Generac 004692-2 User Manual

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Installation and

Owner’s Manual

Air-cooled, Prepackaged

Automatic Standby Generators

Models: 004692-2 (8.5 kW)

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

CENTURION

Not intended for use as Primary Power in place of utility or

in life-support applications.

CENTURION

*This manual should remain with the unit.*

CENTURIONCENTURION

GENERAC

POWER SYSTEMS, INC.

CENTURIONCENTURION

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 This generator will operate using either vapor withdrawn liquid propane (LP) or natural gas (NG).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 any portion of this manual is not understood, contact the nearest Generac Authorized Dealer for starting, operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel 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, 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, read instructions that, if not strictly complied with, may result in personal injury or property damage.

After this heading, read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, read explanatory statements that require special emphasis.

These safety warnings cannot eliminate the hazards that they indicate. Common sense and strict 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 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:

• 004692-2 – 8.5 kW NG, 8.5 kW LP, V-twin GT-990 Engine

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all 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 the generator ensures a minimum number of problems and keep operating expenses at a minimum. See a Generac Authorized Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, simply contact a Generac Authorized Dealer for assistance. Service technicians are factory-trained and are capable of handling all of service needs.

When contacting a Generac Authorized Dealer about parts and service, always supply the complete model number and serial number of the unit as given on its data decal, which is located on the generator. See Figure 1.2 or Figure 1.3 in Section 1.4 for decal location.

Model No. ____________ Serial No. ______________

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AUTHORIZED

DEALER LOCATION

To locate the nearest GENERAC AUTHORIZED

DEALER, please call this number:

1-800-333-1322

DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

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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 NEC Requirement for Arc Fault Circuit

Interruption Breaker for Bedrooms ..............4

1.3.1 Section 210.12 Arc Fault Circuit

Interrupter Protection ........................4

1.4 The Generator ..............................................5

1.5 Specifications ................................................6

1.5.1 Generator ..........................................6

1.5.2 Engine ................................................6

1.6 System Set LED ............................................7

1.7 Fuel Requirements and Recommendations....7

1.8 Fuel Consumption ........................................7

1.9 Reconfiguring the Fuel System ......................7

1.10 Location ........................................................8

1.10.1 Generator ..........................................8

1.10.2 Transfer Switch ..................................8

1.11 Battery Installation ........................................8

1.12 The Battery ....................................................9

Section 2 – Post Installation Start-up

and Adjustments ......................10

2.1 Before Initial Startup ..................................10

2.2 Check Transfer Switch Operation................10

2.3 Electrical Checks ........................................10

2.4 Generator Tests Under Load ......................11

2.5 Checking Automatic Operation ....................11

2.6 Adjusting the Regulator

(Natural Gas Only)........................................11

2.7 Engine Governor Adjustment ......................12

2.7.1 Additional Corrosion Protection ......13

2.8 Voltage Regulator Adjustment......................13

Section 3 – Operation ....................................13

3.1 Break-in Procedure......................................13

3.2 Using the AUTO/OFF/MANUAL Switch ........13

3.2.1 “Auto” Position ..................................13

3.2.2 “Off” Position....................................14

3.2.3 “Manual” Position ............................14

3.3 Automatic Transfer Operation ....................14

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 ......................................16

3.7.1 Low Oil Pressure Switch ..................16

3.7.2 High Temperature Switch ................16

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

4.5.1 8.5kW Generators ............................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....................................32

Section 9 – Notes ............................................46

Section 10 – Warranty....................................48

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 using a procedure, work method or operating technique Generac does not specifically recommend, satisfy yourself that it is safe for others. Also make sure the procedure, work method or operating technique choosen 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

• For safety reasons, Generac recommends that the

installation, initial start-up and maintenance of this equipment is carried out by a Generac Authorized Dealer.

• The engine exhaust fumes contain carbon monox-

ide, which can be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must be installed properly, in strict compliance with applicable codes and standards. Following installation, 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 venti-

lating air is critical to correct generator operation. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can 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 physically or mentally fatigued.

• Inspect the generator regularly, and contact the

nearest Generac Authorized Dealer for parts needing repair or replacement.

• Before performing any maintenance on the genera-

tor, 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 work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• The National Electrical Code (NEC) requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground. Local electrical codes also may require proper grounding of the generator electrical system.

• After installing this home standby electrical 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 there are any questions pertaining to fire extinguishers, consult the 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, 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.

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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, it is 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 a loss or damage is discovered 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 personnel that one of these faults has occurred.

1.3 NEC REQUIREMENT FOR ARC FAULT CIRCUIT INTERRUPTION BREAKER FOR BEDROOMS

The 2002 National Electric Code (NEC) introduced a requirement for new construction. This new requirement indicates the need for Arc Fault Circuit Interrupters to be used to protect the complete branch circuit that feeds a dwelling bedroom. The actual NEC requirement is indicated below.

1.3.1 SECTION 210.12 ARC FAULT CIRCUIT INTERRUPTER PROTECTION

1. Definition: An arc fault circuit interrupter is a device intended to provide protection from the effects of arc faults by recognizing characteristics unique to arcing and by functioning to de-energize the circuit when an arc fault is detected.

2. Dwelling Unit Bedrooms: All branch circuits that supply 125 volt, single-phase, 15 and 20 ampere outlets installed in dwelling unit bedrooms shall be protected by an arc fault circuit interrupter listed to provide protection of the entire branch circuit.

Section 210.12 requires that AFCI protection be provided on branch circuits that supply outlets (receptacle, lighting, etc.) in dwelling bedrooms. The requirement is limited to 15 and 20 ampere, 125 volt circuits. There is no prohibition against providing AFCI protection on other circuits or in locations other than bedrooms. Because circuits are often shared between a bedroom and other areas such as closets and hallways, providing AFCI protection on the complete circuit would comply with 210.12.

If during the installation of the Guardian Home Standby system the decision is made to provide back up power to a bedroom branch circuit, then the circuit breaker in the Guardian Transfer Switch should be replaced with an Arc Fault Circuit Interrupter.

It is most important that breakers only be switched like for like. For instance, if replacing a 15A breaker, it MUST be replaced with a 15A AFCI breaker. Likewise, a 20A breaker MUST be replaced with a 20A AFCI.

These AFCI breakers are available at the nearest hardware store.

Siemens Item # Description

Q115AF 15A Single Pole AFCI

Q120AF 20A Single Pole AFCI

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4 Generac®Power Systems, Inc.

DANGER

Generac®Power Systems, Inc. 5

Section 1 — General Information

Air-cooled 8.5 kW Generator

1.4 THE GENERATOR

Figure 1.1 – 8.5 kW, V-Twin GT-990/760 Engine

Exhaust Enclosure

Oil Dipstick

Air Filter

Oil Filter

Data Decal

Control Panel

Battery Compartment

Fuel Regulator

Fuel Inlet

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 525

at -17.8° C (0° F) Cold-cranking Amperes Minimum Weight 470 Pounds Output Sound Level 68 db (A) Normal Operating Range -20°F (28.8°C to 104°F (40°C)

* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power

decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.

