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Generac Power Systems 004692-2, Installation And Owner'S Manual, Page: 1 / 52

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GENERAC

POWER SYSTEMS,  INC.

R

R

Installation and

Owner’s Manual

Air-cooled, Prepackaged

Automatic Standby Generators

Models:
004692-2 (8.5 kW)

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!

DANGER

CENTURION

CENTURION

CENTURION

®

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

in life-support applications.

!

CENTURION

CENTURION

CENTURION

®

!

*This manual should remain with the unit.*

Summary of Contents for 004692-2

Page 1: ...atic Standby Generators Models 004692 2 8 5 kW DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY DANGER CENTURION CENTURION CENTURION Not intended for use as Primary Power in place of utility or in life...

Page 2: ...thers 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...

Page 3: ...sion 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 Manua...

Page 4: ...installed properly in strict compli ance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards Ke...

Page 5: ...ance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementione...

Page 6: ...lly damaging conditions 1 Low Oil Pressure Sensor 3 Overcrank 2 High Temperature Sensor 4 Overspeed There are LED readouts on the control panel to noti fy personnel that one of these faults has occurr...

Page 7: ...1 General Information Air cooled 8 5 kW Generator 1 4 THE GENERATOR Control Panel Air Filter Exhaust Enclosure Battery Compartment Fuel Inlet Oil Filter Oil Dipstick Data Decal Fuel Regulator Figure...

Page 8: ...m 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 00...

Page 9: ...hes water colum for natural gas or 10 inches water col umn 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 ho...

Page 10: ...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 CODE...

Page 11: ...ools 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...

Page 12: ...source voltage across transfer switch ter minals N1 and N2 Nominal line to line voltage should be 240 volts AC 5 Check UTILITY power source voltage across ter minals N1 and the transfer switch neutra...

Page 13: ...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 UTIL...

Page 14: ...ng the engine If this procedure or equipment are not available locate the nearest Generac Dealer and they can per form the adjustments NOTE A service fee may be charged for this adjustment 2 7 ENGINE...

Page 15: ...ill 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...

Page 16: ...ansfer switch to activate and connect load circuits to the standby power sup ply load terminal lugs T1 T2 connect to terminal lugs E1 E2 Upon restoration of utility source voltage above a pre set leve...

Page 17: ...n i e loads connected to the UTILITY power source Figure 3 2 6 Turn ON the UTILITY power supply to the trans fer switch using the means provided 7 Set the system to automatic operation as outlined in...

Page 18: ...otects the generator from damage by shutting it down if it happens to run faster than the preset limit This protection also prevents the gener ator from supplying an output that could potentially dama...

Page 19: ...n 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 Ret...

Page 20: ...rometer 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 obs...

Page 21: ...ve 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 an...

Page 22: ...pe 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...

Page 23: ...y if Repair is Needed FUEL Fuel lines and connections X M LUBRICATION Oil level X M Oil X AFTER BREAK IN AND Y Oil filter X AFTER BREAK IN AND Y COOLING Enclosure louvers X X W BATTERY Remove corrosio...

Page 24: ...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...

Page 25: ...SUPPLIED DO NOT LIFT BY THE ROOF LIFTING HOLES 4 CORNERS 30 2mm 1 19 ROUNDING LUG 3 4 NPT FUEL INLET GAS PRESSURE OF 11 14 WATER COLUMN REQUIRED ALL DIMENSIONS IN MILLIMETERS INCHES 76 2mm 3 00 PEA G...

Page 26: ...AY FS FUEL SOLENOID SP1 SP2 SPARK PLUGS SC STARTER CONTACTOR IC INLINE CONNECTOR F1 FUSE 15 AMP F2 FUSE 5 AMP SM STARTER MOTOR D DIODE BA BRUSH ASSEMBLY L E D ALARM INDICATORS 3 50 Hz Operation 4 SPAR...

Page 27: ...1a SW2 CONNECTION CUSTOMER SWITCH CONTACTOR 240V GENERATOR 0 CB1 23 N1 N2 194 351 66A 55 77 44 11 55 0 C2 3 1 2 CONTROL PANEL BOX 225B N1 13A N2 225B 224B 14 13A 66 TX 224 225 224A 225A 11 BCR 0 11 6...

Page 28: ...RAM KEY SC STARTER CONTACTER 2 1 5 3 4 J2 2 1 3 2 1 14 16 17 12 10 9 J1 7 5 3 2 1 F2 FUSE 5 AMP BA BRUSH ASSEMBLY CB2 CIRCUIT BREAKER ALT EXCITATION D DIODE SCR STARTER CONTACTOR RELAY 15 2 23 224 77...

