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POWER SYSTEMS, INC.

GENERAC

POWER SYSTEMS, INC.

Installation and

Owner’s Manual

Air-cooled, Prepackaged

Automatic Standby Generators

Models:
004692-0 (8.5 kW)

DEADLY EXHAUST FUMES.

OUTDOOR INSTALLATION ONLY!!

DANGER

Not intended for use as Primary Power in place of utility or in life-
support applications.

Содержание Centurion 004692-0

Страница 1: ...Installation and Owner s Manual Air cooled Prepackaged Automatic Standby Generators Models 004692 0 8 5 kW DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY DANGER Not intended for use as Primary Power in place of utility or in life support applications ...

Страница 2: ...u and others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment We strongly recommend that the operator read this Owner s Manual and thoroughly understand all instructions before using this equip ment We also strongly recommend in...

Страница 3: ...t 12 Section 3 Operation 13 3 1 Break in Procedure 13 3 2 Using the Auto Off Manual Switch 13 3 2 1 Auto Position 13 3 2 2 Off Position 13 3 2 3 Manual Position 13 3 3 Automatic Transfer Operation 13 3 4 Sequence of Automatic Operation 14 3 5 Manual Transfer Operation 14 3 5 1 Transfer to Generator Power Source 14 3 5 2 Transfer Back to Utility Power Source 15 3 6 Setting the Exercise Timer 15 3 7...

Страница 4: ... must be installed properly in strict compli ance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in noncompli ance 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...

Страница 5: ...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 aforementioned codes standards laws and regu lations 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 e...

Страница 6: ...ge is noted at time of delivery have the person s making the delivery note all damage on the freight bill or affix his or her signature under the consignor s memo of loss or damage If you note loss or damage after delivery separate the damaged materials and contact the carrier for claim procedures Concealed damage is understood to mean damage to the contents of a package that is not in evidence at...

Страница 7: ... 5 Section 1 General Information Air cooled 8 5 kW Generator 1 4 YOUR GENERATOR Control Panel Air Filter Exhaust Enclosure 12 Volt Battery Fuel Regulator Oil Filter Oil Dipstick Data Decal Figure 1 1 8 5 kW V Twin GT 990 Engine ...

Страница 8: ...ttage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine power and condition etc Maximum power decreases about 3 5 percent for each 1 000 feet above sea level and also will decrease about 1 percent for each 6 C 10 F above 16 C 60 F ambient temperature 1 5 2 ENGINE Model 004692 Type of Engine GT 990 Number of Cylinders 2 Rated Horsepower 2...

Страница 9: ...to LP follow these steps NOTE The primary regulator for the propane supply is NOT INCLUDED with the generator You must sup ply a fuel pressure of 11 to 14 inches of water col umn 0 6 psi to the fuel inlet of the generator 1 Turn off the main gas supply 2 Remove the three carburetor fuel hoses from the outlet ports of the demand regulator 3 Disconnect wire 0 and wire 14 from the gas solenoid locate...

Страница 10: ...e battery with the proper electrolyte fluid if nec essary 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...

Страница 11: ...tteries present a risk of fire because they generate hydrogen gas The following procedures are to be followed DO NOT SMOKE when near the battery DO NOT cause flame or spark in battery area and Discharge static electricity from your body before touching the battery by first touching a grounded metal surface Be sure the Auto Off Manual switch is set to the OFF position before connecting the battery ...

Страница 12: ...voltage and frequen cy are correct and within the stated limits Generally if both AC frequency and voltage are high or low the engine governor requires adjust ment If frequency is correct but voltage is high or low the generator s voltage regulator requires adjustment 2 4 GENERATOR TESTS UNDER LOAD To test the generator set with electrical loads applied proceed as follows 1 Set generator s main ci...

Страница 13: ...cause natural gas has different BTU or power content across the country the engine may not perform as designed If you experience engine problems at high or full load conditions follow these steps It will require a fre quency 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 ...

Страница 14: ...6 Using your hand push the governor arm to the closed throttle position Make sure the idle spring does not stretch at all 7 Restart the unit 8 Slowly turn the idle adjust screw to adjust the no load idle frequency to 63 63 5 Hz 9 The governor is now set Figure 2 4 Full Load Speed Adjust Screw 2 7 1 ADDITIONAL CORROSION PROTECTION Periodically spray all engine linkage parts and brack ets with corro...