1.5.2 ENGINE

Model 004692

Type of Engine GT-990/760 Number of Cylinders 2 Rated Horsepower 26 @ 3,600 rpm Displacement 992cc Cylinder Block Aluminum w/Cast Iron Sleeve Valve Arrangement Overhead Valves Ignition System Solid-state w/Magneto Recommended Spark Plug RC12YC Spark Plug Gap 0.50 mm (0.020 inch) Compression Ratio 9.5:1 Starter 12 Vdc Oil Capacity Including Filter Approx. 1.7 Qts Recommended Oil Filter Generac Part # 70185 Recommended Air Filter Generac Part # 0C8127 Operating RPM 3,600

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Generac®Power Systems, Inc. 7

1.6 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.

1.7 FUEL REQUIREMENTS

AND RECOMMENDATIONS

With LP gas, use only the vapor withdrawal system. This type of system uses the vapors formed

above the liquid fuel in the storage tank.

The engine has been fitted with a fuel carburetion system that meets the specifications of the 1997 California Air Resources Board for tamper-proof dual fuel systems. The unit will run on natural gas or LP gas, but it has been factory set to run on natural gas. Should the primary fuel need to be changed to LP gas, the fuel system needs to be reconfigured. See Section 1.9 for instructions on reconfiguration of the fuel system.

Recommended fuels should have a Btu content of at least 1,000 Btus per cubic foot for natural gas; or at least 2,520 Btus per cubic foot for LP gas. Ask the fuel supplier for the Btu content of the fuel.

Required fuel pressure for natural gas is 5 inches to

7 inches water colum (0.18 to 0.25 psi); and for liquid propane, 11 inches to 14 inches of water column (0.4 to 0.5 psi).

NOTE:

Any piping used to connect the generator to the fuel supply should be of adequate size to ensure the fuel pressure NEVER drops below 4 inches water colum for natural gas or 10 inches water column for liquid propane for all load ranges.

1.8 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.

1.9 RECONFIGURING THE FUEL SYSTEM

To reconfigure the fuel system from NG to LP, follow these steps:

NOTE:

The primary regulator for the propane supply is NOT INCLUDED with the generator. A fuel pressure of 11 to 14 inches of water column (0.4 to 0.5 psi) to the fuel inlet of the generator MUST BE SUPPLIED.

1. Turn off the gas supply. (if connected)

2. Open the roof and remove the door.

3. Remove the battery. (if installed)

4. Remove the engine air in baffle located on the left-

hand side of the battery compartment. Two M6 screws are located on top of the baffle and two M6 screws are located on the inside of the baffle towards the back.

5. Remove the small hose clamp and hose from the

fuel regulator. It may be necessary to pry the hose off of the brass fitting using a screwdriver to gently lift up the hose edge.

6. Remove the small brass hose fitting from the reg-

ulator casting.

7. Place the small fuel jet, thread side first, into the

threaded hole originally occupied by the brass hose fitting (Figure 1.4).

8. Using a short No. 2 Phillips screw driver, thread

the small fuel jet into the regulator casting. Do not over tighten.

Figure 1.4 - Demand Regulator

OSE

OUSING PORT

JUSTER

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

004692-1 114 170 1.33/45.8 1.98/72.5

TLET PORT

FUEL H

BRASS HOSE FITTIN

IDLE CIRCUI

POR

1/8 NP

BRASS HOSE

FITTIN

REW

REGULAT H

MAL

FUEL JE

9. Apply thread sealant to the threads of the hose fitting and replace it into the regulator body.

10. Re-attach the small hose and hose clamp and tighten as necessary.

11. Replace the engine air in baffle using the four M6 screws.

12. Identify both brass adjustment screws on the regulator.

NOTE:

One adjustment screw can be accessed from the front of the unit and the second can be accessed from the back of the unit enclosure by removing the plastic hole plug. The screw can be turned with a long flat blade screwdriver.

13. To adjust the system to run on LP fuel, turn BOTH adjuster screws 1/2 TURN CLOCKWISE. The system should now be set for maximum power and best perfomance. DO NOT, UNDER

ANY CIRCUMSTANCES, REMOVE THE SET PINS FROM THE REGULATOR HOUSING. THIS WILL VOID THE WARRANTY.

14. It may be necessary to make minor adjustments to the preset adjustment screw settings to achieve maximum power, particularly at higher altitudes. If experiencing problems with the unit producing maximum power, follow the procedure in Section

2.6 (Adjusting the Fuel Regulator).

1.10 LOCATION

1.10.1 GENERATOR

Install the generator set, in its protective enclosure, outdoors, where adequate cooling and ventilating air is always available. Consider these factors:

• Install the unit where air inlet and outlet openings

will not become obstructed by leaves, grass, snow, etc. If prevailing winds will cause blowing or drifting, consider using a windbreak to protect the unit.

• Install the generator on high ground where water

levels will not rise and endanger it.

• Allow sufficient room on all sides of the generator

for maintenance and servicing. A good rule is to allow three feet of space on all sides.

• Where strong prevailing winds blow from one

direction, face the generator air inlet openings to the prevailing winds.

• Install the generator as close as possible to the fuel

supply, to reduce the length of piping.

• Install the generator as close as possible to the

transfer switch. HOWEVER, REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE.

1.10.2 TRANSFER SWITCH

The transfer switch shipped with this generator is rated 100 amps maximum at 120/240 volts AC single phase. The enclosure of the transfer switch is NEMA

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.

1.11 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 con-

tactor) to the battery post indicated by a positive, POS or (+).

4. Connect the black battery cable (from frame

ground) to the battery post indicated by a negative, NEG or (—).

NOTE:

Damage will result if battery connections are made in reverse.

◆

Section 1 — General Information

Air-cooled 8.5 kW Generator

8 Generac®Power Systems, Inc.

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Generac®Power Systems, Inc. 9

Figure 1.5 – Battery Cable Connections

NOTE:

The generator is equipped with a battery trickle charger that is active when the unit is set up for automatic operation. With the battery installed and utility power source voltage available to the transfer switch, the battery receives a trickle charge while the engine is not running, to prevent self-discharge. The trickle charger is designed to help extend the life of the battery by maintaining the battery when the unit is not running. The trickle charge feature cannot be used to recharge a discharged battery.

1.12 THE BATTERY

Servicing of the battery is to be performed or 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, 525 cold-cranking 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 body before touch-

ing the battery by first touching a grounded metal surface.

Be sure the AUTO/OFF/MANUAL switch is set to the OFF position before connecting the battery cables. If the switch is set to AUTO or MANUAL, the generator can crank and start as soon as the battery cables are connected.

Be sure the utility power supply is turned off, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

Section 1 — General Information

Air-cooled 8.5 kW Generator

DANGER

10 Generac®Power Systems, Inc.

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, 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.