Page 29: ...4 BATTERY CUSTOMER SUPPLIED SM 12V SC N2 N1 13 TX 56VA 1VA C2 6 C2 5 CB1 STATOR 14 RED BLACK C2 1 C1 1 C1 5 0 0 D D SCR 16 13 0 0 56 POWER N1 N2 UTILITY 240VAC INPUT RELAY TRANSFER 12Vdc COIL 17 17 15...

Page 30: ...240VAC TO TO GENERATOR OUTPUT PANEL MAIN DISTRIBUTION LC CIRCUIT BREAKER LOADS F1 F2 5A 600V FUSE XA XB LIMIT SWITCHES TS TERMINAL STRIP TR TRANSFER RELAY C2 GENERATOR COIL RECTIFIER LEGEND C1 UTILIT...

Page 31: ...ER CIRCUIT CIRCUIT BREAKER CONTROL PANEL MAIN DISTRIBUTION NEUTRAL WHITE NEUTRAL WHITE RED MAIN 2 BLACK MAIN 1 E1 E2 VIO INSIDE SWITCH CONNECTION NEUTRAL RED 194 N1 N2 OPEN 23 BLACK N1 N2 23 194 PANEL...

Page 32: ...30 Generac Power Systems Inc Section 7 Electrical Data Air cooled 8 5 kW Generator Wiring Diagram 12 Circuit Load Center Drawing No 0E7687...

Page 33: ...Generac Power Systems Inc 31 Section 7 Electrical Data Air cooled 8 5 kW Generator Wiring Diagram 12 Circuit Load Center Drawing No 0E7687...

Page 34: ...80 8 51 46 80 85 81 72 18 86 5 76 48 39 60 62 63 50 21 15 51 71 69 42 10 35 11 49 51 9 49 50 72 44 73 52 41 5 57 27 62 56 1 19 A 40 12 71 59 64 50 38 34 22 89 68 16 69 14 13 54 47 55 75 49 30 17 3 59...

Page 35: ...ER LOCK M6 1 4 45 022473 8 WASHER FLAT 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 1...

Page 36: ...38 21 7 13 33 12 38 17 32 31 28 31 20 19 10 17 15 32 16 2 22 39 9 8 6 37 14 3 40 1 32 25 10 30 19 28 27 28 32 31 41 10 18 35 36 29 42 36 36 5 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW...

Page 37: ...EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VYNL COAT 0 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 1 8 FT TAPE ELEC UL FOAM 1 8 X 1 2 23 049451 1 WASHER FLAT 406ID X 1 62OD 24 022237 5 WASHER LO...

Page 38: ...0 32 35 55 33 36 20 57 58 59 61 60 64 62 63 65 1 2 6 3 32 33 34 35 36 40 72 27 28 29 2 5 19 20 39 40 47 64 93 140 16B 56 54 23 25 30 16A 34 34 15 16A 17 18 22 71 73 72 66 8 14 13 12 10 7 9 4 5 Section...

Page 39: ...RING GOVERNOR ARM 35 0C2988 1 THRUST WASHER GOVERNOR 36 0C2992 1 BUSHING GOVERNOR LOWER ITEM PART NO QTY DESCRIPTION 37 0C3971C 1 ASSEMBLY DIPSTICK WITH HANDLE 38 0C5305 1 TUBE DIPSTICK 39 0C3027 1 O...

Page 40: ...11 102 99 92 101 113 112 105 107 108 103 111 109 125 123 145 96 95 143 130 114 75 78 77 76 99 118 8 97 121 124 124 119 122 125 137 120 127 126 115 116 136 138 32 142 29 134 139 135 Section 8 Exploded...

Page 41: ...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...

Page 42: ...9 27 45 46 44 48 47 10 3 49 35 13 17 5 21 35 23 49 29 21 17 4 2 38 6 7 33 2 20 27 15 40 41 39 45 44 43 1 30 15 11 47 45 24 45 47 49 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generato...

Page 43: ...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 0D844...

Page 44: ...37 26 21 8 34 38 32 34 38 33 23 9 13 15 36 27 30 12 22 3B 22 16 3A 31 7 9 16 3 6 11 5 2 39 42 Generac Power Systems Inc Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator GTS Load C...

Page 45: ...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...

Page 46: ...loded Views and Parts Lists Air cooled 8 5 kW Generator Regulator Drawing No 0D8720 D 17 12 28 11 20 10 32 25 24 19 23 22 22 15 26 14 13 16 29 18 8 28 12 10 11 27 31 4 5 3 2 10 17 1 26 15 14 6 7 16 13...

Page 47: ...TOR 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 DIAPHRAG...

Page 48: ...46 Generac Power Systems Inc Section 9 Notes Air cooled 8 5 kW Generator...

Page 49: ...Generac Power Systems Inc 47 Section 9 Notes Air cooled 8 5 kW Generator...

Page 50: ...responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made...

Page 51: ...ing 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 repla...

Page 52: ...rity 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...

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