Страница 15: ...lso is used for remote starting when it is set up 3 2 2 OFF POSITION This switch position shuts down the engine This position also prevents automatic operation 3 2 3 MANUAL POSITION Set the switch to MANUAL to crank and start the engine Transfer to standby power will not occur unless there is a utility failure Figure 3 1 Generator Control Panel With the switch set to AUTO the engine may crank and ...

Страница 16: ...r monitors utility power supply volt age When that voltage is restored above 80 per cent 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 l...

Страница 17: ...cise To select the desired day and time of day you must perform the following sequence at that time 1 Verify that the Auto Off Manual switch is set to AUTO 2 Hold down the Set Exercise Time Switch until the generator starts approximately 10 seconds and then release During this time all the red LEDs on the control panel will flash to indicate board is resetting itself 3 The generator will start and...

Страница 18: ...ical 15 amp replacement The generator panel s 5 amp fuse protects the battery charge circuit against overload If the fuse element has melted open you will not have battery charging capability You should replace the fuse using only an identical 5 amp replacement To remove fuse push cap down and rotate counterclockwise Figure 4 1 Generator Control Panel 4 2 CHECKING THE ENGINE OIL LEVEL For oil capa...

Страница 19: ...ction 1 5 2 Page 6 for oil capacities 4 4 CHANGING THE OIL FILTER Change the engine oil filter as follows 1 With the oil drained remove the old oil filter by turning it counterclockwise 2 Apply a light coating of clean engine oil to the gas ket of the new filter See Section 1 5 1 Page 6 for recommended filter 3 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapte...

Страница 20: ...spose 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 s...

Страница 21: ...nd hence the engine While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is up as high as it can go Loosen the rocker jam nut Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm NOTE You must hold ...

Страница 22: ...r 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 recommend ed oil is used in the engine see Section 4 3 1 Page 17 If necessa...

Страница 23: ...rly 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 corrosion X X M ensure dryness Clean and tighten X X M 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 X R Y Spark ...

Страница 24: ... and runs rough plugged or damaged 2 Defective spark plug s 2 Clean re gap or replace plug s 3 Fuel regulator not set 3 Set fuel regulator 4 Fuel pressure incorrect 4 Confirm fuel pressure to generator is 11 14 WC 0 6 PSI The Auto Off Manual switch 1 Defective switch 1 is set to OFF but the engine 2 Auto Off Manual switch 2 continues to run wired incorrectly 3 Defective control board 3 There is no...

Страница 25: ...M F 120 240v 120 240v TYPE HOM TYPE HOM CBHOM F CBHOM F 120 240v 120 240v TYPE HOM TYPE HOM CBHOM F CBHOM F 120 240v 120 240v TYPE HOM TYPE HOM CBHOM F CBHOM F 120 240v 120 240v M6PEM T M6PEM T M6PEM T M6PEM T M6PEM T M6PEM T M6PEM T M6PEM T REAR VIEW REAR VIEW LEFT SIDE VIEW LEFT SIDE VIEW TRANSFER SWITCH TRANSFER SWITCH RIGHT SIDE VIEW RIGHT SIDE VIEW FRONT VIEW FRONT VIEW AIR AIR OUTLET OUTLET ...

Страница 26: ...RESSURE SWITCH IM2 IGNITION MODULE CYLINDER 2 IM1 IGNITION MODULE CYLINDER 1 SP2 SP1 D IM1 D IC INLINE CONNECTOR DSW PCB MOUNTED DIP SWITCH D DIODE HTO HIGH OIL TEMPERATURE SWITCH GRD CONTROL PANEL GROUND F1 FUSE 15 AMP FS FUEL SOLENOID CB2 CIRCUIT BREAKER ALTERNATOR EXCITATION CB1 MAIN OUTPUT BREAKER BA BRUSH ASSEMBLY DIAGRAM KEY IC IC 13 86 85 18 14 14 TB 0 13A FS 14 0 CHARGER BATTERY 225B 224B ...

Страница 27: ...CH CONTACTOR OUTPUT TO TRANSFER 240V GENERATOR CB1 194 N2 N1 23 11 44 N2 N1 66A 0 REGULATOR VOLTAGE 162 4 162 13A 6 4 0 22 11 0 4 6 162 CONTROL PANEL BOX N2 4 CB2 33 11 44 22 66 66A 77 55 6 22 11 BA 225 224 NEUTRAL CONNECTION 22 33 CUSTOMER TX 224 225 225B 224B 14 225A 224A 77 77 0 0 66 66 77 BCR 56 0 0 0 1 C2 2 3 4 6 5 7 9 10 2 8 55 55 2 2 6 11 11 22 22 66A F1 F2 13 4 1 1b 1a SW2 13 13 13 13 13 1...