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-to-neutral 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 not to proceed until certain that generator AC voltage and frequency are correct and within the stated limits. Generally, if both AC frequency and voltage are high or low, the engine governor requires adjustment. If frequency is correct, but voltage is high or low, the generator’s voltage regulator requires adjustment.

Section 2 — Post Installation Start-up and Adjustments

Air-cooled 8.5 kW Generator

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Generac®Power Systems, Inc. 11

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).

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.

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 trans-

fer switch, using the means provided (such as a UTILITY main line circuit breaker).

3. Manually set the transfer switch to the UTILITY

position, i.e., load terminals connected to the UTILITY power source side.

4. Turn ON the UTILITY power supply to the trans-

fer switch, using the means provided (such as a UTILITY main line circuit breaker).

5. Set the AUTO/OFF/MANUAL switch to AUTO. The

system is now ready for automatic operation.

6. Turn OFF the UTILITY power supply to the trans-

fer switch.

With the AUTO/OFF/MANUAL switch at AUTO, the engine should crank and start when the utility source power is turned OFF. After starting, the transfer switch should connect load circuits to the standby side. Let the system go through its entire automatic sequence of operation.

With the generator running and loads powered by generator AC output, turn ON the UTILITY power supply to the transfer switch. The following should occur:

• After about six seconds, the switch should transfer

loads back to the UTILITY power source.

• About one minute after 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 experiencing 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.

Section 2 — Post Installation Start-up and Adjustments

Air-cooled 8.5 kW Generator

DANGER

12 Generac®Power Systems, Inc.

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.

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, locate the nearest Generac Dealer 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 (Figure 2.3).

Figure 2.3 — V-twin Engine Governor

Adjustment

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 a hand, push the governor arm to the closed throttle position. Make sure the idle spring does not stretch at all.

7. Restart the unit.

8. Slowly turn the idle adjust screw to adjust the noload idle frequency to 63-63.5 Hz.

9. The governor is now set.

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

V-twin

Adjustment

Screw

(Both Sides)

Adjustment

Screw

(One Side Only)

Set Pin

(Both Sides)

Adjustment Screw

Idle Spring

Governor Shaft

(Rotate Clockwise)

Governor Clamp Bolt

No Load Idle Adjustment Screw

Generac®Power Systems, Inc. 13

Section 3 — Operation

Air-cooled 8.5 kW Generator

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:

The access panel on top of the control panel must be removed to adjust the voltage regulator.

NOTE:

The voltage regulator is housed above the 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.

Figure 2.5 – Voltage Adjustment Potentiometer

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”. Replace the oil with synthetic oil as recommended in Section 4.3, “Changing the Engine Oil”.

11. The generator is now ready for service.

3.2 USING THE AUTO/OFF/MANUAL

SWITCH (FIGURE 3.1)

3.2.1 “AUTO” POSITION

Selecting this switch position activates fully automatic system operation. It also permits starting and exercising the engine every seven days with the setting of the exercise timer (see Section 3.6). This position also is used for remote starting, when it is set up.

Figure 3.1 – Generator Control Panel



◆

Full Load Speed Adjust Screw

FUSE

15A

MAN.

OFFAUTO

SET

EXERCISE

TIME

Locat e your nearest dealer at :

POWER SYSTEMS, INC.

FLASHINGGREEN LED=

4FLASHIN G RED LEDS =

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

N OUTILITYS E NSE

EX ER CIS E RNOT SET

14 Generac®Power Systems, Inc.

Section 3 — Operation

Air-cooled 8.5 kW Generator

3.2.2 “OFF” POSITION

This switch position shuts down the engine. This position also prevents automatic operation.

3.2.3 “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.

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).

2. Be sure that normal UTILITY power source volt-

age is available to transfer switch terminal lugs N1 and N2.

3. Set the generator’s AUTO/OFF/MANUAL switch to

AUTO.

4. Set the generator’s main circuit breaker to its ON

(or closed) position.

With the preceding steps complete, the generator will start automatically when utility source voltage drops below a preset level. After the unit starts, loads are transferred to the standby power source. Refer to Section 3.4, “Sequence of Automatic Operation”.

3.4 SEQUENCE OF AUTOMATIC OPERATION

The generator’s control panel houses a control logic circuit board. This board constantly monitors utility power source voltage. Should that voltage drop below a 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).



Generac®Power Systems, Inc. 15

Do not attempt to activate the transfer switch manually until all power voltage supplies to the switch have been positively turned off. Failure to turn off all power voltage supplies may result in 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).

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.

Figure 3.2 – Manual Transfer Switch Operation

3.5.2 TRANSFER BACK TO UTILITY POWER

SOURCE

When utility power has been restored, transfer back to that source and shut down the generator. This can be accomplished as follows:

1. Set the generator’s main circuit breaker to its OFF (or open) position.

2. 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.

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).

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.

3.6 SETTING THE EXERCISE TIMER

The generator is equipped with an exercise timer. Once it is set, the generator will start and exercise once every seven days, on the day of the week and at the time of day the following sequence is completed. During this exercise period, the unit runs for 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) permits selection of the day and time for system exercise. To select the desired day and time of day, the following sequence must be performed at that time.

1. Verify that the AUTO/OFF/MANUAL switch is set to AUTO.

2. Hold down the “Set Exercise Time Switch” until the generator starts (approximately 10 seconds) and then release. During this time all the red LEDs on the control panel will flash to indicate board is resetting itself.

3. The generator will start and run for approximately 12 minutes and then shut down on its own. The exerciser will then be set to run at that time of day every week.

NOTE:

The exerciser will only work in the AUTO mode and will not work correctly unless this procedure is performed. The exerciser will need to be reset every time the 12-volt battery is disconnected and then reconnected. The exerciser WILL NOT work if 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.



Section 3 — Operation

Air-cooled 8.5 kW Generator

DANGER

16 Generac®Power Systems, Inc.

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. The generator will automatically restart and the LED on the generator control panel will reset once the temperature has returned to a safe operating level.

Figure 3.3 – Low Oil Pressure and

High Temperature Switches

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 the 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, the engine will not crank or start. Replace the fuse using only an identical 15-amp replacement.

The generator panel’s 5 amp fuse protects the battery charge circuit against overload. If the fuse element has melted open, battery charging capabilities will not be possible. Replace the fuse using only an 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. For engine oil recommendations, see Section 4.3.1. To check the engine oil level, proceed as follows (Figure 4.2):

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.



Section 4 — Maintenance

Air-cooled 8.5 kW Generator

Low Oil Switch

High Temp Switch

Oil Drain Hose

Oil Filter

FUSE

15A

OFFAUTO

SET

EXERCISE

TIME

MAN.

Locat e your nearest dealer at :

POWER SYSTEMS, INC.

FLASHINGGREEN LED=

4FLASHIN G RED LEDS =

SYSTEM SET

LOW OIL

HIGH TEMP.

