let the engine run at no­load for a few minutes to stabilize internal engine generator temperatures.
12. Set the generator's Auto/Off/Manual switch to OFF. The engine should shut down.
NOTE:
It is important that you do not proceed until you are certain that generator AC voltage and 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 correct, but voltage is high or low, the generator’s voltage regulator requires adjustment.
2.4 GENERATOR TESTS UNDER LOAD
To test the generator set with electrical loads applied, proceed as follows:
1. Set generator’s main circuit breaker to its OFF (or open) position.
2. Turn OFF all loads connected to the transfer switch terminals T1 and T2.
3. Set the generator's Auto/Off/Manual switch to OFF.
4. Turn OFF the utility power supply to the transfer switch, using the means provided (such as a util­ity main line circuit breaker).
Do not attempt manual transfer switch opera­tion 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. Set the generator’s main circuit breaker to its ON (or closed) position. Loads are now powered by the standby generator.
9. Turn ON electrical loads connected to transfer switch terminals T1 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 frequen­cy meter across terminal lugs E1 and E2. Voltage should be greater than 230 volts; frequency should be greater than 58 Hertz.
11. Let the generator run at full rated load for 20-30 minutes. Listen for unusual noises, vibration or other indications of abnormal operation. Check for oil leaks, evidence of overheating, etc.
12. When testing under load is complete, turn OFF electrical loads.
13. Set the generator's main circuit breaker to its OFF (or open) position.
14. Let the engine run at no-load for a few minutes.
Section 2 Post Installation Start-up and Adjustments
Air-cooled 8.5 kW Generator
DANGER
DANGER
DANGER
Generac®Power Systems, Inc. 11
15. Set the Auto/Off/Manual switch to OFF. The engine should shut down.
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 transfer 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 transfer 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 transfer switch.
With the Auto/Off/Manual switch at AUTO, the engine should crank and start when the utility source power is turned OFF. After starting, the transfer switch should connect load circuits to the standby side. Let the system go through its entire automatic sequence of operation.
With the generator running and loads powered by generator AC output, turn ON the utility power 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 retransfer, the engine
should shut down.
2.6 ADJUSTING THE REGULATOR
(NATURAL GAS ONLY)
Although the generator has been factory set to pro­vide 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 you experience engine problems at high or full load conditions follow these steps. It will require a fre­quency 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 posi­tion.
2. Allow the generator to start. Before loading the generator, confirm that the no load frequency ,with the roof open and door off, is set at 63-63.5 Hz. Transfer load to emergency circuits.
3. Turn on appliances, lights, pumps, etc., that are on the emergency circuits in an attempt to fully load the generator. Be cautious not to overload the generator. Use the following chart as a guide:
4. When full load has been achieved. Connect a fre­quency meter to the output lugs of the generator’s main line circuit breaker.
5. The fuel regulator is fitted with two adjustment screws. While watching the frequency meter, slowly turn the adjustment screws clockwise or counterclockwise one at a time until the highest frequency is read on the meter. (Figures 2.1 and
2.2).
Figure 2.1 — Dual Fuel Regulators
6. When the highest frequency is reached maximum power has been set. From this point, turn both adjustment screws 1/4 turn clockwise. The regu­lator is now set.
Figure 2.2 — Placement of Regulator
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.
Section 2 Post Installation Start-up and Adjustments
Air-cooled 8.5 kW Generator
Unit 120 Volts 240 Volts
8.5 kW 70.8 amps 35.4 amps
990
Adjustment
Screw
(Both sides)
Adjustment Screw
12 Generac®Power Systems, Inc.
Do not make any unnecessary adjustments. Factory settings are correct for most applica­tions. However, when making adjustments, be careful to avoid overspeeding the engine.
If this procedure or equipment are not available to you, locate the Generac Dealer nearest you and they can perform the adjustments.
NOTE:
A service fee may be charged for this adjustment.
2.7 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.
2. Completely remove the idle spring.
3. With governor arm at wide open throttle position, rotate governor shaft fully clockwise. Tighten clamp bolt to 84 inch-pounds.
4. Start unit and apply full load. Use full load speed adjust screw (Figure 2.4) to adjust frequency to 58 Hz.
5. Remove load, stop engine, loosen the idle adjust screw and reconnect the idle spring.
6. Using your hand, push the governor arm to the closed throttle position. Make sure the idle spring does not stretch at all.
7. Restart the unit.
8. Slowly turn the idle adjust screw to adjust the no­load idle frequency to 63-63.5 Hz.
9. The governor is now set.
Figure 2.4 — Full Load Speed Adjust Screw
2.7.1 ADDITIONAL CORROSION PROTECTION
Periodically spray all engine linkage parts and brack­ets 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 volt­age reads 244-252 volts.
NOTE:
You must remove the access panel on top of the control panel to adjust the voltage regulator.
Figure 2.5 – Voltage Adjustment Potentiometer
NOTE:
The voltage regulator is housed above the genera­tor's control panel. The regulator maintains a volt­age in direct proportion to frequency at a 2-to-1 ratio. For example, at 62 Hertz, line-to-neutral voltage will be 124 volts.
Section 2 Post Installation Start-up and Adjustments
Air-cooled 8.5 kW Generator
!
Full Load Speed Adjust Screw
Generac®Power Systems, Inc. 13
Section 3 Operation
Air-cooled 8.5 kW Generator
3.1 BREAK-IN 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. Set the generator’s Auto/Off/Manual switch to AUTO.
2. Turn OFF the utility power supply to the transfer switch using the means provided (such as a utili­ty main line circuit breaker).
3. The unit will start, and the transfer switch will transfer to standby.
4. Using the transfer switch’s built-in emergency load center, turn on circuits to load the generator to approximately 25% rated load and run the unit for one hour.
5. Run the unit for one hour at 50% rated load.
6. Run the unit for one hour at 75% rated load.
7. Run the unit for one hour at 100% rated load.
8. Turn ON the utility power supply to the transfer switch, which will allow the transfer switch to transfer back to utility power. The unit will con­tinue to run for one minute and then shut down.
9. Allow the unit to cool.
10. Drain the oil and remove the oil filter. Replace the oil filter according to Section 4.4, “Changing the Oil Filter” (Page 16). Replace the oil with synthet­ic oil as recommended in Section 4.3, “Changing the Engine Oil” (Page 15).
11. The generator is now ready for service.
3.2 USING THE AUTO/OFF/MANUAL
SWITCH (FIGURE 3.1)
3.2.1 “AUTO POSITION
Selecting this switch position activates fully automatic system operation. It also allows you to start and exercise the engine every seven days with the setting of the exer­cise timer (see Section 3.6, Page 14). This position also is used for remote starting, when it is set up.
3.2.2 OFF POSITION
This switch position shuts down the engine. This position also prevents automatic operation.
3.2.3 MANUAL” POSITION
Set the switch to MANUAL to crank and start the engine. Transfer to standby power will not occur unless there is a utility failure.
Figure 3.1 – Generator Control Panel
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 pre­set level or during the normal exercise cycle. To prevent possible injury that might be caused by such sudden starts, always set the switch to OFF and remove the fuse before working on or around the generator or transfer switch. Then, place a “Do Not Operate” tag on the generator panel and on the transfer switch.
3.3 AUTOMATIC TRANSFER OPERATION
To select automatic operation, do the following:
1. Make sure the transfer switch main contacts are
set to their “Utility” position, i.e., loads connected to the utility power source (Figure 3.2, Page 14).
2. Be sure that normal utility power source voltage
is available to transfer switch terminal lugs N1 and N2.
3. Set the 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 “Sequence of Automatic Operation” (Page 14).
!
FUSE
5A
FUSE
15A
OFFAUTO
SET
EXERCISE
TIME
MAN.
Locat e your nearest dealer at :
R
POWER SYSTEMS, INC.
FLA SHING GR EEN L ED=
4FLASHINGREDLEDS=
R
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
N O U T IL IT Y S E N S E
EX ERCISER N OT S ET
14 Generac®Power Systems, Inc.
Section 3 Operation
Air-cooled 8.5 kW Generator
3.4 SEQUENCE OF AUTOMATIC OPERATION
The generator’s control panel houses a control logic circuit board. This board constantly monitors utility power source voltage. Should that voltage drop below a preset level, circuit board action will signal the engine to crank and start. After the engine starts, the circuit board signals the transfer switch to activate and connect load circuits to the standby power sup­ply (load terminal lugs T1/T2 connect to terminal lugs E1/E2).