Страница 28: ...ONTACTER 2 2 1 1 5 5 3 3 4 4 J2 J2 2 2 1 1 3 3 2 2 1 1 8 8 14 14 16 16 17 17 15 15 11 11 13 13 12 12 10 10 9 9 J1 J1 7 7 5 5 6 6 3 3 4 4 2 2 1 1 F2 FUSE 5 AMP BA BRUSH ASSEMBLY CB2 CIRCUIT BREAKER ALT EXCITATION D DIODE SCR STARTER CONTACTOR RELAY DPE WINDING 2 23 77 FIELD 11 4 22 6 162 REGULATOR ELECTRONIC VOLTAGE 0 0 4 22 0 11 0 13A 66 0 85 HTO 0 6 4 WINDING 13A 77 66 BCR LOP 351 4 SW2 86 0 0 13...

Страница 29: ...20V 33 NEUTRAL N2 N1 23 CUSTOMER CONNECTIONS 194 0 17 66A 0 SC FS 16 14 BATTERY CUSTOMER SUPPLIED SM 12V SC N2 N1 13 225A 14 225 224 TX 239 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 Section 7 Electrical Data Air cooled 8 5 kW Generator Electrical Schematic Drawing No 0D8501 Generac Power Systems Inc 27 ...

Страница 30: ... 59 25 35 14 47 54 9 8 27 35 22 51 49 50 51 49 49 11 50 16 17 51 5 47 19 12 6 31 44 47 30 29 28 18 86 41 40 55 57 56 58 52 49 20 52 72 64 65 66 45 71 69 68 71 68 69 38 58 34 73 75 46 74 76 82 78 77 80 82 79 80 81 48 44 85 84 72 62 63 60 49 83 53 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Compartment Drawing No 0D8445 A ...

Страница 31: ...N LOCKING ITEM PART NO QTY DESCRIPTION 43 0A2115 4 WASHER NYLON 250 44 022097 7 WASHER LOCK M6 1 4 45 022473 4 WASHER FLAT ZINC 46 036261 14 RIVET POP 125 X 129 133 30 47 047411 14 SCREW HHC M6 1 0 X 16 G8 8 48 043116 5 SCREW HHC M6 1 0 X 12 G8 8 49 0D3700 18 NUT LOCKING FLANGE M6 1 0 50 083512 12 SCREW TAPTITE M8 1 25 X 16 BP 51 090388 33 SCREW TAPTITE M6 1 0 X 12 YC 52 092120 2 NUT LOCK TRIC M6 ...

Страница 32: ...21 38 9 3 1 4 5 23 11 24 31 12 25 22 14 20 38 15 30 24 26 32 10 19 16 28 27 17 10 19 32 28 31 32 17 32 31 33 29 28 13 28 39 18 10 40 29 2 42 41 41 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Engine Alternator Drawing No 0D8446 ...

Страница 33: ...1 CABLE 6 48 BLACK BATTERY 19 0C2417A 1 EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VYNL COAT 0 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 029451 1 8 FT TAPE ELEC UL FOAM 1 8 X 1 2 23 049451 1 WASHER FLAT 406ID X 1 62OD 24 022237 5 WASHER LOCK 3 8 25 022511 4 SCREW HHC 3 8 16 X 1 1 4 G5 26 022131 4 WASHER FLAT 3 8 ZINC 27 039288 4 SCREW HHC M8 1 25 x 55 G8 8 28 022145 14 WASHER FLAT 5 16 ZINC 29 049...

Страница 34: ... 34 33 39 3 3 40 2 3 26 10 4 34 25 11 30 20 66 2 5 19 20 39 40 47 64 93 140 8 11 12 13 67 4 5 6 68 16A 16B 17 18 69 7 48 49 50 51 52 53 54 55 56 58 59 60 70 48 49 50 51 52 53 54 55 56 58 59 60 62 71 27 28 29 72 3 32 33 34 35 36 40 72 73 140 53 55 56 54 16A 16B 16A Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Engine Drawing No 0D8674 C Part 1 ...