OVER SPEED

OVER CRANK

N OUTILITYS E NSE

EX ER CIS E RNOT SET

Generac®Power Systems, Inc. 17

2. Remove the dipstick and wipe it dry with a clean cloth.

3. Install the dipstick; then, remove it again. The oil level should be at the dipstick “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

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, 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.

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 for oil capacities.

Figure 4.3 – Oil Drain Hose and Filter

4.4 CHANGING THE OIL FILTER

Change the engine oil filter as follows:

1. With the oil drained, remove the old oil filter by turning it counterclockwise.

2. Apply a light coating of clean engine oil to the gasket of the new filter. See Section 1.5.1 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 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 1.1, for the location of the air cleaner. Use the following procedure:

1. Turn the two screws counterclockwise to loosen (Figure 4.4).

2. Remove the cover and air filter.

3. Wipe away dust or debris from inside of the air box and around edges.

4. Install the new air cleaner into the air box.



Section 4 — Maintenance

Air-cooled 8.5 kW Generator

Oil Dipstick

Oil Fill

Oil Drain Hose

Oil Filter

18 Generac®Power Systems, Inc.

5. Install the cover. Turn the two cover screws clockwise to tighten.

See the “Service Schedule,” Section 4.11 for air cleaner maintenance. See Section 1.5.1 for air filter replacement part number.

Figure 4.4 — V-twin Engine Air Cleaner

4.6 SPARK PLUG(S)

Reset the spark plug(s) gap or replace the spark plug(s) as necessary. See Section 4.11 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 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. 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

Lead-acid batteries present a risk of fire because they generate hydrogen gas. The following procedures are to be followed:

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

• DO NOT SMOKE when near the battery;

• DO NOT cause flame or spark in battery area; and

• Discharge static electricity from body before touching the battery by first touching a grounded metal surface.

Be sure the utility power supply is turned off, or sparking may occur at the battery posts as the cables are attached and cause an explosion.

4.8 ADJUSTING VALVE CLEARANCE

After the first 50 hours of operation, adjust the valve clearance in the engine.

Important: If feeling uncomfortable about doing this

procedure or the proper tools are not available, please contact the Generac Authorized Dealer for service assistance. This is a very important step to insure the longest life for the engine.

To adjusting valve clearance:

• Make sure the engine is at room temperature.

• Make sure that the spark plug wire is removed

from the spark plug and out of the way.

• Remove the four screws attaching the valve cover

with a #2 or #3 phillips screwdriver.

• Make sure the piston is at Top Dead Center (TDC)

of its compression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a large socket and socket wrench to rotate the nut and hence the engine. While watching the piston through the spark plug hole. The piston should move up and down. The piston is at TDC when it is up as high as it can go.

• Loosen the rocker jam nut. Use an 10mm allen

wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance is

0.002-0.004 inch (0.05-0.1 mm).

NOTE:

The rocker arm jam nut must be held in place as the pivot ball stud is turned.

When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change.

• Install new valve cover gasket.

• Re-attach the valve cover.

Figure 4.6 - Valve Clearance Adjustment

NOTE:

Start all four screws before tightening or it will not be possible to get all the screws in place. Make sure the valve cover gasket is in place.

• Re-attach the spark plug wire to the spark plug.

• Repeat the process for the other cylinder.

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)

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.

The maximum ambient temperature for the generator is 48.9° C (104° F).

Section 4 — Maintenance

Air-cooled 8.5 kW Generator

Pivot Ball

Jam Nut

Stud

Rocker

Arm

Valve Stem

20 Generac®Power Systems, Inc.

4.10 ATTENTION AFTER SUBMERSION

If the generator has been submerged in water, it must not be started and operated. Following any submersion in water, have a Generac Authorized Dealer thoroughly clean and dry the generator.

4.11 OUT OF SERVICE PROCEDURE

4.11.1 REMOVAL FROM SERVICE

If the generator cannot be exercised every seven days, and it is to be out of service longer than 90 days, 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.

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). 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, for type and size.

4. Clean and wipe the entire generator.

5. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly.

6. Open the fuel shutoff valve.

7. Start the unit by moving the AUTO/OFF/MANUAL switch to MANUAL. Allow the unit to warm up thoroughly.

8. Stop the unit and set the AUTO/OFF/MANUAL switch to AUTO.

9. Turn on the utility power to the transfer switch.

10. The generator is now ready for service.

NOTE:

If the battery was dead or disconnected, the exercise timer must be reset.

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 the nearest Generac Authorized Dealer.

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action Inspect Change Clean W = Weekly R = Replace as Necessary M = Monthly * = Notify Dealer Y = Yearly

if Repair is Needed.

FUEL

Fuel lines and connections* 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 regulator

is 11-14” water column (0.4-0.5 psi) for LP, and 5-7” water colum (0.18-0.25 psi) for natural gas.

The AUTO/OFF/MANUAL switch 1. Defective switch 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 the nearest Generac Authorized Dealer for assistance.

Generac®Power Systems, Inc. 23

Section 6 — Mounting Dimensions

Air-cooled 8.5 kW Generator

Drawing No. 0D3739-B

)

[

] OU

SSU

[

]

[

]

G U

[

36.0"

]

O OU

[

8 [

]

[

]

] ]

3 9

[

]

] [

]

[

]

[

]

[

)

PEN AREA

14mm

INIM

NIT

LL AR

46.2"

172.3

UIRED

F 11-14"

EL INLET

PRE

ATER COLUMN RE

4" NPT F

ABLE A

NDIN

REMOVE PLUG FOR ACCESS

10.2"

INCHES

IN: N

ILLIMETERS

*ALL DIMEN

IDE VIEW

5.9"

HT I

90.7

.19"

0.2mm

47"

193

RNER

T LIFT BY THE R

IFTIN

27.7"

8.14"

48.5"

232

NT VIEW

3.00" M

RAVEL

6.2mm

12"

IF SUPPLIED

23.5"

24.5"

IDE VIEW

EFT

)

CUSTO

SP2

SP1

OCK

SSU

1 - 20 Vac Sense Transformer

CIC

316

SCR

8618

66A

3J25

351

5618

351

24 Generac®Power Systems, Inc.

Section 7 — Electrical Data

Air-cooled 8.5 kW Generator Wiring Diagram - Drawing No. 0D8500-B

DIAGRAM KE

BA - BRUSH ASSEMBL BCR - BATTERY CHARGE RELA

B1 - MAIN OUTPUT BREAKE CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATIO D - DIOD

DSW - PCB MOUNTED DIP SWIT FS - FUEL SOLENOI F1 - FUSE 15 AM F2 - FUSE 5 AM

RD - CONTROL PANEL GROUN

HTO - HIGH OIL TEMPERATURE SWIT IC - INLINE CONNECT ICT - INTERCONNECTION TERMINAL IM1 - IGNITION MODULE, CYLINDER # IM2 - IGNITION MODULE, CYLINDER # LOP - LOW OIL PRE