Upon restoration of utility source voltage above a pre­set 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 per­cent 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 volt­age. 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 retransfer time delay starts timing.
E.Retransfer Time Delay
• This timer runs for about 15 seconds.
• At end of a 15-second delay, circuit board action de-energizes transfer relay in the transfer switch.
• Retransfer to utility power source then occurs.
F. Engine Cool-down Timer
• When the load is transferred back to utility power source, the engine cool-down timer starts timing.
• The timer will run for about one minute, and the generator will then shut down.
3.5 MANUAL TRANSFER OPERATION
3.5.1 TRANSFER TO GENERATOR POWER SOURCE
To start the generator and activate the transfer switch manually, proceed as follows:
1. Set the generator’s Auto/Off/Manual switch to OFF.
2. Set the 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).
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 trans­fer switch to move the main contacts to their “Standby” position, i.e., loads connected to the standby power source (Figure 3.2).
Figure 3.2 – Manual Transfer Switch Operation
5. To crank and start the engine, set the Auto/Off/Manual switch to MANUAL.
6. Let the engine stabilize and warm up for a few minutes.
7. Set the generator’s main circuit breaker to its ON (or closed) position. The standby power source now powers the loads.
DANGER
Generac®Power Systems, Inc. 15
3.5.2 TRANSFER BACK TO UTILITY POWER SOURCE
When utility power has been restored, you will want to transfer back to that source and shut down the 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 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.
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 trans­fer switch to move the main contacts back to their “Utility” position, i.e., loads connected to the util­ity power source (Figure 3.2 on page 14).
6. Turn ON the utility power supply to the transfer switch using the means provided.
7. Set the system to automatic operation as outlined in “Automatic Transfer Operation,” Section 3.3 (Page 13).
3.6 SETTING THE EXERCISE TIMER
Your generator is equipped with an exercise timer. Once it is set, the generator will start and exercise once every seven days, on the day of the week and at the time of day you complete the following sequence. During this exercise period, the unit runs for approx­imately 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, Page
13) allows you to select the day and time for system
exercise. To select the desired day and time of day, you must perform the following sequence at that time.
1. Verify that the Auto/Off/Manual switch is set to AUTO.
2. Hold down the “Set Exercise Time Switch” until the generator starts (approximately 10 seconds) and then release. During this time all the red LEDs on the control panel will flash to indicate board is resetting itself.
3. The generator will start and run for approximately 12 minutes and then shut down on its own. The exerciser will then be set to run at that time of day every week.
NOTE:
The exerciser will only work in the AUTO mode and will not work correctly unless this procedure is performed. The exerciser will need to be reset every time the 12-volt battery is disconnected and then reconnected. The exerciser WILL NOT work if dip switch 2 on the controller printed circuit board (“Remote Not Auto”) is ON.
If the exerciser is not set using the “Set Exercise Time Switch”, the generator will automatically exercise 7 days after the battery connection was made.
3.7 PROTECTION SYSTEMS
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.
3.7.2 HIGH TEMPERATURE SWITCH
This switch’s (Figure 3.3) contacts close if the tem­perature should exceed approximately 140º C (284º F), initiating an engine shutdown. Your generator will automatically restart and the LED on the generator control panel will reset once the temperature has returned to a safe operating level.
Figure 3.3 – Low Oil Pressure and
High Temperature Switches
Section 3 Operation
Air-cooled 8.5 kW Generator
DANGER
Oil Drain Hose
Low Oil Switch
L
o
o
Oil Filter
s
e
n
High Temp Switch
16 Generac®Power Systems, Inc.
3.7.3 OVERCRANK
This feature prevents the generator from damaging itself when it continually attempts to start and anoth­er problem, such as no fuel supply, prevents it from starting. The unit will crank and rest for a preset time limit. Then, it will stop cranking, and the LED on the generator control panel will light indicating an over­crank failure. The Auto/Off/Manual switch will need to be set to OFF and then back to AUTO to reset the generator control board.
NOTE:
If the fault is not repaired, the overcrank feature will continue to activate.
3.7.3.1 Approximate Crank Cycle Times
• 15 seconds ON
• 7 seconds OFF
• 7 seconds ON
• 7 seconds OFF
• Repeat for 45 seconds Approximately 90 seconds total
3.7.4 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 gener­ator from supplying an output that could potentially damage appliances connected to the generator cir­cuit. Contact your nearest Generac Authorized Dealer if this failure occurs.
4.1 FUSE
The generator panel’s 15 amp fuse (Figure 4.1) pro­tects the DC control circuit against overload. The fuse is wired in series with the battery output lead to the panel. If the fuse element has melted open, you can­not crank or start the engine. You should replace the fuse using only an identical 15-amp replacement.
The generator panel’s 5 amp fuse protects the battery charge circuit against overload. If the fuse element has melted open, you will not have battery charging capability. You should replace the fuse using only an identical 5 amp replacement. To remove fuse, push cap down and rotate counterclockwise.
Figure 4.1 – Generator Control Panel
4.2 CHECKING THE ENGINE OIL LEVEL
For oil capacities, see “Specifications,” Section 1.5 (Page 6). For engine oil recommendations, see Section 4.3.1. To check the engine oil level, proceed as follows (Figure 4.2, on page 17):
1. Start the generator by moving the Auto/
Off/Manual switch to the MANUAL position. Allow it to run for a short while and then shut it down by moving the switch to the OFF position.
2. Remove the dipstick and wipe it dry with a
clean cloth.
3. Install the dipstick; then, remove it again. The oil
level should be at the dipstick “Full” mark. If nec­essary, add oil to the “Full” mark only. DO NOT FILL ABOVE THE “FULL” MARK.
Never operate the engine with the oil level below the “Add” mark on the dipstick. Doing this could damage the engine.
4. Install the dipstick.
5. Reset the Auto/Off/Manual switch to its original
position.
Figure 4.2 — Oil Dipstick and Fill, 8.5 kW
Section 4 Maintenance
Air-cooled 8.5 kW Generator
FUSE
5A
FUSE
15A
OFFAUTO
SET
EXERCISE
TIME
MAN.
Locat e your nearest dealer at :
R
POWER SYSTEMS, INC.
FLA SHING GR EEN L ED=
4FLASHINGREDLEDS=
R
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
N O U T IL IT Y S E N S E
EX ERCISER N OT S ET
!
Oil Dipstick
Oil Fill
Generac®Power Systems, Inc. 17
4.3 CHANGING THE ENGINE OIL
4.3.1 ENGINE OIL RECOMMENDATIONS
Use oil of American Petroleum Institute (API) Service Class SG, SH or SJ. Use all season SAE 5W-30 Synthetic oil. Organic break-in oil is required before using synthetic oil.
NOTE:
The unit is supplied with “break-in” oil. See the “Break-in Procedure,” Section 3.1 (Page 13), for the first required oil change.
Any attempt to crank or start the engine before it has been properly serviced with the recom­mended oil may result in an engine failure.
4.3.2 OIL CHANGE PROCEDURE
To change the oil, proceed as follows:
1. Run the engine until it is thoroughly warmed up then shut OFF the engine.
2. Immediately after the engine shuts OFF, pull the oil drain hose (Figure 4.3) free of its retaining clip. Remove the cap from the hose and drain the oil into a suitable container.
Figure 4.3 – Oil Drain Hose and Filter
3. After the oil has drained, replace the cap onto the end of the oil drain hose. Retain the hose in the clip.
4. Refill with the proper recommended oil (see Section 4.3.1). See Section 1.5.2 (Page 6) for oil capacities.
4.4 CHANGING THE OIL FILTER
Change the engine oil filter as follows:
1. With the oil drained, remove the old oil filter by turning it counterclockwise.
2. Apply a light coating of clean engine oil to the gas­ket of the new filter. See Section 1.5.1 (Page 6) for recommended filter.
3. Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter. Then, tighten the filter an additional 3/4 to one turn (Figure 4.3).
4. Refill with the proper recommended oil (see Section 4.3.1). See Section 1.5.2 (Page 6) for oil capacities.
5. Start the engine and check for leaks.
4.5 CHANGING THE ENGINE
AIR CLEANER
4.5.1 8.5 KW GENERATORS
See Figure 1.2, (Page 5), for the location of your air cleaner. Use the following procedure:
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover and air filter.