Страница 35: ...C5998 1 CLAMP OIL TUBE 33 0D1667 1 ARM GOVERNOR 34 0C2991 2 E RING GOVERNOR ARM 35 0C2988 1 THRUST WASHER GOVERNOR ITEM PART NO QTY DESCRIPTION 36 0C2992 1 BUSHING GOVERNOR LOWER 37 0C3971C 1 ASSEMBLY DIPSTICK WITH HANDLE 38 0C5305 1 TUBE DIPSTICK 39 0C3027 1 O RING OIL CLR 3 8 X 1 2 40 0C3007 1 SEAL 42 I D CRANKSHAFT 41 0C5731 1 ASSEMBLY HOUSING COVER WITH SLEEVE 42 0C3006 9 SCREW HHFC M10 1 5 X ...

Страница 36: ...89 88 86 85 83 84 82 81 130 99 118 114 126 94 93 117 79 78 76 77 75 74 122 125 123 125 119 120 137 136 134 133 132 131 127 129 135 113 101 110 121 112 128 124 124 80 87 98 97 98 97 138 139 115 116 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Engine Drawing No 0D8674 C Part 2 ...

Страница 37: ...8 SS 106 051754 2 SCREW HHC M8 1 25 X 12 G8 8 107 0C3033 1 WASHER 25mm I D ITEM PART NO QTY DESCRIPTION 108 0C3034 1 NUT HEX M24 109 0C8549 1 SNORKEL AIR INTAKE 110 0C3022A 1 HOUSING BLOWER NG COOLER 111 0D1131 1 GUARD FAN 112 045756 27 SCREW TAPTITE M6 1X10 YELLOW CHROME 113 0C9763 4 NUT GROMMET 1 4 PLUG 114 0C3036 1 HOSE BREATHER 115 0C8919 1 BRACKET STARTER 116 079246 1 SCREW HHC M6 1 0 x 16 WI...

Страница 38: ...14 15 35 25 17 49 14 15 5 34 16 23 36 39 38 45 48 2 28 29 21 17 16 4 6 7 49 23 27 42 12 45 44 20 40 11 1 43 15 35 14 30 29 28 3 28 29 41 24 45 47 31 47 45 31 33 Section 8 Exploded Views and Parts Lists Air cooled 8 5 kW Generator Control Panel Assembly Drawing No 0D8503 B ...

Страница 39: ...CONTROL PANEL BOTTOM 21 075235 4 SCREW HHC M5 0 8 x 30mm ITEM PART NO QTY DESCRIPTION 22 0D5240 1 SWITCH SPDT ON MOM ON 23 051714 4 NUT HEX M3 0 5 24 0D8502 1 NEUTRAL ISOLATOR 25 0A1661 2 RIVET POP 156 X 160 164 20 26 0D8441 1 HARNESS CONTROL PANEL WIRE NOT SHOWN 27 074908 4 SCREW TAPTITE M5 0 8 x 10 BP 28 049226 6 WASHER LOCK M5 29 051716 6 NUT HEX M5 0 8 30 0C3910 1 TRANSFORMER 31 022507 2 SCREW...

Страница 40: ...10 32 X 3 8 23 077033 6 LUG SLDLSS 1 0 14X9 16 AL CU 24 048850 1 BLOCK TERMINAL 20A 5 X 6 X 1100V 25 028739 4 TIE WRAP 3 9 X 10 NAT L UL 26 038150 2 WASHER FLAT 8 ZINC 27 0D3191 1 COVER RELAY TERM BLOCK 28 0D3088 1 WIRE HARNESS GTS LOAD CENTER NOT SHOWN FOR CLARITY 29 073591 2 FUSE HOLDER 30 073590A 2 ASSEMBLY FUSE 5A X BUSS HLDR73591 31 040213B 4 PCB SUPPORT SNAP IN 1 3 8 32 0C8037 3 CIRCT BRK 20...

Страница 41: ... M4X8 BP 045764 8 SCREW TAPTITE M4X8 BP 7KW 22 0C6731 2 RIVET POP 118 X 125 23 0C6067 2 SUPPORT DIAPHRAGM 24 0C4706 2 DIAPHRAGM TWIN REGULATOR 25 0C6068 2 CAP DIAPHRAGM SUPPORT 26 0C4643A 2 INLET TWIN REGULATOR 11 11 DIA 27 026073 1 PLUG STANDARD PIPE 1 8 STEEL SQUARE HEAD 28 0A4032 2 PIN LIMITED ADJUSTMENT 29 0D3308 4 WASHER FLAT M3 X 10mm O D 0D3308 2 WASHER FLAT M3 X 10mm O D 7KW 30 0C4643 1 IN...

Страница 42: ...or 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 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 reasonabl...

Страница 43: ...ding 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 Authoriz...

Страница 44: ...nical 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 ...

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