- STARTER CONTACT R - STARTER CONTACTOR RELA

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT W2 - SET EXERCISE SWIT

M - STARTER MOT TB - INSULATED TERMINAL BL TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

RE SWIT

ENGINE WIRIN

HARGE

PRINTED CIRCUIT BOAR

BLA

MER SUPPLIE

L.E.D - ALARM INDICATOR

NTR

2 - Remote Not Aut

3 - 50 Hz Operatio

4 - SPAR

Generac®Power Systems, Inc. 25

313

Section 7 — Electrical Data

Air-cooled 8.5 kW Generator

Wiring Diagram - 8.5 kW – Drawing No. 0D8500-B

NTROL PANEL B

LOSEST TO BEARIN

VOLTA

REGULAT

TAT

AUT

240V GENERAT TPUT TO TRANSFE

WITCH CONTACT

240VA

RELAY

NEUTRAL

NNE

12Vdc TRAN

UTILITY INPU

TOME

MANUA

NNECTI

26 Generac®Power Systems, Inc.

Section 7 — Electrical Data

Air-cooled 8.5 kW Generator Electrical Schematic - Drawing No. 0D8501-B

SSU

)

OPW2225

9423

8194

02-9

)

72-8

)

2-1

ELECTRONI

VOLTA

REGULAT

BA - BRUSH ASSEMBL BCR - BATTERY CHARGE RELA CB1 - CIRCUIT BREAKER, MAIN OUTPU CB2 - CIRCUIT BREAKER, ALT. EXCITATIO D - DIOD FS - FUEL SOLENOI F1 - FUSE 15 AM F2 - FUSE 5 AM HTO - HIGH OIL TEMPERATURE SWIT IM1 - IGNITION MODULE, CYLINDER # IM2 - IGNITION MODULE, CYLINDER # LOP - LOW OIL PRE

- STARTER CONTACTE R - STARTER CONTACTOR RELAY

SP1, SP2 - SPARK PLUG

W1 - AUTO / OFF / MANUAL SWIT W2 - SET EXERCISE SWIT M - STARTER MOT

TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.

2-1

STATOR

DIAGRAM KE

RE SWIT

HARGE

BATTERY CHAR

WINDIN

ENGINE R

WINDIN

STATOR

PRINTED CIRCUI

BOAR

NTR

)

Section 7 — Electrical Data

Air-cooled 8.5 kW Generator

Electrical Schematic - Drawing No. 0D8501-B

Generac®Power Systems, Inc. 27

240VA

TILIT INP

12V

TRANSFE

TOME

NNECTION

BLA

TOME

PPLIE

WINDIN

STATOR

POWE

ONCNCNO

)

TRGBLU

TRY

28 Generac®Power Systems, Inc.

Section 7 — Electrical Data

Air-cooled 8.5 kW Generator Electrical Schematic - 12 Circuit Load Center - Drawing No. 0E7815

12Vdc TRANSE

240VA

TS T

ENERAT

NTROL PANE

BLA

TO GENERAT

IRCUIT BREAKE

NEUTRA

NNECTI

INSIDE SWIT

NEUTRAL (WHITE

RED (MAIN 2

240VAC T MAIN DISTRIBUTI

BLACK (MAIN 1

BLU/WH

20A/120V CIRCUIT 1

15A/120V CIRCUIT

LEGEN ATS-AUTOMATIC TRANSFER SWIT

1-UTILITY COIL & RECTIFIE

2-GENERATOR COIL & RECTIFIE F1,F2-5A, 600V FUS LC-CIRCUIT BREAKER (LOADS TR-TRANSFER RELA TS-TERMINAL STRI XA,XB-LIMIT SWITCHE

20A/120V CIRCUIT

15A/120V CIRCUIT

20A/240V CIRCUIT

BRN/WH

YEL/WH

A/240V CIRCUIT

20A/240V CIRCUIT

TOME

IRCUI

NNECTI

15A/120V CIRCUIT

20A/120V CIRCUIT

VIO/WH

RG/WH

15A/120V CIRCUIT 1

Generac®Power Systems, Inc. 29

ONO

6205

TRY

)

Section 7 — Electrical Data

Air-cooled 8.5 kW Generator

Electrical Schematic - 12 Circuit Load Center - Drawing No. 0E7815

12Vdc TRANSE

240VA

TS T

ENERAT

NTROL PANE

BLA

TO GENERAT

IRCUIT BREAKE

NEUTRA

NNECTI

INSIDE SWIT

NEUTRAL (WHITE

RED (MAIN 2

240VAC T MAIN DISTRIBUTI

BLACK (MAIN 1

LEGEN ATS-AUTOMATIC TRANSFER SWIT C1-UTILITY COIL & RECTIFIE

2-GENERATOR COIL & RECTIFIE F1,F2-5A, 600V FUS LC-CIRCUIT BREAKER (LOADS TR-TRANSFER RELA TS-TERMINAL STRI XA,XB-LIMIT SWITCHE

15A/120V CIRCUIT

20A/120V CIRCUIT

BRN/WH

YLW/WH

A/240V CIRCUIT

15A/120V CIRCUIT

TOME

IRCUI

NNECTI

15A/120V CIRCUIT

30 Generac®Power Systems, Inc.

Section 7 — Electrical Data

Air-cooled 8.5 kW Generator Wiring Diagram - 12 Circuit Load Center - Drawing No. 0E7687

Generac®Power Systems, Inc. 31

Section 7 — Electrical Data

Air-cooled 8.5 kW Generator

Wiring Diagram - 12 Circuit Load Center - Drawing No. 0E7687

32 Generac®Power Systems, Inc.

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator Enclosure – Drawing No. 0F0100-A

Generac®Power Systems, Inc. 33

ITEM PART NO. QTY. DESCRIPTION

1 0D8312 1 ASSEMBLY, ENCLOSURE BASE 2 0C6735 2 SUPPORT, ROOF FOLDING 3 0F0063 1 ENCLOSURE, FRONT 4 0C7062 1 ENCLOSURE, EXHAUST SIDE 5 0F0066 1 ENCLOSURE, SIDE & BACK 6 0E9873 1 ENCLOSURE, ROOF 7 0D8333 1 PANEL, ALTE RNATOR DIVIDER 8 0C8101A 1PANEL, MUFFLER BOX SIDE 9 0C8101B 1 COVER, MUFFLER BOX

10 0C8283 1 GASKET, DOOR S

EAL 11 0C8284A 1FOAM, BACK ENCLOSURE 12 0C8284B 1 FOAM, ROOF ENCLOSURE 13 0C8284C 1 FOAM, FRONT ENCLOSURE 14 0C8285 1 BRACKET, BATTERY SUPPORT 15 0C8899A 1PAD, 24"X48" WITH MOUNTING HOLES

16 0D1128 1 PANEL, ENGINE DIVIDER 17 0E4244 1 BAFFLE, INTAKE 18 0D2538A 1HINGE, 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 0E4245 1 FOAM, FRONT INTAKE BAFFLE 29 0E4245A 1FOAM, TOP INTAKE BAFFLE 30 0E4245B 1 FOAM, BACK INTAKE BAFFLE