3. Wipe away dust or debris from inside of the air box and around edges.
4. Install the new air cleaner into the air box.
5. Install the cover. Turn the two cover screws clock­wise to tighten.
See the “Service Schedule,” Section 4.11 (Page 19) for air cleaner maintenance. See Section 1.5.1 (Page 6) for air filter replacement part number.
!
Section 4 Maintenance
Air-cooled 8.5 kW Generator
L
o
o
s
e
n
Oil Drain Hose
Oil Filter
18 Generac®Power Systems, Inc.
Figure 4.4 — 12 kW and 15 kW Engine
Air Cleaner
4.6 SPARK PLUG(S)
Reset the spark plug(s) gap or replace the spark plug(s) as necessary. See Section 4.11 (Page 19) for maintenance requirements.
1. Clean the area around the base of the spark plug(s) to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plug(s) to clean.
2. Remove the spark plug(s) and check the condi­tion. Replace the spark plug(s) if worn or if reuse is questionable. See Section 4.11 (Page 19) for recommended inspection.
3. Check the spark plug gap using a wire feeler gauge, carefully bending the ground electrode (Figure 4.5).
Figure 4.5 – Setting the Spark Plug Gap
4.7 BATTERY MAINTENANCE
The battery should be inspected per the “Service Schedule,” Section 4.11 (Page 19). 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 bat­tery hydrometer.
Do not dispose of the battery in a fire. The battery is capable of exploding.
A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when working on batteries:
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery; and
• Disconnect charging source prior to connecting or dis-
connecting battery terminals.
Do not open or mutilate the battery. Released electrolyte has been known to be harmful to the skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek medical attention; and
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicar­bonate 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.
!
!
Section 4 Maintenance
Air-cooled 8.5 kW Generator
SET PLUG GAP AT 0.50 mm
(0.020 inch)
Screw
Cover
Filter
DANGER
Generac®Power Systems, Inc. 19
Lead-acid batteries present a risk of fire because they generate hydrogen gas. The following procedures are to be followed:
• DO NOT SMOKE when near the battery;
• DO NOT cause flame or spark in battery area; and
• Discharge static electricity from your body before touching the battery by first touching a grounded metal surface.
Be sure the Auto/Off/Manual switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.
Be sure the utility power supply is turned off, or sparking may occur at the battery posts as you attach the cables and cause an explosion.
4.8 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, you should adjust the valve clearance in the engine.
Important: If you feel uncomfortable about doing this
procedure or you don't have the proper tools, please contact your Generac Authorized Dealer for service assistance. This is a very important step to insure the longest life for your engine.
To adjusting valve clearance:
• Make sure the engine is at room temperature.
• Make sure that the spark plug wire is removed
from the spark plug and out of the way.
• Remove the four screws attaching the valve cover
with a #2 or #3 phillips screwdriver.
• Make sure the piston is at Top Dead Center (TDC)
of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a large socket and socket wrench to rotate the nut and hence the engine. While watching the piston through the spark plug hole. The piston should move up and down. The piston is at TDC when it is up as high as it can go.
• Loosen the rocker jam nut. Use an 10mm allen
wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance is 0.002-0.004 inch (0.05-0.1 mm).
NOTE:
You must hold the rocker arm jam nut in place as you turn the pivot ball stud.
When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change.
Figure 4.6 - Valve Clearance Adjustment
• Install new valve cover gasket.
• Re-attach the valve cover.
NOTE:
Start all four screws before tightening or you will not be able to get all the screws in place. Make sure the valve cover gasket is in place.
• Re-attach the spark plug wire to the spark plug.
• Repeat the process for the other cylinder.
4.9 COOLING SYSTEM
Air inlet and outlet openings in the generator com­partment must be open and unobstructed for contin­ued proper operation. This includes such obstruc­tions as high grass, weeds, brush, leaves and snow.
Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to quickly shut down. (See Figure 4.7 for vent locations.)
Figure 4.7 – Cooling Vent Locations
The exhaust from this product gets extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.
Section 4 Maintenance
Air-cooled 8.5 kW Generator
!
Pivot Ball
Jam Nut
Stud
Rocker
Arm
Valve Stem
20 Generac®Power Systems, Inc.
The maximum ambient temperature for your generator is 48.9° C (104° F).
4.10 ATTENTION AFTER SUBMERSION
If the generator has been submerged in water,
it MUST NOT be started and operated. Following any
submersion in water, have a Generac Authorized Dealer thoroughly clean and dry the generator.
4.11 OUT OF SERVICE PROCEDURE
4.11.1 REMOVAL FROM SERVICE
If you cannot exercise the generator every seven days, and it is to be out of service longer than 90 days, pre­pare the generator for storage as follows:
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
3. Once the unit has shut down, it will signal a low
oil fault.
4. Set the Auto/Off/Manual switch to OFF and turn
off the utility power to the transfer switch.
5. While the engine is still warm from running,
drain the oil completely. Refill the crankcase with oil. See ”Engine Oil Recommendations,” Section
4.3.1 (Page 17).
6. Attach a tag to the engine indicating the viscosity
and classification of the oil in the crankcase.
7. Remove the spark plug(s) and spray fogging agent
into the spark plug(s) threaded openings. Reinstall and tighten the spark plug(s).
8. Remove the battery and store it in a cool, dry
room on a wooden board. Never store the battery on any concrete or earthen floor.
9. Clean and wipe the entire generator.
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 recommend­ed oil is used in the engine (see Section 4.3.1, Page 17). If necessary, drain and refill with the proper oil.
3. Check the state of the battery. Fill all cells of unsealed batteries to the proper level with dis­tilled water. DO NOT USE TAP WATER IN THE BATTERY. Recharge the battery to 100 percent state of charge, or, if defective, replace the battery. See “Specifications,” Section 1.5 (Page 6), for type and size.
4. Clean and wipe the entire generator.
5. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly.
6. Open the fuel shutoff valve.
7. Start the unit by moving the Auto/Off/Manual switch to MANUAL. Allow the unit to warm up thoroughly.
8. Stop the unit and set the Auto/Off/Manual switch to AUTO.
9. Turn on the utility power to the transfer switch.
10. Your generator is now ready for service.
NOTE:
If the battery was dead or disconnected, you must reset the exercise timer.
4.12 CORROSION PROTECTION
Periodically wash and wax the enclosure using auto­motive type products. Frequent washing is recom­mended in a salt water, coastal area. Spray engine linkages with a light oil such as WD-40.
!
Section 4 Maintenance
Air-cooled 8.5 kW Generator
Generac®Power Systems, Inc. 21
Section 4 Maintenance
Air-cooled 8.5 kW Generator
4.13 SERVICE SCHEDULE
ATTENTION: It is recommended that all service work
be performed by your nearest Generac Authorized Dealer.
SYSTEM/COMPONENT PROCEDURE FREQUENCY
X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Yearly
if Repair is Needed.
FUEL
Fuel lines and connections* XM
LUBRICATION
Oil level XM
Oil X AFTER BREAK-IN
AND Y
Oil filter X AFTER BREAK-IN
AND Y
COOLING
Enclosure louvers XXW
BATTERY
Remove corrosion, XXM
ensure dryness
Clean and tighten
XXM
battery terminals
Check charge state X R EVERY 6 M
Electrolyte level X R EVERY 6 M (unsealed batteries only)*
ENGINE AND MOUNTING
Air cleaner XR Y
Spark plug(s) XR Y
GENERAL CONDITION
Vibration, Noise, Leakage, XM Temperature*
COMPLETE TUNE-UP* TO BE COMPLETED BY A GENERAC Y
AUTHORIZED DEALER
22 Generac®Power Systems, Inc.
Section 5 Troubleshooting
Air-cooled 8.5 kW Generator
5.1 TROUBLESHOOTING GUIDE
PROBLEM CAUSE CORRECTION
The engine will not crank. 1. Fuse blown 1. Replace fuse.
2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary.
3. Defective starter contactor 3. *
4. Defective starter motor 4. *
5. Dead Battery 5. Charge or replace battery.
The engine cranks but 1. Out of fuel 1. Replenish fuel. will not start. 2. Defective fuel solenoid (FS) 2. *
3. Open #14 wire from 3. * engine control board
4. Defective spark plug(s) 4. Clean, re-gap or replace plug(s).
5. Valve Lash 5. Reset Valve Lash.
The engine starts hard 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. Fuel regulator not set. 3. Set fuel regulator.
4. Fuel pressure incorrect. 4. Confirm fuel pressure to generator
is 11-14” WC (0.6 PSI)
The Auto/Off/Manual switch 1. Defective switch 1. * is set to OFF, but the engine 2. Auto/Off/Manual switch 2. *
continues to run. wired incorrectly
3. Defective control board 3. *
There is no AC output from 1. Main line circuit breaker open 1. Reset circuit breaker the generator. to ON (or closed).
2. Generator internal failure 2. *
There is no transfer to 1. Defective transfer switch coil 1. * standby after utility 2. Defective transfer relay 2. * source failure. 3. Transfer relay circuit open 3. *
4. Defective control logic board 4. *
Unit consumes large 1. Break-in procedure 1. * amounts of oil. not followed (see Section 2.1)
*Contact your nearest Generac Authorized Dealer for assistance.
Generac®Power Systems, Inc. 23
Section 6 Mounting Dimensions
Air-cooled 8.5 kW Generator
Drawing No. 0D3739-A
TYPE HOM 120/240v
CBHOM-F
TYPE HOM
CBHOM-F
120/240v
TYPE HOM 120/240v
CBHOM-F
TYPE HOM 120/240v
CBHOM-F
TYPE HOM 120/240v
CBHOM-F
TYPE HOM
CBHOM-F
120/240v
TYPE HOM
CBHOM-F
120/240v TYPE HOM
CBHOM-F
120/240v
TYPE HOM
CBHOM-F
120/240v TYPE HOM
CBHOM-F
120/240v
TYPE HOM
CBHOM-F
120/240v TYPE HOM
CBHOM-F
120/240v
M6PEM-T
M6PEM-T
M6PEM-T
M6PEM-T
REAR VIEW
LEFT SIDE VIEW
TRANSFER SWITCH
RIGHT SIDE VIEW
FRONT VIEW
AIR
OUTLET
AIR INTAKE
914mm [ 36.0" ]
ALL AROUND UNIT
MINIMUM OPEN AREA
AIR INTAKE
REAR VIEW
GROUNDING LUG
260
[10.2"]
3/4" NPT FUEL INLET
1172.3 [46.2"]
GAS PRESSURE OF 11-14"
WATER COLUMN REQUIRED
149
[5.9"]
AIR
OUTLET
RIGHT SIDE VIEW
490.7 [19.3"]
Ø30.2mm [Ø1.19"]
1193 [47"]
1232 [48.5"]
FRONT VIEW
LIFTING HOLES 4-CORNERS
"DO NOT LIFT BY THE ROOF"
MINUMUM
PEA GRAVEL
704
[27.7"]
207 [8.14"]
743
120/240v TYPE HOM
CBHOM-F
CBHOM-F
TYPE HOM 120/240v
[29.25"]
M6PEM-T
120/240v
120/240v
120/240v
120/240v
120/240v
TYPE HOM
TYPE HOM
TYPE HOM
TYPE HOM
TYPE HOM
CBHOM-F
CBHOM-F
CBHOM-F
CBHOM-F
CBHOM-F
CBHOM-F
CBHOM-F
CBHOM-F
CBHOM-F
CBHOM-F
TYPE HOM
TYPE HOM
TYPE HOM
TYPE HOM
TYPE HOM
120/240v
120/240v
120/240v
120/240v
120/240v
M6PEM-T
604 [23.5"]
TRANSFER SWITCH
716 [28"]
M6PEM-T
308
[12"]
M6PEM-T
76.2mm [3.00"]
622 [24.5"]
LEFT SIDE VIEW
-
+
9BA7
6314
24 Generac®Power Systems, Inc.
Section 7 Electrical Data
Air-cooled 8.5 kW Generator Wiring Diagram - Drawing No. 0D8500
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 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 & 16 Vac 1 VA (DUAL SEC.)
SP1
IM1
SP2
IM2
HTO
0
LOP
0
BLACK
+
-
12V
BATTERY
CUSTOMER SUPPLIED
ENGINE WIRING
D
D
85
86
RED
3 2
BATTERY
1
CHARGER
14
FS
0
14
0
0
IC
6
0
18
86
IC
IC
SM
SC
5
85
4
3
2
13
1
C1
16
13
L.E.D - ALARM INDICATORS
16
SCR
AB
86
56
85
PRINTED CIRCUIT BOARD
ON
ON - INDICATES
1 - 20 Vac Sense Transformer
2 - Remote Not Auto
3 - 50 Hz Operation
4 - SPARE
14
14
16
0
CONTROL
TB
DSW
13
321
2 1
224B
13A
0
0
13
18
351
56
12 435
J2
4
225B
14
86
J1
Generac®Power Systems, Inc. 25
9
A
7
6
1
4
Section 7 Electrical Data
Air-cooled 8.5 kW Generator
Wiring Diagram - 8.5 kW – Drawing No. 0D8500
225
224
N1
225
224
0
13
13
225
224A
225A
224A
225A
TX
N2
13A
13
225B
224B
14
N2
77
VOLTAGE
REGULATOR
N1
BCR
331
6
4
9
7
BBA
11
22
4
0
6
162
0
66A
11
22
4
CONTROL PANEL BOX
66
0
77
4
4
0
6
162
66A
CB2
CLOSEST TO BEARING
BA
4
0
STATOR
162
2
4
2
6
0
11
66
77
55
10
9
8
7
6
5
22
4
0
3
2
1
55
C2
2
11
6
55
22
66A
77
66
11
44
33
22
GRD
351
224
194
23
4
56
23
194
345612
10111213 789
17
15
0
141617 15
224
13
18
14
66A
15A
13
239
225
13
351
13A
15A
0
13
F1F2
13
15
17
17
15
N1
SW1
AUTO
MANUAL
N2
44
11
351
239
1a
1
1b
SW2
CUSTOMER CONNECTION
0
CB1
240V GENERATOR
OUTPUT TO TRANSFER
SWITCH CONTACTOR
22
33
OFF
NEUTRAL CONNECTION
23
N2
N1
194
UTILITY FROM T/SW
UTILITY FROM T/SW
TRANSFER RELAY COIL
TRANSFER RELAY COIL
26 Generac®Power Systems, Inc.
Section 7 Electrical Data
Air-cooled 8.5 kW Generator Electrical Schematic - Drawing No. 0D8501
1
4
J2
2 1
3
2 1
8
14
16 17
15
11
13
12
10
9
J1
7
5 6
3 4
2
1
11
22
11
22
11
22
ELECTRONIC
VOLTAGE
REGULATOR
4
C2-10
4
0
6
162
CB2
C2-8
DIAGRAM KEY
BA - BRUSH ASSEMBLY
BCR - BATTERY CHARGE RELAY
CB1 - CIRCUIT BREAKER, MAIN OUTPUT
CB2 - CIRCUIT BREAKER, ALT. EXCITATION
D - DIODE
FS - FUEL SOLENOID
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
HTO - HIGH OIL TEMPERATURE SWITCH
IM1 - IGNITION MODULE, CYLINDER #1
IM2 - IGNITION MODULE, CYLINDER #2
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTER
SCR - STARTER CONTACTOR RELAY
SP1, SP2 - SPARK PLUGS
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
SM - STARTER MOTOR
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
13A
0
77
0
BA
FIELD
0
C2-7
2
DPE WINDING
(STATOR)
3
2 1
C2-1
BATTERY
CHARGER
0C2-11
6
2
1
13A
BATTERY CHARGE
WINDING
C2-4
0
0
C2-9
C1-6
0
225B
55
224B
77
0
ENGINE RUN
WINDING
(STATOR)
4
7174939
66
C2-3
66A
PRINTED CIRCUIT
225A
224A
C2-2
C1-4
CONTROL
HTO
BOARD
F2
13A
13
F1
BCR
6
0
66
0
0
SW2
14
0
LOP
C1-3
14
85
86
351
4
66A
221
55334
J2
4
1
J1
2
3 4 5 6 7
14
8 9
10
11 12 13 14 15 16 17
86
66A
23
239
194
15A
225
23
194
56
18
17
15
0
224
Section 7 Electrical Data
Air-cooled 8.5 kW Generator
Electrical Schematic - Drawing No. 0D8501
Generac®Power Systems, Inc. 27
225
224
14
225A
15
0
66A
225
15
239
224
224A
13
15A
17
17
56VA
1VA
11
TX
N2
22
N1
17
0
194
0
0
SCR
56
0
239
13
16
C1-5
C2-6
C2-5
194
23
N2
N1
11
23
15A
SW1
194
239
15
23
15
14
15
13
C1-1
16
SC FS
0
18
00
14
22
POWER WINDING
(STATOR)
11
C2-1
SM
IM1
IM2
SP1
SP2
D
D
SC
33
44
RED
BLACK
N2
N1
CB1
CUSTOMER
CONNECTIONS
NEUTRAL
120V
120V
240V
BATTERY
12V
CUSTOMER SUPPLIED
28 Generac®Power Systems, Inc.
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator Compartment – Drawing No. 0D8445-A
26
35
2
47
46
49
43
20
43
49
49
82
51
80
A
51
25
33
8
83
18
35
72
76
86
82
23
48
5
49
52
53
44
72
48
47
51
45
31
11
49
51
50
62
63
60
50
9
41
73
52
67
35
49
70
49
49
38
58
69
50
66
71
59
71
49
13
69
75
30
42
14
55
17
51
29
28
47
54
35
25
59
3
39
10
68
40
A
47
19
57
27
56
58
1
62
51
7
21
15
6
12
68
16
64
65
51
22
34
85
44
77
84
78
81
79
80
46
74
37
24
36
32
4
Generac®Power Systems, Inc. 29
ITEM PART NO. QTY. DESCRIPTION
1 0D8312 1 ASSEMBLY, ENCLOSURE BASE 2 0C6735 2 SUPPORT, ROOF FOLDING 3 0C7061 1 ENCLOSURE, FRONT 4 0C7062 1 ENCLOSURE, EXHAUST SIDE 5 0C7063 1 ENCLOSURE, SIDE & BACK 6 0C7064 1 ENCLOSURE, ROOF 7 0D8333 1 PANEL, ALTERNATOR DIVIDER 8 0C8101A 1 PANEL, MUFFLER BOX SIDE
9 0C8101B 1 COVER, MUFFLER BOX 10 0C8283 1 GASKET, DOOR SEAL 11 0C8284A 1 FOAM, BACK ENCLOSURE 12 0C8284B 1 FOAM, ROOF ENCLOSURE 13 0C8284C 1 FOAM, FRONT ENCLOSURE 14 0C8285 1 BRACKET, BATTERY SUPPORT 15 0C8899A 1 PAD, 24"X48" WITH MOUNTING HOLES 16 0D1128 1 PANEL, ENGINE DIVIDER 17 0D1605 1 BAFFLE, INTAKE 18 0D2538A 1 HINGE, LIFT OFF, TYPE B KNUCKLE 19 0D1839 2 BRACKET, TOP SUPPORT 20 0D1840 2 BRACKET, BOTTOM SUPPORT 21 0D2425 1 DUCT, BASE AIR 22 0D2588 1 GASKET, FRONT DIVIDER 23 0D2676 1 COVER, FRONT EXHAUST ENCLOSURE 24 0D2677 1 COVER, BACK EXHAUST ENCLOSURE 25 0D2979B 2 CLOTH, HARDWARE 266.7mm x 146mm 26 0D2979C 1 CLOTH, HARDWARE 543mm x 146mm 27 0D2979D 1 CLOTH, HARDWARE 266.7mm x 387.4mm
28** 0D3057A 1 FOAM, FRONT INTAKE BAFFLE 29** 0D3057B 1 FOAM, TOP INTAKE BAFFLE 30** 0D3057C 1 FOAM, BACK INTAKE BAFFLE
31 0D3057D 1 FOAM, BACK ENCL. STRIP 32 0D3059A 1 FOAM, EXHAUST SIDE ENCLOSURE
END
33 0D3059B 1 FOAM, EXHAUST SIDE ENCLOSURE
FRONT 34 0A2311 1 SCREW SWAGE 1/4-20 X 1 35 0D7176 24 WASHER, SELF LOCKING 36 0D3059D 1 FOAM, FRONT EXHAUST ENCLOSURE
COVER 37 0D3059E 1 FOAM, BACK EXHAUST ENCLOSURE
COVER 38 0C7781 2 DOOR, PAWL 39 0D3037 1 LATCH, QUARTER TURN LOCKING 40 0D2537 1 HINGE, LIFT OFF, TYPE A PIN 41 0D2538 1 HINGE, LIFT OFF, TYPE B PIN 42 0D3037A 1 LATCH, QUARTER TURN NON-LOCKING
ITEM PART NO. QTY. DESCRIPTION
43 0A2115 4 WASHER NYLON .250" 44 022097 7 WASHER LOCK M6-1/4" 45 022473 4 WASHER FLAT ¼" ZINC 46 036261 14 RIVET POP .125 X .129-.133/#30 47 047411 14 SCREW HHC M6-1.0 X 16 G8.8 48 043116 5 SCREW HHC M6-1.0 X 12 G8.8 49 0D3700 18 NUT, LOCKING FLANGE M6-1.0 50 083512 12 SCREW TAPTITE M8-1.25 X 16 BP 51 090388 33 SCREW TAPTITE M6-1.0 X 12 YC 52 092120 2 NUT LOCK TRIC M6 X 1.0 Y/ZNC 53 0D1606 1 HOUSING, FAN 54 0D3167 1 GASKET, BATTERY HOLD DOWN 55 0A3328 1 PLUG, PLASTIC 0.593" 56 055414 1 LUG SLDLSS #2-#8X17/64 CU 57 092079 1 SCREW TAPTITE M6-1.0X25 BP 58 0A1658 2 L/WASH SPECIAL ¼ 59 0C3906 2 SELF-ALIGN SCREW M6 HH 60 045771 4 NUT HEX M8-1.25 G8 YC
61* 0388040AJ0 1 CABLE, #6 RED BATTERY 38.5"
62 022145 8 WASHER FLAT 5/16" ZINC 63 022129 4 WASHER LOCK 5/16 64 074908 8 SCREW TAPTITE M5-0.8 X 10 BP 65 0D2346 1 HARNESS, ENGINE 66 023484F 1 BUSHING, SNAP SB-1000-12 67 043107 4 SCREW HHC M8-1.25 X 25 G8.8 68 0A7836 2 RIVET,1/8" X 0.126" - 0.375" LSH POP 69 0A8475 2 L/WASH SPECIAL #10 70 0912970069 1 ASSEMBLY,BASE/C-PNL GRND WIRE 71 0912970070 2 ASSEMBLY,BASE/DOOR GROUND WIRE 72 055450 2 PLUG PLASTIC 1.375 73 0D2023 10.5 GASKET, CLIP-ON SELF GRIPPING 74 0D3701 1 PLATE, "HOT" 75 0D3472 1 GROMMET 2.75 X 1/16 76 0C8742 1 EXTERNAL CONNECTION BOX 77 0C8911 1 POWER BLOCK 78 0D8442 1 HARNESS GENERATOR TO EXTERNAL
CONNECTION BOX 79 036937 2 SCREW PPHM #10-32 X 1 80 022152 5 WASHER LOCK #10 81 023897 2 WASHER FLAT #10 ZINC 82 022158 5 NUT HEX #10-32 STEEL 83 0D3059C 1 FOAM, EXHAUST FAN HOUSING 84 026850 1 WASHER SHAKPROOF EXT 1/4 STEEL 85 049813 1 NUT HEX M6-1.0 G8 YELLOW CHROME 86 0D2537A 1 HINGE, LIFT OFF, TYPE A KNUCKLE
* NOT SHOWN ** ITEMS INCLUDED IN KIT 0D3057
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Compartment – Drawing No. 0D8445-A
30 Generac®Power Systems, Inc.
36
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator Engine & Alternator – Drawing No. 0D8446
41
35
42
41
29
10
32
31
28
36
40
1
28
37
18
28
27
29
26
24
25
32
30
19
10
17
10
16
32
19
15
2
3
22
14
20
38
31
28
32
17
31
6
39
34
7
21
9
8
4
12
13
33
38
24
5
23
11
Generac®Power Systems, Inc. 31
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Engine & Alternator – Drawing No. 0D8446
ITEM PART NO. QTY. DESCRIPTION
1 0C6934 1 ADAPTOR, ENGINE 2 0D8062H 1 STATOR 3 0D8057H 1 ROTOR 4 0C6043A 1 CARRIER, REAR BEARING 5 0D8274 1 FAN, 12" CURVED BLADE 6 0D6634A 1 MUFFLER 7 0D3220 1 TAIL PIPE, MUFFLER 8 0D8314 1 PANEL, MUFFLER BASE
9 056482 1 BEARING 1.1811-2.8346 10 0C3168 3 5/16 SPECIAL LOCK WASHER 11 0D8313 1 BOLT, IHCS 3/8"-24 x 14.2" 12 0D1846 4 BOLT, IHCS M8-1.25 x 345mm 13 0C7038 1 BRACKET, ALTERNATOR MOUNTING 14 0D1647 1 DUCT, ALTERNATOR AIR 15 0D2558 1 GASKET, ALTERNATOR AIR DUCT 16 0C7038A 1 BRACKET, ENGINE MOUNTING 17 0C7758 4 RUBBER MOUNT 18 0388050AD0 1 CABLE, #6 48" BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3/8X 3/8 20 082121C 1 CLIP-J, VYNL COAT 0.625" ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 1.8 FT TAPE ELEC UL FOAM 1/8 X 1/2 23 049451 1 WASHER FLAT .406ID X 1.62OD 24 022237 5 WASHER LOCK 3/8 25 022511 4 SCREW HHC 3/8-16 X 1-1/4 G5 26 022131 4 WASHER FLAT 3/8 ZINC 27 039288 4 SCREW HHC M8-1.25 x 55 G8.8 28 022145 14 WASHER FLAT 5/16 ZINC 29 049820 4 NUT LOCK HEX M8-1.25 NYL INSERT 30 045756 2 SCREW TAPTITE M6-1.0X10 YC 31 022129 10 WASHER LOCK M8-5/16 32 022259 8 NUT HEX 5/16-18 STEEL 33 059637 2 SCREW TAPTITE 3/8-16 X 3/4 CZ 34 083512 4 SCREW TAPTITE M8-1.25 X 16 YC 35 074994 2.83 FT HOSE RES 1/2 LP GAS 36 057822 4 CLAMP HOSE #8 .53 - 1.00 37 052858 4 NUT LOCK M8 38 0C2824 3 SCREW TAP-R #10-32 x 9/16 39 025145 1 U-BOLT 5/16"-18 X 1.25" WITH SADDLE 40 0C4138 2 GASKET, EXHAUST PORT 41 048031C 2 CLAMP HOSE BAND 1/4" 42 030340 1.33 FT HOSE 1/4" I.D.
32 Generac®Power Systems, Inc.
38
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator Engine – Drawing No. 0D8674-C Part 1
3
39
37
34
36
35
140
34
22
66
2, 5, 19, 20, 39, 40, 47, 64, 93, 140
67
8, 11, 12, 13 4, 5, 6
68
16A, 16B, 17, 18
69
7, 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59, 60
70
48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59, 60, 62
71
27, 28, 29
72
3, 32, 33, 34, 35, 36, 40, 72
73
42
40
41
45
44
29
43
46
28
27
47
48
3
49
31
50
26
32
51
33
3
21
12
13
9
10
25
11
24
23
30
16B
16A
15
14
16A
8
53
55
56
54
57
18
17
19
20
7
6
5
4
62
3
2
52
63
64
1
65
58
59
60
61
Generac®Power Systems, Inc. 33
ITEM PART NO. QTY. DESCRIPTION
1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING WITH
SLEEVE 2 0C3008 1 SEAL, 38 I.D. CRANKSHAFT 3 090388 8 SCREW, TAPTITE M6-1.0 X 12 YC 4 0C5372 1 ASSEMBLY, BREATHER 5 0C3005 1 GASKET, BREATHER COVER 6 0C3003 3 SEPARATOR, OIL BREATHER 7 0D8067A 1 ASSEMBLY, HEAD #1 G&S 8 071983 4 RETAINER, PISTON PIN 20 9 0C2981C 1 ROCKER, COVER NO OIL FILL
10 045761A 4 STUD M8-1.25/10MM X 30 G5 ZINC 11 0C5848 2 PISTON, HC 12 021533 2 SET, PISTON RING 90MM 13 071980 2 PIN PISTON D20 14 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR
15 0C2983 1 SHAFT, GOVERNOR 16A 0C2985A 2 ROLLER BEARING, GOVERNOR PLATE 16B 0C2985B 1 ROLLER BEARING, GOVERNOR
17 0D4042 1 ASSEMBLY,GOVERNOR GEAR
18 0A7811 1 SPOOL, GOVERNOR MACHINED
19 0C2977 1 GASKET, CRANK CASE
20 0C5943 1 SEAL, OIL PASSAGE
21 0D4040E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE (GT-990)
21 0D4122E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE (GT-760) 22 0C2969 2 ASSEMBLY, CONNECTING ROD (GT-990) 22 0D3961 2 ASSEMBLY, CONNECTING ROD (GT-760) 23 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8 24 0C5313 1 SCREEN, OIL PICKUP 25 0D4123 1 ASSEMBLY, OIL PUMP 26 078699E 2 SLEEVE, SEAMED DOWEL 10 DIA. 27 0C3011 2 COVER, OIL RELIEF 28 0C3009 2 SPRING, OIL RELIEF 29 0C3010 2 BALL, 1/2D OIL RELIEF 30 093873 2 WASHER, LOCK RIB M6 31 0C5315 1 GEROTOR, OUTER 32 0C5998 1 CLAMP, OIL TUBE 33 0D1667 1 ARM, GOVERNOR 34 0C2991 2 E-RING, GOVERNOR ARM 35 0C2988 1 THRUST WASHER, GOVERNOR
ITEM PART NO. QTY. DESCRIPTION
36 0C2992 1 BUSHING, GOVERNOR LOWER 37 0C3971C 1 ASSEMBLY, DIPSTICK WITH HANDLE 38 0C5305 1 TUBE, DIPSTICK 39 0C3027 1 O-RING, OIL CLR 3/8 X 1/2 40 0C3007 1 SEAL, 42 I.D. CRANKSHAFT 41 0C5731 1 ASSEMBLY, HOUSING COVER WITH
SLEEVE 42 0C3006 9 SCREW, HHFC M10-1.5 X 55 43 0C8566 8 SCREW HHFC M6-1.0 X 20 44 093064 1 ASSEMBLY, OIL FILL CAP 45 0C8808 2 HOOK, LIFTING 46 0D2723B 1 ROCKER, COVER WITH OIL FILL 47 0C2979 2 GASKET, VALVE COVER 48 086515 8 KEEPER, VALVE SPRING 49 0D2274 4 RETAINER, VALVE SPRING 50 0D3867 4 SPRING, VALVE 51 078672 2 SEAL, VALVE STEM D7 52 0C5371 4 WASHER, VALVE SPRING 53 0D5326 4 NUT, JAM ROCKER ARM 54 0D6023 4 STUD, ROCKER ARM M8-1.0 x 57mm 55 0D5354 4 PIVOT, ROCKER ARM 56 0D5313 4 ROCKER ARM 57 0D6024 2 PLATE, PUSH ROD GUIDE 58 0C2976 12 SCREW HHFC M8-1.25 X 65 59 086516 2 VALVE, EXHAUST 60 0C2229 2 VALVE, INTAKE 61 083897 4 TAPPET, SOLID 62 0D8067B 1 ASSEMBLY, HEAD #2 G&S 63 088396D 4 PUSHROD, 144.6 64 0C2978 2 GASKET, HEAD 65 043790A 1 BARBED ELBOW 90 3/8NPT X 3/8
L0CKTITE 66 0D4010 1 KIT GASKET 67 0D4011 1 KIT PISTON & RINGS 68 0D4012 1 KIT BREATHER ASSEMBLY 69 0D4013 1 KIT GOVERNOR ASSEMBLY 70 0D8675A 1 KIT HEAD ASSEMBLY CYLINDER 1 71 0D8675B 1 KIT HEAD ASSEMBLY CYLINDER 2 72 0D4015 1 KIT OIL RELIEF 73 0D4016 1 KIT GEAR COVER
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Engine – Drawing No. 0D8674-C Part 1