31 0D3057D 1 FOAM, BACK ENCL. STRIP 32 0D3059A 1FOAM, EXHAUST SIDE ENCLOSURE

END

33 0D3059B 1 FOAM, EXHAUST SIDE ENCLOSURE

FRONT 34 0E2874 1 SCREW HHTR 1/4-20 X 3/4 35 0D7176 24 WASHER, SELF LOCKING 36 0D3059D 1 FOAM, FRONT EXHAUST ENCLOSURE

COVER 37 0D3059E 1 FOAM, BACK EXHAUST ENCLOSU

COVER 38 0C7781A 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 1LATCH, QUARTER TURN NON-LOCKING 43 0A2115 4 WASHER NYLON .250" 44 022097 9 WASHER LOCK M6-1/4" 45 022473 8 WASHER FLAT ¼" ZINC

ITEM PART NO. QTY. DESCRIPTION

46 0F0710 14 RIVET POP 0.125" X 0.337" 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 0D4662 11 SCREW HHTT M8-1.2 X 20 BP 51 090388 35 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 SPECI

AL 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" (NOT

SHOWN) 62 022145 10 WASHER FLAT 5/16" ZINC 63 022129 6 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 ASSEMB LY, B ASE/C-PNL GRND WIRE 71 0912970070 2 ASSEMB LY, B ASE/DOOR GROUND WIRE 72 055450 2 PLUG PLASTIC 1.375 73 0E5968 11 GASKET, EXTRUDED TRIM 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 051713 2 WASHER FLAT M5 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 1HINGE, LIFT OFF, TYPE A KNUCKLE 87 0E4321 1 PANEL, EXHAUST ALIGNMENT 88 0E1330A 1GROMMET, 38.1 CROSS SLIT WITH

HOLE 89 0E9692 1 BRACKET, REGULATOR MOUN

TING

90 042907 2 SCREW HHC M8-1.25 X 16mm

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator

Compartment – Drawing No. 0F0100-A

34 Generac®Power Systems, Inc.

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator Engine & Alternator – Drawing No. 0D8446-C

Generac®Power Systems, Inc. 35

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator

Engine & Alternator – Drawing No. 0D8446-C

ITEM PART NO. QTY. DESCRIPTION

1 0C6934 1 ADAPTOR, ENGINE 2 0D8062H 1 STATOR 3 0D8057H 1 ROTOR 4 0C6043A 1CARRIER, 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, HHCS 3/8"-24 x 14.2" 12 0D1846 4 BOLT, HHCS M8-1.25 x 345mm 13 0C7038 1 BRACKET, ALT ERNATOR MOUNTIN

G 14 0D1647 1 DUCT, ALT ERNATOR AIR 15 0D2558 1 GASKET, ALT ERNATOR AIR DUCT 16 0C7038A 1BRACKET, ENGINE MOUNTING 17 0C7758 4 RUBBER MOUNT 18 0388050AD0 1 CABLE, #6 48" BLACK BATTERY 19 0C2417A 1EARTH 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 BP 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 BP 34 0D4662 4 SCREW 5/16-18X3/4" HH THD ROLL 35 074994 3 FT HOSE RES 1/2 LP GAS 36 057822 4 CLAMP HOSE #8 .53 - 1.00 37 0F0462 4 NUT HEX

W/TOOTH WSHR M8-1.25 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. 41 048031C 2 CLAMP HOSE BAND 1/4" 42 030340 1.33 FT HOSE 1/4" I.D.

36 Generac®Power Systems, Inc.

140

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator Engine – Drawing No. 0E8774-G Part 1

93 64 47 40 39 20 19

72 40 36

2 28

35 34 33 32

Generac®Power Systems, Inc. 37

ITEM PART NO. QTY. DESCRIPTION

1 0C5729 1 ASSEMBLY, CRANKCASE HOUSING

WITH SLEEVE

2 0E9843 1 SEAL, 38 I.D. CRANKSHAFT 3 090388 3 SCREW, TAPTITE M6-1.0 X 12 YC 4 0C5372 1 ASSEMBLY, BREATHER 5 0C3005 1 GASKET, BREATHER COVER 6 0E3372B 3 SEPARATOR, OIL BREATHER 7 0D8067A 1 ASSEMB LY, H E AD #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 0E2985 2 PISTON, HC 12 021533 2 SET, PISTON RING 90MM 13 0E1466 2 PIN PISTON 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 0

A7811 1 SPOOL, GOVERNOR MACHINED 19 0C2977 1 GASKET, CRANK CASE 20 0C5943 1 SEAL, OIL PASSAGE 21 0E4357E 1 ASSEMBLY, CRANKSHAFT HORIZONTAL

DIRECT DRIVE 22 0E3223 2 ASSEMB LY, C ONNECTING ROD 23 0D2157 2 SCREW SHC M6-1.0 X 50 G8.8 24 0E6098 1 SCREEN, OIL PICKUP 25 0D4123A 1 ASSEMBLY, OIL PUMP 26 078699E 2 SLEEVE, SEAMED DOWEL 10 DIA. 27 0C3011 2 COVER, OIL R

ELIEF 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 36 0C2992 1 BUSHING, GOVERNOR LOWER

ITEM PART NO. QTY. DESCRIPTION

37 0C3971C 1 ASSEMB LY, D I P STICK WITH HANDLE 38 0C5305 1 TUBE, DIPSTICK 39 0C3027 1 O-RING, OIL CLR 3/8 X 1/2 40 0E9842 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 080318 8 SCREW HHFC M6-1.0 X 25 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 SPRIN

G 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 072694 4 STUD, ROCKER ARM PIVOT 54 0D3998 4 NUT HEX M8-1.0 G8 YEL CHR 55 0C3027 2 O-RING, 3/8" X 1/2" 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 V

ALVE, INTAKE 61 083897 4 TAPPET, SOLID 62 0D8067B 1 ASSEMB LY, H E AD #2 G&S 63 0D9853D 4 PUSHROD, 147 64 0C2978 2 GASKET, HEAD 65 043790A 1BARBED 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 GE

AR COVER

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator

Engine – Drawing No. 0E8774-G Part 1

38 Generac®Power Systems, Inc.

01113

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator Engine – Drawing No. 0E8774-G Part 2

123, 14

Generac®Power Systems, Inc. 39

ITEM PART NO. QTY. DESCRIPTION

74 0C5136A 2KNOB, AIR CLEANER 75 0C3024 1 COVER, AIRBOX NG/LP 76 0C3040 1 PRE-CLEANER, 77 0C8127 1 ELEMENT, AIR CLEANER 78 0D8564A 1 ASSEMB LY, MIXER/AIRBOX 990

0D8564B 1 ASSEMB LY, 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 ASS

EMBLY, OIL DRAIN HOSE 83 0C7292 1 NIPPLE, 3/4"-16 UNF 84 070185B 1 OIL FILTER 85 075281 1 SWITCH, THERMAL 284F 86 0F2094 2 SCREW, M3-0.5 X 6 SEMS 87 88 035461A 2BARBED STR 1/4NPT X 3/8 WITH VIBRA

SEAL 89 0C7649 4 CLAMP HOSE .38-.87 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 0C3041A 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 1PLATE, BACKING WITH OIL COOLER 101 0E4997 1 GROUND WIRE CONNECTOR 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. 108 0C3034 1

NUT,HEX M24

109 0C8549A 1 SNORKEL, AIR INTAKE

ITEM PART NO. QTY. DESCRIPTION

110 0C3022A 1 HOUSING, BLOWER NG COOLER 111 0D1131 1 GUARD, FAN 112 045756 25 SCREW TAPTITE M6-1X10 YELLOW

CHROME 113 0C9763 4 NUT, GROMMET 1/4 PLUG 114 0C3036A 1HOSE, BREATHER 115 022145 1 WASHER FLAT 5/16-M8 ZINC 116 022129 1 WASHER LOCK M8-5/16 117 0C3018 1 WRAPPER, UPPER CYLINDER 1 118 0C3019 1 WRAPPER, LOWER CYLINDER 1 119 0D1142A 1 WRAPPE

R, LOWER CYLINDER 2 120 0D1143 1 WRAPPER, UPPER CYLINDER 2 121 0E6043 2 SCREW TAPTITE M5-0.8 X 8 ZP 122 0F1177 1 ASSEMBLY, GROUND WIRE 123 0F1338B 1 ASSY, I GN COIL W/DIODE NO ADV 124 022097 4 WASHER LOCK M6-1/4 125 092079 4 SCREW TAPTITE M6-1.0 X 25 BP 126 0E4271 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 0E5343 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 0E0486 1 SCREW SHC M10-1.5 X 75 G10.9 138 0D3743 1 SPRING, GOVERNOR IDLE 139 0D3705 1 ASSEMBLY, GOVERNOR ADJUSTE

BRACKET 140 0C2993 1 SEAL, GOVERNOR SHAFT 142 045771 1 NUT HEX M8-1.25 G8 143 0D6147 7 SCREW HHFC M6-1.0 X 10mm 144 0E8152 1 O-RING 0.49" I.D. X 0.07" THICK 145 0F1338A 1 ASSY, I GN COIL W/DIODE NO ADV

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator

Engine – Drawing No. 0E8774-G Part 2

40 Generac®Power Systems, Inc.

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator Control Panel Assembly – Drawing No. 0E7974-F

Generac®Power Systems, Inc. 41

ITEM PART NO. QTY. DESCRIPTION

1 0E7886A 1CIRCUIT BREAKER 30A X 2P 240V (7KW)

0E7886C 1 CIRCUIT BREAKER 40A X 2P 240V

(8.5KW)

0E7886D 1 CIRCUIT BREAKER 45A X 2P 240V

(11KW)

0E7886E 1 CIRCUIT BREAKER 50A X 2P 240V

(12KW)

0E7886F 1 CIRCUIT BREAKER 60A X 2P 240V

(13KW)

0E7886G 1 CIRCUIT BREAKER 70A X 2P 240V

(15KW)

20A1801 1 ASSEMBLY, BATTERY CHARGER

GINE 3 083049 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

0D8615A 1 ASSEMBLY, HOME STANDBY

CONTROLLER (7KW) 8 032300 2 HOLDER, FUSE 9 022676 1 FUSE, 15AMP X AGC15

10 0E4494 1 SWITCH, ROCKER DPDT ON-OFF-ON 11 0E7890 1 CIRCUIT BRE

AKER MOUNTING

BRACKET

12 023484E 1 SNAP BUSHING 13 075476 4 SCREW PPHM M4-0.7 x 16mm 15 0E6480 6 NUT HEX LOCK M4-0.7 NYLON INSERT 17 0C1085 4 SCREW PPHM M3-0.5 X 8mm 18 0D8443 1 DECAL, CONTROL PANEL (NOT SHOWN) 19 054502 1 CIRCUIT BREAKER 3 X 1 ETA 46-500-P

053623 1 CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P

(7KW)

20 0E7870 1 CONTROL, PAN

EL BOTTOM

0E7871 1 CONTROL, PANEL BOTTOM (7KW)

21 075235 4 SCREW HHC M5-0.8 x 30mm

ITEM PART NO. QTY. DESCRIPTION

22 0D5240 1 SWITCH, SPST (ON)-ON N/O 23 0D9784 6 NUT HEX LOCK M3-0.5 NYLON INSERT

0D9784 4 NUT HEX LOCK M3-0.5 NYLON INSERT

(7KW) 24 0D8502 1 NEUTRAL CONNECTOR 26 0D8441 1 HARNESS, CONTROL PANEL (NOT

SHOWN)

0E0120 1 HARNESS, CONTROL PANEL WIRE (NOT

SHOWN) (7KW) 27 074908 4 SCREW TAPTITE, M5-0.8 x 10 BP 29 082025 6 NUT HEX LOCK M5-0.8 NYLON INSERT 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 BLOCK TERMINAL STRIP 20A 4 X 6 X

1100V 34 063617 1 RELAY PANEL 12VDC DPDT 10A 240VAC 35 075475 4 SCREW PPHM M4-0.7 x 10mm 36 043180 2 WASHER FLAT M4 37 0D8439 1 COVER, CONTROL PANEL COMPONENT

0E0119 1 COVER, CONTROL PANEL COM

PONENT

(7KW) 38 092036 8 SCREW PPHMS/LW #6-32 x 1/4" 39 045770 2 SCREW HHC M5-0.8 x10mm 40 0E7866 1 COVER, CONTROL PANEL

0E7867 1 COVER, CONTROL PANEL (7KW) 41 0D3700 8 NUT FLANGE M6-1.0 NYLOK 42 0912970069 1 ASSEMB LY, ROOF/DOOR GROUND WIRE 43 0E2874 1 SCREW HHTR 1/4"-20 X 3/4" 44 0A1658 2 WASHER LOCK SPECIAL 1/4" 45 022473 3 WASHER FLAT 1/4"-

M6 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 6 WASHER FLAT #4

031879 4 WASHER FLAT #4 (7KW)

50 023897 2 WASHER FLAT #10

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator

Control Panel Assembly – Drawing No. 0E7974-F

42 Generac®Power Systems, Inc.

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator GTS Load Center – Drawing No. 0E7973-B

Generac®Power Systems, Inc. 43

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 100A 2P 250V 3A 077220 1 COIL UTILITY 3B 077220A 1 COIL STANDBY 3C 082574 1 INSULATOR-SIDEWALL (NOT SHOWN) 3D 084464 1 LIMIT SWITCH OPERATION (NOT SHOWN)