34 Generac®Power Systems, Inc.
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator Engine – Drawing No. 0D8674-C Part 2
82
87
83
81
84
79
86
80
88
74
85
89
90
93
117
89
94
91
97
98
76
77
92
96
75
78
95
99
130
114
112
122
118
97
101
119
121
98
124
124
99
100
125
102
123
125
107
108
103
104
120
105
106
137
126
136
131
138
127
109
132
115
133
116
110
139
135
134
128
129
112
112
113
111
Generac®Power Systems, Inc. 35
ITEM PART NO. QTY. DESCRIPTION
74 0C5136A 2 KNOB, AIR CLEANER 75 0C3024 1 COVER, AIRBOX NG/LP 76 0C3040 1 PRE-CLEANER, 77 0C8127 1 ELEMENT, AIR CLEANER 78 0D8564A 1 ASSEMBLY, MIXER/AIRBOX 990
0D8564B 1 ASSEMBLY, MIXER/AIRBOX 760 79 0D2595 4 SCREW SHOULDER (8MM) M6-1.0 X 18 80 0D4417 4 WASHER,RUBBER 1/4" X 1/8" THICK 81 0C3025 1 SWITCH, OIL PRESS 82 0D3083 1 ASSEMBLY, OIL DRAIN HOSE 83 0C7292 1 NIPPLE, 3/4"-16 UNF 84 070185 1 FILTER, OIL D 69 X 64 LONG 85 075281 1 SWITCH, THERMAL 284F 86 0C1085 2 SCREW PPHM M3-0.5 X 8 87 043182 2 WASHER LOCK M3 88 035461A 2 BARBED STR 1/4NPT X 3/8 WITH VIBRA
SEAL 89 040173 4 CLAMP HOSE #5.5 .62 - .62 90 0C9806 2 HOSE, 3/8" I.D. X 6" LONG 91 0C3026 1 COOLER, OIL 92 0C9764 4 PLASTITE,1/4-15 X 3/4 93 0C3043 2 GASKET, MANIFOLD / PORT 94 0C7694 1 MANIFOLD CYLINDER 2 95 0C7693 1 MANIFOLD CYLINDER 1 96 0C3041 2 SLEEVE, RUBBER 97 070008 4 WASHER FLAT M8 SS 98 070006 4 WASHER LOCK M8 SSTL 99 040976 4 SCREW SHC M8-1.25 X 20 G12.9
100 0C3016A 1 PLATE, BACKING GT990 WITH OIL COOL 101 085011 1 INSULATOR ASSEMBLY IGNITION 102 0C3725B 1 FLYWHEEL ASSEMBLY 103 0C3031 1 FAN, NYLON 104 0C3032 1 PLATE, FAN 105 0A5992 2 WASHER SHAKEPROOF INT M8 SS 106 051754 2 SCREW HHC M8-1.25 X 12 G8.8 107 0C3033 1 WASHER, 25mm I.D.
ITEM PART NO. QTY. DESCRIPTION
108 0C3034 1 NUT,HEX M24 109 0C8549 1 SNORKEL, AIR INTAKE 110 0C3022A 1 HOUSING, BLOWER NG COOLER 111 0D1131 1 GUARD, FAN 112 045756 27 SCREW TAPTITE M6-1X10 YELLOW
CHROME 113 0C9763 4 NUT, GROMMET 1/4 PLUG 114 0C3036 1 HOSE, BREATHER 115 0C8919 1 BRACKET, STARTER 116 079246 1 SCREW HHC M6-1.0 x 16 WITH LOCK-
WASHER 117 0C3018 1 WRAPPER, UPPER CYLINDER 1 118 0C3019 1 WRAPPER, LOWER CYLINDER 1 119 0D1142A 1 WRAPPER, LOWER CYLINDER 2 120 0D1143 1 WRAPPER, UPPER CYLINDER 2 121 066849B 2 SCREW TAPTITE M5-0.8 X 8 BP 122 0C3053 1 ASSEMBLY, GROUND WIRE 123 0C3052 2 ASSEMBLY, IGNITION COIL 124 022097 4 WASHER LOCK M6-1/4 125 092079 4 SCREW TAPTITE M6-1.0 X 25 BP 126 0C3017 1 STARTER 127 0D4529 2 SPARKPLUG 128 022129 2 WASHER LOCK M8-5/16 129 061906 2 SCREW HHC M8-1.25 X 85 G8.8 130 082774 1 KEY, WOODRFF 4 X 19D 131 052859 1 NUT HEX LOCK M10-1.50 132 0C8468 1 SPRING, ANTI-LASH 133 0C3048 1 ROD, GOVERNOR CONTROL 134 0D3754 1 ASSEMBLY, GOVERNOR LEVER 135 0D3742 1 SPRING, GOVERNOR 136 0C8482 1 ASSEMBLY, GOVERNOR ADJUSTER 137 0D2576 1 SCREW SHC M10-1.5 X 70 G10.9 138 0D3743 1 SPRING, GOVERNOR IDLE 139 0D3705 1 ASSEMBLY, GOVERNOR ADJUSTER
BRACKET 140 0C2993 1 SEAL, GOVERNOR SHAFT
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Engine – Drawing No. 0D8674-C Part 2
36 Generac®Power Systems, Inc.
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator Control Panel Assembly – Drawing No. 0D8503-B
41
22
8,9
37
8,32
38
27
10
44
47
46
45
48
15
14
29 28
12
17
33
40
25
20
49
23 16
34
43
45
44
14
15
42
36
39
21
1
31
47
45
24
45
47
31
15
29 28
11
14
30
29 28
3
35
27
38
7
6
23
16
49
2
21
35
19
4
17
13
5
Generac®Power Systems, Inc. 37
ITEM PART 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 0A18010SRV 1 ASSEMBLY, BATTERY CHARGER ENGINE 3 0830490SRV 1 ASSEMBLY, POTTED REGULATOR 4 0C2174 1 RELAY, 12V 25A SPST 5 075210A 1 BLOCK 1 POSITION 6 0D3062 4 HEX STAND-OFF #6-32 x 3/8" 7 0D8615 1 ASSEMBLY, HOME STANDBY CONTROLLER 8 032300 2 HOLDER, FUSE 9 022676 1 FUSE, 15AMP X AGC15
10 033873 1 SWITCH, ROCKER 11 0D5045 1 DIN RAIL 12 023484E 1 SNAP BUSHING SB-687-8 13 075476 2 SCREW PPHM M4-0.7 x 16mm 14 022264 6 WASHER LOCK M4 15 051715 6 NUT HEX M4-0.7 16 043182 4 WASHER LOCK M3 17 043181 4 SCREW PHM M3-0.5 x 10mm 18 0D8443 1 DECAL, CONTROL PANEL (NOT SHOWN) 19 054502 1 CIRCUIT BREAKER 3 X 1 ETA 46-500-P 20 0D8438 1 CONTROL, PANEL BOTTOM 21 075235 4 SCREW HHC M5-0.8 x 30mm
ITEM PART NO. QTY. DESCRIPTION
22 0D5240 1 SWITCH, SPDT ON-MOM-ON 23 051714 4 NUT HEX M3-0.5 24 0D8502 1 NEUTRAL ISOLATOR 25 0A1661 2 RIVET POP .156 X .160-.164/#20 26 0D8441 1 HARNESS, CONTROL PANEL WIRE (NOT
SHOWN) 27 074908 4 SCREW TAPTITE, M5-0.8 x 10 BP 28 049226 6 WASHER LOCK M5 29 051716 6 NUT HEX M5-0.8 30 0C3910 1 TRANSFORMER 31 022507 2 SCREW HHC 1/4"-20 x 1/2" 32 099727 1 FUSE 5A X AGC5 33 046689 1 TERMINAL STRIP 34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 35 075475 4 SCREW PPHM M4-0.7 x 10mm 36 022985 2 WASHER FLAT #6 37 0D8439 1 COVER, CONTROL PANEL COMPONENT 38 092036 8 SCREW PPHMS/LW #6-32 x 1/4" 39 045770 2 SCREW HHC M5-0.8 x10mm 40 0C7171 1 COVER, CONTROL PANEL 41 0D3700 10 NUT FLANGE M6-1.0 NYLOCK 43 0A2311 1 SCREW SWAGE 1/4"-20 x 1" 44 0A1658 2 LOCKWASHER SPECIAL 1/4" 45 022473 3 WASHER FLAT 1/4" 46 038750 1 SCREW HHC M6-1.0 x 30mm 47 022097 3 WASHER LOCK M6-1/4" 48 049813 1 NUT HEX M6-1.0 49 031879 4 WASHER FLAT #4
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Control Panel Assembly – Drawing No. 0D8503-B
ITEM PART NO. QTY. DESCRIPTION
1 0D3086 1 BOX GTS LOAD CENTER 2 0D3092 1 COVER, 12 POSITION GTS LOAD CENTER 3 0C2237 1 TRANSFER SWITCH HOME STANDBY
100A2P250V 4 074908 6 SCREW TAPTITE M5-0.8 X 10 BP 5 024912 1 SCREW TAPTITE 1/4-20 X 5/8 BP 6 0A1658 1 LOCK WASHER, SPECIAL-1/4" 7 063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC 8 0D3030 1 BASE, MOUNTING 6 POLE 125A/240V 9 0A1495 4 SCREW TAPTITE M4-0.7X10 BP
10 0A1661 2 RIVET POP .156 X .160-.164/#20 11 022473 1 WASHER FLAT 1/4 ZINC 12 055450 1 PLUG HEYMAN DP1375
(10KW / 12KW / 13KW)
025034 1 PLUG STEEL 1.0625 STMPSN 3811
(14KW / 15KW / 16KW)
13 0D4684 1 HARNESS ADAPTER PLATE 14 0D3319 1 PANEL-SUB BREAKER BASE 15 056326 1 FT TRIM VINYL BLACK 1/8GP 16 022152 6 WASHER LOCK #10 17 087680 1 NUT WING M6-1.0 18 077441 1 HANDLE, TRANSFER SWITCH HOME
STANDBY
19 063378 4 HOLDER CABLE TIE 21 074138 2 LUG DIS QK NI-S 10X45 DEG BR/T
ITEM PART NO. QTY. DESCRIPTION
22 036933 6 SCREW PPHM #10-32 X 3/8" 23 077033 6 LUG SLDLSS 1/0-#14X9/16 AL/CU 24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V 25 028739 4 TIE WRAP 3.9" X .10" NAT'L UL 26 038150 2 WASHER FLAT #8 ZINC 27 0D3191 1 COVER, RELAY & TERM BLOCK 28 0D3088 1 WIRE HARNESS,GTS LOAD CENTER
(NOT SHOWN FOR CLARITY) 29 073591 2 FUSE HOLDER 30 073590A 2 ASSEMBLY FUSE 5A X BUSS HLDR73591 31 040213B 4 PCB SUPPORT SNAP-IN 1-3/8" 32 0C8037 3 CIRCT BRK 20 X 1 HOM120 33 0D3190 1 CIRCT BRK 20 X 2 HOM220 34 0C8036 5 CIRCT BRK 15 X 1 HOM115 35 0C8035 1 CIRCT BRK 30 X 2 HOM230 36 0D3320 1 COVER - HARNESS ENTRY 37 0D3093 1 HARNESS, GTS TO EXT CONN BOX
(10KW / 12KW / 13KW)
0D3926 1 HARNESS, GTS TO EXT CONN BOX
(14KW / 15KW / 16KW) 38 022264 2 WASHER LOCK M4 39 0A7215 4 SCREW SW 1/4-20X5/8 N WA JS500 40 0A2110 4 SCREW SWAGE 1/4-20 X 1/2 ZINC 41 075475 2 SCREW PPHM M4-0.7 X 10 42 0D3094 1 HARNESS,GTS TO MAIN PANEL
38 Generac®Power Systems, Inc.
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator GTS Load Center – Drawing No. 0D3996-C
12
37
17
18
24
10
13
1
19
25
42
14
4
15
8
31
7
9
29
30
36
40
35
34
22
9
27
23
16
26
38
6
11
5
4
3
16
22
21
23
41
33
32
34
2
39
Generac®Power Systems, Inc. 39
ITEM PART NO. QTY. DESCRIPTION
1 0D5694 1 CASTING, TWIN REGULATOR HOUSING 2 0C5765 1 SOLENOID, TWIN REGULATOR 3 0C4647 1 GASKET , SOLENOID 4 0C4680 1 PLUNGER, LP REGULATOR ASSEMBLY 5 0C6070 1 SPRING-SOLENOID, PLUNGER 6 022985 4 WASHER, FLAT #6 7 022264 4 WASHER, LOCK M4 8 075475 4 SCREW PPHM M4-0.7 X 10
9 0C5760A 1 JET, GN 410 ENGINE LP (7KW) 10 0C6606 2* BARBED STRAIGHT 1/2NPT x 1/2 11 097934 2* O-RING, CHECK VALVE 12 0C4645 2* ADJUSTER SCREW, TWIN REGULATOR 13 0C5761 2* LEVER, REGULATOR 14 0C5968 2* SUPPORT, INLET SEAL 15 0C6066 2* SEAL, INLET 16 0C5759 2* PIN, PIVOT ARM 17 0C5764 2 SPRING, REGULATOR
0C5764A 1 SPRING, REGULATOR (7KW)
18 070728 4 SCREW, PFHMS M3-0.5 x 5
070728 2 SCREW, PFHMS M3-0.5 x 5 (7KW) 19 0C6069 2* GASKET, DIAPHRAGM 20 0C5762 2* COVER, TWIN REGULATOR
ITEM PART NO. QTY. DESCRIPTION
21 045764 16 SCREW, TAPTITE M4X8 BP
045764 8 SCREW, TAPTITE M4X8 BP (7KW) 22 0C6731 2* RIVET, POP .118 X .125 23 0C6067 2* SUPPORT, DIAPHRAGM 24 0C4706 2* DIAPHRAGM, TWIN REGULATOR 25 0C6068 2* CAP, DIAPHRAGM SUPPORT 26 0C4643A 2* INLET, TWIN REGULATOR 11.11 DIA. 27 026073 1 PLUG, STANDARD PIPE 1/8 STEEL
SQUARE HEAD 28 0A4032 2* PIN, LIMITED ADJUSTMENT 29 0D3308 4 WASHER, FLAT M3 X 10mm O.D.
0D3308 2 WASHER, FLAT M3 X 10mm O.D. (7KW)
30 0C4643 1 INLET, TWIN REGULATOR NO HOLE -
NOT SHOWN (7KW) 31 028414A 1 BARBED STRAIGHT 1/8"NPT X 1/4" 32 0D5698A 1 JET IDLE PRIMER PHILLIPS HD 33 0C5760B 1 JET, GT760 CYL 1 NAT GAS 34 0C5760C 1 JET, GT760 CYL 2 NAT GAS 35 0C5760D 1 JET, GT 760 LP CYL 1 36 0C5760E 1 JET, GT760 LP CYL 2 37 0D3973 2 PLUG, EXPANSION 16mm
* A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY
Section 8 Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Regulator – Drawing No. 0D8720-B
12
20
28
21
32
25
10
11
24
10
34
36
37
10
8
7
2
5
4
3
6
37
33
32
FOR GT 760
18
17
1
15
16
14
13
26
ENGINE ONLY
35
29
18
19
23
22
24
25
20
22
23
19
12
15
14
11
27 31
29
16
13
28
26
17
9
21
40 Generac®Power Systems, Inc.
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission
Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be
designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifi­cation 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, dur­ing 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.
PURCHASERS/OWNERS 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 unap­proved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.
You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs.
The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “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 impor­tant 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 serv­ice, evidence must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:
ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS, INC. P.O. BOX 297 WHITEWATER, WI 53190
Part 1
Section 9 – 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.
Generac®Power Systems, Inc. 41
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 con­tinue 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 man­ufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsi-
ble for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such 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:
*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
Section 9 – Warranty
Air-cooled 8.5 kW Generator
1) Fuel Metering System:
1.2) LPG/Natural Gas carburetion assembly and its internal components.
a) Fuel controller (if so equipped) b) Mixer and its gaskets (if so equipped) c) Carburetor and its gaskets (if so equipped) d) Primary gas regulator (if so equipped) e) LP liquid vaporizer (if so equipped)
2) Air Induction System including:
a) Intake pipe/manifold b) Air cleaner
3) Ignition System including: a) Spark plug b) Ignition module
4) Catalytic Muffler Assembly (if so equipped) including: a) Muffler gasket b) Exhaust manifold
5) Crankcase Breather Assembly including: a) Breather connection tube
GENERAC POWER SYSTEMS "TWO YEAR" STANDARD WARRANTY FOR
®
"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"
For a period of two years or 2000 hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective under normal use and service, in accor­dance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Dealer. All transportation costs under the war­ranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac prepackaged emergency automatic standby generators sold and rated for use in "Standby" applications.
WARRANTY SCHEDULE
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):
• Engine - All Components
• Alternator - All Components
• Transfer System - All Components 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 Guardian generators that utilize non-Generac replacement parts.
• Any Generac Guardian generators used as rental or trailer mounted applications.
• Units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist.
• Costs of normal maintenance, adjustments, installation and start-up.
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or 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
Part No. 0D8444 Revision 0 (04/03/02) Printed in U.S.A.
Section 9 – Warranty
Air-cooled 8.5 kW Generator
Loading...