4 074908 6 SCREW HHTT M5-0.8 X 10

5 024912 1 SCREW HHTT 1/4-20 X 5/8

60A1658 1 LOCK WASHER

, SPECIAL-1/4" 7 063617 1 RELAY PANEL 12VDC DPDT 10A@240VAC 8 0E7889 1 12 CIRCUIT LOAD CENTER 125A/240V 90A1495 4 SCREW HHTT M4-0.7 X 10

10 0A1661 2 RIVET POP .156" X .675" 11 022473 1 WASHER FLAT 1/4-M6 ZINC 12 055450 1 PLUG PLASTIC 1.375 13 0D4684 1 HARNESS ADAPTER PLATE 14 0E7900 1 SUBPLATE, LOAD CENTER 15 056326 10.5" TRIM VINYL BLACK 1/8"GP 16 022152 6 WASHER LOCK #10 17 064526 2 SCREW H

WHS #6-25 X 3/8" 18 0E6155 1 ARM EXTENDER PIN 19 063378 4 HOLDER CABLE TIE 20 0D3094 1 HARNESS,GTS TO MAIN PANEL 21 074138 2 LUG QUICK DISCONNECT NI-S 10X45 DEG BRASS / TIN 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" 26 0A2110 4 SCREW SWAGE 1/4-20 X 1/2" ZINC 27 0D3191 1 COVER, RELAY & TERMINAL BLOCK 28 0D3088 1 WIRE HARNESS,GT

S LOAD CENTER (NOT SHOWN FOR CLARITY) 29 073591 2 FUSE HOLDER 30 073590A 2FUSE 5A X BUSS 31 040213B 4 PCB SUPPORT SNAP-IN 1-3/8" 32 0E7888C 3 CIRCUIT BREAKER 20A 1P 33 0E7888 1 CIRCUIT BREAKER 20A 2P

34 0E7888B 5 CIRCUIT BREAKER 15A 1P 35 0E7888A 1CIRCUIT BREAKER 30A 2P 36 0D3320 1 COVER - HARNESS ENTRY 37 0D3093 1 HARNESS

, GTS TO EXT CONN BOX

0D8597 1 HARNESS, GTS TO EXT CONN BOX (8.5KW) 38 075475 2 SCREW PPHM M4-0.7 X 10 39 0A7215 4 SCREW SW 1/4"-20 X 5/8" WITH WASHER 40 0E6193 1 BRACKET, ARM EXTENDER

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator

GTS Load Center – Drawing No. 0E7973-B

44 Generac®Power Systems, Inc.

Section 8 — Exploded Views and Parts Lists

Air-cooled 8.5 kW Generator Regulator – Drawing No. 0D8720-D

Generac®Power Systems, Inc. 45

ITEM PART NO. QTY. DESCRIPTION

1 0D5694 1 CASTING, TWIN REGULATOR HOUSING 2 0F3154 1 SOLENOID COIL, 12VDC 3 0C4647 1 GASKET , SOLENOID 4 0D4166 1 PLUNGER, LP REGULATOR ASSEMBLY 5 0C6070 1 SPRING-SOLENOID, PLUNGER 6 043180 4 WASHER, FLAT M4 7 022264 4 WASHER, LOCK M4 8 075475 4 SCREW PPHM M4-0.7 X 10 9 0C5760E 1 JET, GN 410 ENGINE LP (7KW)

10 0C6606 2* BARBED ST

RAIGHT 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, I NLET SEAL

15 0C6066 2 SEAL, INLET 16 0C5759 2 PIN, PIVOT ARM 17 0C5764 2 SPRING, REGULATOR

0C5764A 2 SPRING, REGULATOR (7KW)

18 070728 4 SCREW, PFHMS

M3-0.5 x 5 19 0C6069 2 GASKET, DIAPHRAGM 20 0C5762 2 COVER, TWIN REGULATOR 21 045764 16 SCREW, TAPTITE M4X8 BP 22 0C6731 2 RIVET, POP .118 X .125 23 0C6067 2 SUPPORT, D IAPHRAGM 24 0C4706 2 DIAPHRAGM, TWIN REGULATOR 25 0C6068 2 CAP, D I APHRAGM SUPPORT 26 0C4643A 2INLET, TWIN REGULATOR 11.11 DIA. 27 026073 1 PLUG, STANDARD PIPE 1/8"

STEEL SQUARE HEAD

026073 2 PLUG, STANDARD PIPE 1/8" STEEL SQUARE HEAD (7KW) 28 0A4032 2* PIN, LIMITED ADJUSTMENT 29 0D3308 4 WASHER, FLAT M3 X 10mm O.D. 30 024310 1 PLUG, STANDARD PIPE 1/2" STEEL SQUARE HEAD (7KW) 31 028414A 1BARBED STRAIGHT 1/8"NPT X 1/4" 32 0D5698A 1 JET IDLE PRIMER PHILLIPS HD (V-TWIN ONLY ) 37 0D3973 1 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-D

46 Generac®Power Systems, Inc.

Section 9 — Notes

Air-cooled 8.5 kW Generator

Generac®Power Systems, Inc. 47

Section 9 — Notes

Air-cooled 8.5 kW Generator

48 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.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.

As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect , improper maintenance or 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 10 – 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. 49

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.

(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 10 – 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

Part No. 0F0091 Revision B (11/15/04) Printed in U.S.A.

Section 10 – Warranty

Air-cooled 8.5 kW Generator

GENERAC POWER SYSTEMS "TWO YEAR" LIMITED WARRANTY FOR CENTURION

"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be 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 Centurion prepackaged emergency automatic standby generators sold and rated for use in "Standby" applications.

WARRANTY SCHEDULE

YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):

• Engine - All Components

• Alternator - All Components

• Transfer System - All Components Steel enclosures are warranted against rusting for the first year of ownership only. Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty. Nicks, srapes, dents or scratches to the painted enclosure should be repaired promptly by the owner.

All warranty expense allowances are subject to the conditions defined in Generac's Warranty Policies, Procedures and Flat Rate Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Generac Centurion generators that utilize non-Generac replacement parts.

• Generac Centurion generators utilizing non-Generac transfer switches.

• Repairs performed by individuals other than Centurion/Generac authorized dealers.

• Any Generac Centurion generators used as rental or trailer mounted applications.

• Air-cooled units used for prime power in place of existing utility power where utility power is present or in place of utility power where utility power service does not normally exist.

• Steel enclosures that are rusting due to the improper installation, location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised.

• Costs of normal maintenance, adjustments, installation and start-up.

• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as 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 and/or insect infestation.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or 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.

• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e., cranes, hoists, lifts, etc,)

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICAL LY, GE NERAC 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 L I ABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES

ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.

This warranty gives you specific legal rights.You also have other rights from state to state.

GENERAC

POWER SYSTEMS, INC.

P.O. BOX 297 • WHITEWATER, WI 53190

Revision 10/01/04

Generac 004692-2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual