CENTURION
®
Installation and
Owner’s Manual
Air-cooled, Prepackaged
Automatic Standby Generators
Models:
004692-2 (8.5 kW)
CENTURION
®
*This manual should remain with the unit.*
Not intended for use as Primary Power in place of utility or
!
!
in life-support applications.
DANGER
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
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Table of Contents
Air-cooled 8.5 kW Generator
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
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
3.5.1 Transfer to Generator
Safety Rules ........................................................2
Standards Index..................................................3
Section 1 – General Information ..................4
1.1 Unpacking/Inspection ....................................4
1.2 Protection Systems ........................................4
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
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
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
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
Section 5 – Troubleshooting ........................22
2.6 Adjusting the Regulator
5.1 Troubleshooting Guide................................22
(Natural Gas Only)........................................11
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
2.7 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
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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.
!
!
!
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GENERAL HAZARDS
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
• 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 sys-
tem must be 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.
• 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 seri-
ously 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 need-
ing repair or replacement.
• Before performing any maintenance on the genera-
tor, disconnect its battery cables to prevent acci-
dental start up. Disconnect the cable from the bat-
tery 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 con-
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
!
!
WARNING:
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
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 precau-
tions.
Generac cannot possibly anticipate every possible
circumstance that might involve a hazard. The warn-
ings 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 tech-
nique Generac does not specifically recommend, sat-
isfy yourself that it is safe for others. Also make sure
the procedure, work method or operating technique
choosen does not render the generator unsafe.
DANGER
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.
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IMPORTANT SAFETY INSTRUCTIONS
Air-cooled 8.5 kW Generator
• 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 extin-
guisher properly charged and be familiar with its
use. If there are any questions pertaining to fire
extinguishers, consult the local fire department.
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 opera-
tion. Avoid contact with bare wires, terminals, con-
nections, 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 sys-
tem, 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, imme-
diately 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.
EXPLOSION HAZARDS
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no com-
bustible materials are left in the generator com-
partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing 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 applica-
ble fuel-gas codes. Before placing the home stand-
by 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, regula-
tions 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, avail-
able same as Item 1.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving com-
ponents causing injury.
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 SYS-
TEMS, available from the American Society of
Agricultural Engineers, 2950 Niles Road, St.
Joseph, MI 49085.
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 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.
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE
LIQUIDS CODE, available same as Item 1.
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Section 1 — General Information
Air-cooled 8.5 kW Generator
There are LED readouts on the control panel to noti-
fy personnel that one of these faults has occurred.
DANGER
Only qualified electricians or contractors should
attempt such installations, which must comply
strictly with applicable codes, standards and
regulations.
!
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 require-
ment 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.
1.1 UNPACKING/INSPECTION
After unpacking, carefully inspect the contents
for damage.
• This standby generator set has been factory sup-
plied 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.
‹
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-ener-
gize 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 pro-
vided on branch circuits that supply outlets (recepta-
cle, lighting, etc.) in dwelling bedrooms. The require-
ment is limited to 15 and 20 ampere, 125 volt cir-
cuits. 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 hall-
ways, providing AFCI protection on the complete cir-
cuit would comply with 210.12.
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 trans-
fer switch. The transfer switch must effectively
isolate the electrical system from the utility dis-
tribution system when the generator is operat-
ing (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 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 cir-
cuit breaker in the Guardian Transfer Switch should
be replaced with an Arc Fault Circuit Interrupter.
If a loss or damage is discovered after delivery, sepa-
rate the damaged materials and contact the carrier
for claim procedures.
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.
“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
These AFCI breakers are available at the nearest
hardware store.
Unlike an automobile engine, the generator may have
to run for long periods of time with no operator pres-
ent to monitor engine conditions. For that reason, the
engine is equipped with the following systems that
protect it against potentially damaging conditions:
Siemens Item #
Q115AF
Description
15A Single Pole AFCI
20A Single Pole AFCI
Q120AF
1. Low Oil Pressure Sensor
2. High Temperature Sensor
3. Overcrank
4. Overspeed
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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
Data
Decal
Control
Panel
Oil Dipstick
Air Filter
Exhaust
Enclosure
Fuel Regulator
Fuel Inlet
Battery Compartment
Oil Filter
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Section 1 — General Information
Air-cooled 8.5 kW Generator
1.5 SPECIFICATIONS
1.5.1 GENERATOR
‹
Model 004692
8,500 NG/8,500 LP
120/240
Rated Max. Continuous Power Capacity (Watts*)
Rated Voltage
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
Phase
Number of Rotor Poles
Rated AC Frequency
Power Factor
40 Amp
1
2
60 Hz
1
Battery Requirement
at -17.8° C (0° F)
Group 26/26R 12 Volts and 525
Cold-cranking Amperes Minimum
Weight
Output Sound Level
Normal Operating Range
470 Pounds
68 db (A)
-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
GT-990/760
Type of Engine
Number of Cylinders
Rated Horsepower
Displacement
2
26 @ 3,600 rpm
992cc
Cylinder Block
Valve Arrangement
Ignition System
Recommended Spark Plug
Spark Plug Gap
Compression Ratio
Starter
Aluminum w/Cast Iron Sleeve
Overhead Valves
Solid-state w/Magneto
RC12YC
0.50 mm (0.020 inch)
9.5:1
12 Vdc
Oil Capacity Including Filter
Recommended Oil Filter
Recommended Air Filter
Operating RPM
Approx. 1.7 Qts
Generac Part # 70185
Generac Part # 0C8127
3,600
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Section 1 — General Information
Air-cooled 8.5 kW Generator
1.6 SYSTEM SET LED
The “System Set” LED is lit when all of the following
conditions are true:
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. 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.
1.9 RECONFIGURING THE
FUEL SYSTEM
To reconfigure the fuel system from NG to LP,
3. The “Not In Auto” dip switch is set to the OFF
follow these steps:
position on the control board.
NOTE:
4. No alarms are present, for example, low oil pres-
sure, high temperature, etc.
The primary regulator for the propane supply is
NOT INCLUDED with the generator. A fuel pres-
sure of 11 to 14 inches of water column (0.4 to 0.5
psi) to the fuel inlet of the generator MUST BE
SUPPLIED.
1.7 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.
1. Turn off the gas supply. (if connected)
2. Open the roof and remove the door.
3. Remove the battery. (if installed)
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.
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 gen-
tly lift up the hose edge.
6. Remove the small brass hose fitting from the reg-
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.
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.
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:
Figure 1.4 - Demand Regulator
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 col-
umn for liquid propane for all load ranges.
OUTLET PORTS
FUEL HOSE
BRASS HOSE
FITTING
IDLE CIRCUIT
PORT
BRASS HOSE
FITTING
SMALL
FUEL JET
1
NP
REGULATOR
HOUSING PORT
1.8 FUEL CONSUMPTION
ADJUSTER
SCREWS
Model #
Nat. Gas (*)
LP Vapor (**)
1/2 Load Full Load 1/2 Load
Full Load
1.98/72.5
004692-1
114
170
1.33/45.8
* Natural gas is in cubic feet per hour.
** LP is in gallons per hour/cubic feet per hour.
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Section 1 — General Information
Air-cooled 8.5 kW Generator
9. Apply thread sealant to the threads of the hose fit-
ting and replace it into the regulator body.
10. Re-attach the small hose and hose clamp and
tighten as necessary.
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:
11. Replace the engine air in baffle using the four M6
screws.
12. Identify both brass adjustment screws on the reg-
ulator.
• Install the transfer switch indoors on a firm, stur-
dy supporting structure.
NOTE:
• To prevent switch distortion, level the switch if nec-
essary. This can be done by placing washers
between the switch enclosure and mounting surface.
• Never install the switch where water or any corro-
sive substance might drip onto the enclosure.
• Protect the switch at all times against excessive
moisture, dust, dirt, lint, construction grit and cor-
rosive vapors.
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.
1.11 BATTERY INSTALLATION
Fill the battery with the proper electrolyte fluid if nec-
essary and have the battery fully charged before
installing it.
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).
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.
1.10 LOCATION
DANGER
1.10.1 GENERATOR
◆
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 connect-
ed. If the utility power supply is not turned off,
sparking can occur at the battery posts and
cause an explosion.
Install the generator set, in its protective enclosure,
outdoors, where adequate cooling and ventilating air
is always available. Consider these factors:
• Install the unit where air inlet and outlet openings
will not become obstructed by leaves, grass, snow,
etc. If prevailing winds will cause blowing or drift-
ing, 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.
Battery cables were factory connected at the genera-
tor (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 nega-
tive, NEG or (—).
• Where strong prevailing winds blow from one
direction, face the generator air inlet openings to
the prevailing winds.
NOTE:
• Install the generator as close as possible to the fuel
Damage will result if battery connections are made
in reverse.
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 DIS-
TANCE.
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Section 1 — General Information
Air-cooled 8.5 kW Generator
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
Figure 1.5 – Battery Cable Connections
• 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 bicar-
bonate 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.
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.
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
1.12 THE BATTERY
Servicing of the battery is to be performed or super-
vised by personnel knowledgeable of batteries and
the required precautions. Keep unauthorized person-
nel away from batteries.
• 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.
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 connect-
ed and terminals are tight. Observe battery polarity
when connecting the battery to the generator set.
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.
DANGER
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:
®
Generac Power Systems, Inc.
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Section 2 — Post Installation Start-up and Adjustments
Air-cooled 8.5 kW Generator
4. Use an accurate AC voltmeter to check UTILITY
2.1 BEFORE INITIAL START-UP
power source voltage across transfer switch ter-
minals N1 and N2. Nominal line-to-line voltage
should be 240 volts AC.
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).
5. Check UTILITY power source voltage across ter-
minals 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 com-
patible with transfer switch and load circuit rat-
ings, turn OFF the UTILITY power supply to the
transfer switch.
7. On the generator panel, set the AUTO/OFF/MAN-
UAL 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.
3. Turn OFF all loads connected to the tranfer
switch terminals T1 and T2.
4. Check the engine crankcase oil level and, if nec-
essary, 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.
DANGER
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
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.
!
2.2 CHECK TRANSFER SWITCH
9. Connect an accurate AC voltmeter and a frequen-
cy meter across transfer switch terminal lugs E1
and E2. Voltage should be 242-252 volts; fre-
quency should read about 61-63 Hertz.
10. Connect the AC voltmeter test leads across termi-
nal lug E1 and neutral; then across E2 and neu-
tral. In both cases, voltage reading should be 121-
126 volts AC.
11. Set the generator’s main circuit breaker to its
OFF (or open) position. Let the engine run at no-
load for a few minutes to stabilize internal engine
generator temperatures.
OPERATION
Refer to Section 3.5, of the owner’s manual for man-
ual operation procedures.
Do not attempt manual transfer switch opera-
tion 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.
12. Set the generator's AUTO/OFF/MANUAL switch to
OFF. The engine should shut down.
2.3 ELECTRICAL CHECKS
NOTE:
Complete electrical checks as follows:
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 cor-
rect, but voltage is high or low, the generator’s
voltage regulator requires adjustment.
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 trans-
fer switch using the means provided (such as a
utility main line circuit breaker).
DANGER
The transfer switch is now electrically “hot.”
Contact with “hot” parts will result in extreme-
ly hazardous and possibly fatal electrical shock.
Proceed with caution.
®
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Section 2 — Post Installation Start-up and Adjustments
Air-cooled 8.5 kW Generator
2.4 GENERATOR TESTS UNDER LOAD
2.5 CHECKING AUTOMATIC
To test the generator set with electrical loads applied,
proceed as follows:
OPERATION
To check the system for proper automatic operation,
proceed as follows:
1. Set generator’s main circuit breaker to its OFF
(or open) position.
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.
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 trans-
fer switch, using the means provided (such as a
utility main line circuit breaker).
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.
DANGER
Do not attempt manual transfer switch opera-
tion until all power voltage supplies to the
transfer switch have been positively turned off.
Failure to turn off all power voltage supplies
will result in extremely hazardous and possibly
fatal electrical shock.
5. Manually set the transfer switch to the STANDBY
position, i.e., load terminals connected to the
generator's E1/E2 terminals. The transfer switch
operating lever should be down.
6. Set the generator's AUTO/OFF/MANUAL switch to
MANUAL. The engine should crank and start
immediately.
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:
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 frequen-
cy 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.
• 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 pro-
vide 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 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 posi-
tion.
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.
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.
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Section 2 — Post Installation Start-up and Adjustments
Air-cooled 8.5 kW Generator
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:
Do not make any unnecessary adjustments.
Factory settings are correct for most applica-
tions. However, when making adjustments, be
careful to avoid overspeeding the engine.
!
Unit
120 Volts
70.8 amps
240 Volts
35.4 amps
8.5 kW
If this procedure or equipment are not available,
locate the nearest Generac Dealer and they can per-
form the adjustments.
4. When full load has been achieved. Connect a fre-
quency 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).
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:
Figure 2.1 — Dual Fuel Regulators
1. Loosen governor clamp bolt (Figure 2.3).
V-twin
Figure 2.3 — V-twin Engine Governor
Adjustment
Idle Spring
Governor
Adjustment
Screw
(Both Sides)
Shaft
(Rotate
Clockwise)
Set Pin
(Both Sides)
6. When the highest frequency is reached maximum
power has been set. From this point, turn both
adjustment screws 1/4 turn clockwise. The regu-
lator is now set.
No Load Idle
Adjustment Screw
Governor Clamp Bolt
Figure 2.2 — Placement of Regulator
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.
Adjustment Screw
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.
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.
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Section 3 — Operation
Air-cooled 8.5 kW Generator
Figure 2.4 — Full Load Speed Adjust Screw
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.
Full Load Speed Adjust Screw
1. Set the generator’s AUTO/OFF/MANUAL switch to
AUTO.
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. 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.
2.7.1 ADDITIONAL CORROSION
PROTECTION
Periodically spray all engine linkage parts and brack-
ets with corrosion inhibiting spray such as WD-40 or
a comparable product.
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 trans-
fer 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.
◆
2.8 VOLTAGE REGULATOR
9. Allow the unit to cool.
ADJUSTMENT
With the frequency between 62-63 Hertz, slowly turn
the slotted potentiometer (Figure 2.5) until line volt-
age reads 244-252 volts.
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”.
NOTE:
The access panel on top of the control panel must
be removed to adjust the voltage regulator.
11. The generator is now ready for service.
3.2 USING THE AUTO/OFF/MANUAL
SWITCH (FIGURE 3.1)
NOTE:
The voltage regulator is housed above the genera-
tor's control panel. The regulator maintains a volt-
age in direct proportion to frequency at a 2-to-1
ratio. For example, at 62 Hertz, line-to-neutral
voltage will be 124 volts.
3.2.1 “AUTO” POSITION
‹
Selecting this switch position activates fully automat-
ic system operation. It also permits starting and exer-
cising 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 2.5 – Voltage Adjustment Potentiometer
Figure 3.1 – Generator Control Panel
FUSE
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d e a le r a t
:
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POWER SYSTEMS, INC.
5A
AUTO OFF MAN.
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
FUSE
F L
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H
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G
O
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G R E E N L E D
=
SET
EXERCISE
TIME
15A
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IS E R
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=
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®
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Section 3 — Operation
Air-cooled 8.5 kW Generator
Upon restoration of utility source voltage above a pre-
set 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.
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.
‹
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 per-
cent of the nominal supply voltage, the sensor
energizes a 15-second timer.
• Once the timer has expired, the engine will crank
and start.
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 pre-
set 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.
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 volt-
age. When the voltage has reached 50 percent of
the nominal rated voltage, transfer to standby
can occur.
3.3 AUTOMATIC TRANSFER
D.Utility Voltage Pickup Sensor
OPERATION
To select automatic operation, do the following:
• This sensor monitors UTILITY power supply
voltage. When that voltage is restored above 80
percent of the nominal source voltage, a retrans-
fer time delay starts timing.
1. Make sure the transfer switch main contacts are
set to their UTILITY position, i.e., loads connect-
ed 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.
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.
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”.
• The timer will run for about one minute, and the
generator will then shut down.
3.5 MANUAL TRANSFER OPERATION
3.4 SEQUENCE OF AUTOMATIC
3.5.1 TRANSFER TO GENERATOR
POWER SOURCE
‹
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 sup-
ply (load terminal lugs T1/T2 connect to terminal
lugs E1/E2).
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).
®
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Section 3 — Operation
Air-cooled 8.5 kW Generator
DANGER
DANGER
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.
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 trans-
fer switch to move the main contacts to their
“Standby” position, i.e., loads connected to the
standby power source (Figure 3.2).
5. Use the manual transfer handle inside the trans-
fer switch to move the main contacts back to their
UTILITY position, i.e., loads connected to the
UTILITY 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.
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 “Automatic Transfer Operation,” Section 3.3.
7. Set the generator’s main circuit breaker to its ON
(or closed) position. The standby power source
now powers the loads.
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 approx-
imately 12 minutes and then shuts down. Transfer of
loads to the generator output does not occur during
the exercise cycle.
Figure 3.2 – Manual Transfer Switch Operation
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.
3.5.2 TRANSFER BACK TO UTILITY POWER
SOURCE
‹
NOTE:
When utility power has been restored, transfer back
to that source and shut down the generator. This can
be accomplished as follows:
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.
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.
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.
4. Check that UTILITY power supply to the transfer
switch is turned OFF.
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Section 4 — Maintenance
Air-cooled 8.5 kW Generator
3.7.3.1 Approximate Crank Cycle Times
• 15 seconds ON
• 7 seconds OFF
3.7 PROTECTION SYSTEMS
3.7.1 LOW OIL PRESSURE SWITCH
‹
• 7 seconds ON
• 7 seconds OFF
• Repeat for 45 seconds
Approximately 90 seconds total
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.
3.7.4 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 gener-
ator from supplying an output that could potentially
damage appliances connected to the generator cir-
cuit. Contact the nearest Generac Authorized Dealer
if this failure occurs.
3.7.2 HIGH TEMPERATURE SWITCH
‹
This switch’s (Figure 3.3) contacts close if the tem-
perature 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.
4.1 FUSE
Figure 3.3 – Low Oil Pressure and
High Temperature Switches
The generator panel’s 15 amp fuse (Figure 4.1) pro-
tects 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.
Low Oil Switch
High Temp Switch
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 iden-
tical 5 amp replacement. To remove fuse, push cap
down and rotate counterclockwise.
Figure 4.1 – Generator Control Panel
Oil
Drain
Hose
FUSE
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L o c a t
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y o u r n e a r e s t
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:
R
Oil Filter
POWER SYSTEMS, INC.
5A
AUTO OFF MAN.
SYSTEM SET
LOW OIL
HIGH TEMP.
OVER SPEED
OVER CRANK
FUSE
3.7.3 OVERCRANK
‹
This feature prevents the generator from damaging
itself when it continually attempts to start and anoth-
er problem, such as no fuel supply, prevents it from
starting. The unit will crank and rest for a preset time
limit. Then, it will stop cranking, and the LED on the
generator control panel will light indicating an over-
crank failure. The AUTO/OFF/MANUAL switch will
need to be set to OFF and then back to AUTO to reset
the generator control board.
F L
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EXERCISE
TIME
15A
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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):
NOTE:
If the fault is not repaired, the overcrank feature
will continue to activate.
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.
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Section 4 — Maintenance
Air-cooled 8.5 kW Generator
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 nec-
essary, add oil to the “Full” mark only. DO NOT
FILL ABOVE THE “FULL” MARK.
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 capaci-
ties.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
!
Figure 4.3 – Oil Drain Hose and Filter
this could damage the engine.
4. Install the dipstick.
5. Reset the AUTO/OFF/MANUAL switch to its origi-
nal position.
Figure 4.2 — Oil Dipstick and Fill, 8.5 kW
Oil Dipstick
Oil
Drain
Hose
Oil Fill
Oil 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 gas-
ket of the new filter. See Section 1.5.1 for recom-
mended filter.
4.3 CHANGING THE ENGINE OIL
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 capaci-
ties.
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:
5. Start the engine and check for leaks.
The unit is supplied with “break-in” oil. See the
“Break-in Procedure,” Section 3.1, for the first
required oil change.
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:
‹
Any attempt to crank or start the engine before
it has been properly serviced with the recom-
mended oil may result in an engine failure.
!
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.
4.3.2 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.
4. Install the new air cleaner into the air box.
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Section 4 — Maintenance
Air-cooled 8.5 kW Generator
5. Install the cover. Turn the two cover screws clock-
wise to tighten.
See the “Service Schedule,” Section 4.11 for air
cleaner maintenance. See Section 1.5.1 for air filter
replacement part number.
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 bat-
tery hydrometer.
Figure 4.4 — V-twin Engine Air Cleaner
Screw
DANGER
Do not dispose of the battery in a fire. The
battery is capable of exploding.
Cover
Filter
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.
4.6 SPARK PLUG(S)
Reset the spark plug(s) gap or replace the spark
plug(s) as necessary. See Section 4.11 for mainte-
nance requirements.
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to
!
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 condi-
tion. Replace the spark plug(s) if worn or if reuse
is questionable. See Section 4.11 for recom-
mended inspection.
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
3. Check the spark plug gap using a wire feeler
gauge, carefully bending the ground electrode
(Figure 4.5).
• 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 bicar-
bonate 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.
Figure 4.5 – Setting the Spark Plug Gap
SET PLUG GAP AT 0.50 mm
(0.020 inch)
Lead-acid batteries present a risk of fire
because they generate hydrogen gas. The
following procedures are to be followed:
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Section 4 — Maintenance
Air-cooled 8.5 kW Generator
• 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.
Figure 4.6 - Valve Clearance Adjustment
Rocker
Arm
Pivot Ball
Stud
Jam Nut
Valve
Stem
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.
4.8 ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, adjust the
valve clearance in the engine.
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.
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.
• Re-attach the spark plug wire to the spark plug.
• Repeat the process for the other cylinder.
To adjusting valve clearance:
4.9 COOLING SYSTEM
Air inlet and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. This includes such obstruc-
tions as high grass, weeds, brush, leaves and snow.
• 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
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it to
quickly shut down. (see Figure 4.7)
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.
Figure 4.7 – Cooling Vent Locations
• 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.
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.
• Install new valve cover gasket.
• Re-attach the valve cover.
The maximum ambient temperature for the
!
generator is 48.9° C (104° F).
®
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Section 4 — Maintenance
Air-cooled 8.5 kW Generator
4.11.2 RETURN TO SERVICE
To return the unit to service after storage, proceed
as follows:
‹
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.
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). 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 dis-
tilled 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.
4.11 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, pre-
pare 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
4. Clean and wipe the entire generator.
5. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected
incorrectly.
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. 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.
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.
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 exer-
cise timer must be reset.
9. Clean and wipe the entire generator.
4.12 CORROSION PROTECTION
Periodically wash and wax the enclosure using auto-
motive type products. Frequent washing is recom-
mended in a salt water, coastal area. Spray engine
linkages with a light oil such as WD-40.
®
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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
M = Monthly
Y = Yearly
R = Replace as Necessary
* = Notify Dealer
if Repair is Needed.
FUEL
Fuel lines and connections*
X
X
M
M
LUBRICATION
Oil level
Oil
X
X
AFTER BREAK-IN
AND Y
Oil filter
AFTER BREAK-IN
AND Y
COOLING
Enclosure louvers
BATTERY
X
X
W
Remove corrosion,
ensure dryness
X
X
X
X
M
M
Clean and tighten
battery terminals
Check charge state
X
X
R
R
EVERY 6 M
EVERY 6 M
Electrolyte level
(unsealed batteries only)*
ENGINE AND MOUNTING
Air cleaner
X
X
R
R
Y
Y
Spark plug(s)
GENERAL CONDITION
Vibration, Noise, Leakage,
Temperature*
X
M
Y
COMPLETE TUNE-UP*
TO BE COMPLETED BY A GENERAC
AUTHORIZED DEALER
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Section 5 — Troubleshooting
Air-cooled 8.5 kW Generator
5.1 TROUBLESHOOTING GUIDE
PROBLEM
The engine will not crank.
CAUSE
CORRECTION
1. Replace fuse.
2. Tighten, clean or replace
as necessary.
1. Fuse blown
2. Loose, corroded or defective
battery cables
3. Defective starter contactor
4. Defective starter motor
5. Dead Battery
3. *
4. *
5. Charge or replace battery.
The engine cranks but
will not start.
1. Out of fuel
1. Replenish fuel.
2. *
3. *
2. Defective fuel solenoid (FS)
3. Open #14 wire from
engine control board
4. Defective spark plug(s)
5. Valve Lash
4. Clean, re-gap or replace plug(s).
5. Reset Valve Lash.
The engine starts hard
and runs rough.
1. Air cleaner
1. Check, replace air cleaner.
plugged or damaged
2. Defective spark plug(s)
3. Fuel regulator not set.
4. Fuel pressure incorrect.
2. Clean, re-gap or replace plug(s).
3. Set fuel regulator.
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
is set to OFF, but the engine
continues to run.
1. Defective switch
1. *
2. *
2. AUTO/OFF/MANUAL switch
wired incorrectly
3. Defective control board
3. *
There is no AC output from
the generator.
1. Main line circuit breaker open
2. Generator internal failure
1. Reset circuit breaker
to ON (or closed).
2. *
There is no transfer to
standby after utility
source failure.
1. Defective transfer switch coil
2. Defective transfer relay
3. Transfer relay circuit open
4. Defective control logic board
1. *
2. *
3. *
4. *
Unit consumes large
amounts of oil.
1. Break-in procedure
1. *
not followed (see Section 2.1)
*Contact the nearest Generac Authorized Dealer for assistance.
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Section 6 — Mounting Dimensions
Air-cooled 8.5 kW Generator
Drawing No. 0D3739-B
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Section 7 — Electrical Data
Air-cooled 8.5 kW Generator
Wiring Diagram - Drawing No. 0D8500-B
ENGINE WIRING
DIAGRAM KEY
3
2
1
BA - BRUSH ASSEMBLY
BCR - BATTERY CHARGE RELAY
BATTERY
CHARGER
CB1 - MAIN OUTPUT BREAKER
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION
14
2
1
D
-
DIODE
0
DSW - PCB MOUNTED DIP SWITCH
FS - FUEL SOLENOID
225B
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
GRD - CONTROL PANEL GROUND
HTO - HIGH OIL TEMPERATURE SWITCH
IC - INLINE CONNECTOR
ICT - INTERCONNECTION TERMINALS
FS
224B
13A
0
13A
0
225B
IM1 - IGNITION MODULE, CYLINDER #1
IM2 - IGNITION MODULE, CYLINDER #2
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTOR
0
224B
SCR - STARTER CONTACTOR RELAY
SP1, SP2 - SPARK PLUGS
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
14
0
0
14
SM - STARTER MOTOR
TB - INSULATED TERMINAL BLOCK
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
14
IC
TB
D
SP1
6
0
0
14
IM1
18
85
4
3
86
13
13
16
13
13
13
D
1
IC
IC
SP2
C1
16
SCR
IM2
13
18
351
85
A
B
86
351
HTO
0
0
14
86
56
18
85
56
1
56
16
13
18
86
2
3
4
5
J2
56
14
4
LOP
0
J1
86
23
56
14
239
17
0
194
18
CONTROL
PRINTED CIRCUIT BOARD
66A
15A
15
RED
BLACK
DSW
225
1 - 20 Vac Sense Transformer
2 - Remote Not Auto
3 - 50 Hz Operation
4 - SPARE
SM
224
+
12V
BATTERY
SC
CUSTOMER SUPPLIED
L.E.D - ALARM INDICATORS
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Section 7 — Electrical Data
Air-cooled 8.5 kW Generator
Wiring Diagram - 8.5 kW – Drawing No. 0D8500-B
CONTROL PANEL BOX
225
224
224A
225A
224A
225A
CLOSEST TO BEARING
TX
BCR
CB2
1
4
7
3
6
9
4
0
N1 N2
STATOR
162
2
66
13A
A
B
77
0
225B
225B
4
10
9
224B
224B
0
2
11
6
66
8
2
14
55
4
6
22
0
6
5
66A
11
0
11
11
22
22
77
11
66
66
13A
225
22
4
0
4
3
2
0
6
0
77
6
44
1
224
162
162
55
C2
VOLTAGE
REGULATOR
66A
0
0
0
33
66A
4
55
22
N2
N1
13
13
225
GRD
13
351
224
194
23
N2
4
23
N1
13
44
351
11
13
13A
351
15A
194
N2
22
23
13
33
194
N1
0
13
66A
F2
F1
239
CB1
0
15A
17
OFF
17
15
13
239
17
0
SW1
225
224
15
1a
1
15
1b
SW2
240V GENERATOR
AUTO
OUTPUT TO TRANSFER
SWITCH CONTACTOR
CUSTOMER
CONNECTION
MANUAL
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Section 7 — Electrical Data
Air-cooled 8.5 kW Generator
Electrical Schematic - Drawing No. 0D8501-B
11
22
225A
3
2
1
225A
224A
224A
BATTERY
CHARGER
225B
F2
225
13A
13
224B
13A
2
1
224
F1
7
7
9
BCR
6
3
4
11
0
13A
13
77
C2-1
0
15
77
14
BATTERY CHARGE
WINDING
66
0
66
C2-2
22
0
0
C2-4
55
HTO
0
C2-11
0
LOP
11
22
ENGINE RUN
WINDING
BA
FIELD
SW2
C1-4
0
14
(STATOR)
15
C1-3
0
C2-9
C2-3
4
0
ELECTRONIC
VOLTAGE
REGULATOR
C2-10
4
4
66A
0
85
23
194
6
86
162
C1-6
4
6
CB2
0
351
225
14
224
C2-7
C2-8
66A
2
(STATOR)
1
2
3
4
5
15A
J2
239
23
18
1
4
66A
J1
DIAGRAM KEY
194
86
3
5
7
23
194
56
BA - BRUSH ASSEMBLY
BCR - BATTERY CHARGE RELAY
CB1 - CIRCUIT BREAKER, MAIN OUTPUT
CB2 - CIRCUIT BREAKER, ALT. EXCITATION
D - DIODE
FS - FUEL SOLENOID
F1 - FUSE 15 AMP
F2 - FUSE 5 AMP
HTO - HIGH OIL TEMPERATURE SWITCH
IM1 - IGNITION MODULE, CYLINDER #1
IM2 - IGNITION MODULE, CYLINDER #2
LOP - LOW OIL PRESSURE SWITCH
SC - STARTER CONTACTER
SCR - STARTER CONTACTOR RELAY
SP1, SP2 - SPARK PLUGS
SW1 - AUTO / OFF / MANUAL SWITCH
SW2 - SET EXERCISE SWITCH
SM - STARTER MOTOR
14
66A
239
15A
17
CONTROL
PRINTED CIRCUIT
BOARD
9
12
14
15
0
225
224
16
17
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)
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Section 7 — Electrical Data
Air-cooled 8.5 kW Generator
Electrical Schematic - Drawing No. 0D8501-B
11
C2-6
22
C2-5
TX
240VAC
UTILITY
INPUT
225A
224A
N2
N1
N2
56VA
1VA
N2
N1
12Vdc
TRANSFER
RELAY
225
224
23
194
COIL
N1
CUSTOMER
CONNECTIONS
13
17
11
NEUTRAL
23
22
33
15A
0
SW1
194
120V
120V
POWER
WINDING
(STATOR)
15A
239
13
15
17
44
CB1
23
15
194
239
11
0
240V
14
15
13
RED
0
C2-1
13
SC
SCR
15
56
16
16
0
14
C1-1
18
BATTERY
12V
0
SC
0
FS
0
SM
17
BLACK
15
CUSTOMER
SUPPLIED
IM1
IM2
0
SP1
18
D
18
C1-5
D
SP2
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Section 7 — Electrical Data
Air-cooled 8.5 kW Generator
Electrical Schematic - 12 Circuit Load Center - Drawing No. 0E7815
E1
N1A
194
23
194
23
194
23
12Vdc TRANSER
COIL
194
TR
23
A
B
7
7
9
9
E1
TS TO
GENERATOR
CONTROL PANEL
1
4
3
6
OPEN
N2
N1A
F2
N2
126
205
240VAC
OUTPUT
N2A
F1
N1A
N1A
N1
N1
N1A
E1
E1
BLACK
RED
TO GENERATOR
OUTPUT
CIRCUIT BREAKER
E2
E1
E2
NEUTRAL (WHITE)
NEUTRAL (WHITE)
RED (MAIN 2)
NEUTRAL
CONNECTION
INSIDE SWITCH
B
N2A
240VAC TO
MAIN DISTRIBUTION
PANEL
205
B
N1A
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
BLU/WHT
ORG
BLU
20A/120V CIRCUIT 10
15A/120V CIRCUIT 9
20A/120V CIRCUIT 6
15A/120V CIRCUIT 5
20A/240V CIRCUIT 2
30A/240V CIRCUIT 1
30A/240V CIRCUIT 3
20A/240V CIRCUIT 4
15A/120V CIRCUIT 7
20A/120V CIRCUIT 8
15A/120V CIRCUIT 11
15A/120V CIRCUIT 12
E2
E2
B
VR2
C2
N2A
VIO
C1
A
T1
T2
YEL
ATS
T1
BRN
N2A
CUSTOMER
CIRCUIT
CONNECTION
B
E2
T2
BRN/WHT
YEL/WHT
GRY
B
E2
LEGEND
PNK
ATS-AUTOMATIC TRANSFER SWITCH
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2-5A, 600V FUSE
LC-CIRCUIT BREAKER (LOADS)
TR-TRANSFER RELAY
TS-TERMINAL STRIP
VIO/WHT
ORG/WHT
LC
XA,XB-LIMIT SWITCHES
®
28 Generac Power Systems, Inc.
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Section 7 — Electrical Data
Air-cooled 8.5 kW Generator
Electrical Schematic - 12 Circuit Load Center - Drawing No. 0E7815
E1
N1A
194
23
194
23
194
23
12Vdc TRANSER
COIL
194
TR
23
A
B
7
7
9
9
E1
TS TO
GENERATOR
CONTROL PANEL
1
4
3
6
OPEN
N2
N1A
F2
N2
126
205
240VAC
OUTPUT
N2A
F1
N1A
N1A
N1
N1
N1A
E1
E1
BLACK
RED
TO GENERATOR
OUTPUT
CIRCUIT BREAKER
E2
E1
E2
NEUTRAL (WHITE)
NEUTRAL (WHITE)
RED (MAIN 2)
NEUTRAL
CONNECTION
INSIDE SWITCH
B
N2A
240VAC TO
MAIN DISTRIBUTION
PANEL
205
B
N1A
126
N2A
BLACK (MAIN 1)
E1
NO
NC
NC
NO
E2
XB
XA
E2
B
BLU
VIO
15A/120V CIRCUIT 6
15A/120V CIRCUIT 5
20A/120V CIRCUIT 2
30A/240V CIRCUIT 1
30A/240V CIRCUIT 3
15A/120V CIRCUIT 4
15A/120V CIRCUIT 7
15A/120V CIRCUIT 8
N2A
T1
T2
YLW
BRN
ATS
T1
N2A
CUSTOMER
CIRCUIT
CONNECTION
B
E2
T2
BRN/WHT
YLW/WHT
GRY
B
E2
LEGEND
ATS-AUTOMATIC TRANSFER SWITCH
C1-UTILITY COIL & RECTIFIER
C2-GENERATOR COIL & RECTIFIER
F1,F2-5A, 600V FUSE
PNK
LC-CIRCUIT BREAKER (LOADS)
TR-TRANSFER RELAY
TS-TERMINAL STRIP
LC
XA,XB-LIMIT SWITCHES
®
Generac Power Systems, Inc. 29
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Section 7 — Electrical Data
Air-cooled 8.5 kW Generator
Wiring Diagram - 12 Circuit Load Center - Drawing No. 0E7687
®
30 Generac Power Systems, Inc.
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Section 7 — Electrical Data
Air-cooled 8.5 kW Generator
Wiring Diagram - 12 Circuit Load Center - Drawing No. 0E7687
®
Generac Power Systems, Inc. 31
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Enclosure – Drawing No. 0F0100-A
76
85
44
77
71
40
68
69
80
82
41
73
48
81
30
17
79
80
72
1
86
72
5
52
18
A
29
12
49
44
16
19
28
55
75
89
64
47
54
50
9
35
46
11
49
51
25
14
8
74
57
35
27
56
50
22
34
49
5
1
59
49
62
13
35
59
38
26
3
39
37
42
43
36
51
21
49
43
83
33
2
10
49
50
53
52
20
4
15
62
63
71
69
35
25
60
68
®
32 Generac Power Systems, Inc.
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Compartment – Drawing No. 0F0100-A
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
8
9
0D8312
0C6735
0F0063
0C7062
0F0066
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
1
1
1
1
1
1
1
ASSEMBLY, ENCLOSURE BASE
SUPPORT, ROOF FOLDING
ENCLOSURE, FRONT
ENCLOSURE, EXHAUST SIDE
ENCLOSURE, SIDE & BACK
ENCLOSURE, ROOF
PANEL, ALTERNATOR DIVIDER
PANEL, MUFFLER BOX SIDE
COVER, MUFFLER BOX
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
0F0710
047411
043116
0D3700
0D4662
090388
092120
0D1606
0D3167
0A3328
055414
092079
0A1658
0C3906
045771
0388040AJ0
14
14
5
18
11
35
2
1
1
1
1
RIVET POP 0.125" X 0.337"
SCREW HHC M6-1.0 X 16 G8.8
SCREW HHC M6-1.0 X 12 G8.8
NUT, LOCKING FLANGE M6-1.0
SCREW HHTT M8-1.2 X 20 BP
SCREW TAPTITE M6-1.0 X 12 YC
NUT LOCK TRIC M6 X 1.0 Y/ZNC
HOUSING, FAN
GASKET, BATTERY HOLD DOWN
PLUG, PLASTIC 0.593"
LUG SLDLSS #2-#8X17/64 CU
SCREW TAPTITE M6-1.0X25 BP
L/WASH SPECIAL ¼
SELF-ALIGN SCREW M6 HH
NUT HEX M8-1.25 G8 YC
CABLE, #6 RED BATTERY 38.5" (NOT
SHOWN)
WASHER FLAT 5/16" ZINC
WASHER LOCK 5/16
SCREW TAPTITE M5-0.8 X 10 BP
HARNESS, ENGINE
BUSHING, SNAP SB-1000-12
SCREW HHC M8-1.25 X 25 G8.8
RIVET,1/8" X 0.126" - 0.375" LSH POP
L/WASH SPECIAL #10
ASSEMBLY,BASE/C-PNL GRND WIRE
ASSEMBLY,BASE/DOOR GROUND WIRE
PLUG PLASTIC 1.375
GASKET, EXTRUDED TRIM
PLATE, "HOT"
GROMMET 2.75 X 1/16
0E9873
0D8333
0C8101A
0C8101B
0C8283
0C8284A
0C8284B
0C8284C
0C8285
0C8899A
0D1128
0E4244
0D2538A
0D1839
0D1840
0D2425
0D2588
0D2676
0D2677
0D2979B
0D2979C
0D2979D
0E4245
0E4245A
0E4245B
0D3057D
0D3059A
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
GASKET, DOOR SEAL
FOAM, BACK ENCLOSURE
FOAM, ROOF ENCLOSURE
FOAM, FRONT ENCLOSURE
BRACKET, BATTERY SUPPORT
PAD, 24"X48" WITH MOUNTING HOLES
PANEL, ENGINE DIVIDER
BAFFLE, INTAKE
HINGE, LIFT OFF, TYPE B KNUCKLE
BRACKET, TOP SUPPORT
BRACKET, BOTTOM SUPPORT
DUCT, BASE AIR
GASKET, FRONT DIVIDER
COVER, FRONT EXHAUST ENCLOSURE
COVER, BACK EXHAUST ENCLOSURE
CLOTH, HARDWARE 266.7mm x 146mm
CLOTH, HARDWARE 543mm x 146mm
CLOTH, HARDWARE 266.7mm x 387.4mm
FOAM, FRONT INTAKE BAFFLE
FOAM, TOP INTAKE BAFFLE
FOAM, BACK INTAKE BAFFLE
FOAM, BACK ENCL. STRIP
FOAM, EXHAUST SIDE ENCLOSURE
END
1
2
2
4
1
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
022145
022129
074908
10
6
8
1
1
4
2
2
1
2
2
11
1
1
1
1
1
0D2346
023484F
043107
0A7836
0A8475
0912970069
0912970070
055450
0E5968
0D3701
0D3472
0C8742
0C8911
0D8442
EXTERNAL CONNECTION BOX
POWER BLOCK
HARNESS GENERATOR TO EXTERNAL
CONNECTION BOX
33
0D3059B
1
FOAM, EXHAUST SIDE ENCLOSURE
FRONT
34
35
36
0E2874
0D7176
0D3059D
1
24
1
SCREW HHTR 1/4-20 X 3/4
WASHER, SELF LOCKING
FOAM, FRONT EXHAUST ENCLOSURE
COVER
FOAM, BACK EXHAUST ENCLOSURE
COVER
79
80
81
82
83
84
85
86
87
88
036937
022152
051713
022158
0D3059C
026850
049813
0D2537A
0E4321
0E1330A
2
5
2
5
1
1
1
1
1
1
SCREW PPHM #10-32 X 1
WASHER LOCK #10
WASHER FLAT M5
NUT HEX #10-32 STEEL
37
0D3059E
1
FOAM, EXHAUST FAN HOUSING
WASHER SHAKPROOF EXT 1/4 STEEL
NUT HEX M6-1.0 G8 YELLOW CHROME
HINGE, LIFT OFF, TYPE A KNUCKLE
PANEL, EXHAUST ALIGNMENT
GROMMET, 38.1 CROSS SLIT WITH
HOLE
38
39
40
41
42
43
44
45
0C7781A
0D3037
0D2537
0D2538
0D3037A
0A2115
022097
022473
2
1
1
1
1
4
9
8
DOOR, PAWL
LATCH, QUARTER TURN LOCKING
HINGE, LIFT OFF, TYPE A PIN
HINGE, LIFT OFF, TYPE B PIN
LATCH, QUARTER TURN NON-LOCKING
WASHER NYLON .250"
89
90
0E9692
042907
1
2
BRACKET, REGULATOR MOUNTING
SCREW HHC M8-1.25 X 16mm
WASHER LOCK M6-1/4"
WASHER FLAT ¼" ZINC
®
Generac Power Systems, Inc. 33
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Engine & Alternator – Drawing No. 0D8446-C
®
34 Generac Power Systems, Inc.
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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
2
3
4
5
6
7
8
9
0C6934
0D8062H
0D8057H
0C6043A
0D8274
0D6634A
0D3220
0D8314
056482
0C3168
0D8313
0D1846
0C7038
0D1647
0D2558
0C7038A
0C7758
0388050AD0
0C2417A
082121C
066386
029451
049451
022237
022511
022131
039288
022145
049820
045756
022129
022259
059637
0D4662
074994
057822
0F0462
0C2824
025145
0C4138
048031C
030340
048031C
030340
1
1
1
1
1
1
1
1
1
3
1
4
1
1
1
1
ADAPTOR, ENGINE
STATOR
ROTOR
CARRIER, REAR BEARING
FAN, 12" CURVED BLADE
MUFFLER
TAIL PIPE, MUFFLER
PANEL, MUFFLER BASE
BEARING 1.1811-2.8346
5/16 SPECIAL LOCK WASHER
BOLT, HHCS 3/8"-24 x 14.2"
BOLT, HHCS M8-1.25 x 345mm
BRACKET, ALTERNATOR MOUNTING
DUCT, ALTERNATOR AIR
GASKET, ALTERNATOR AIR DUCT
BRACKET, ENGINE MOUNTING
RUBBER MOUNT
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
41
42
4
1
1
1
CABLE, #6 48" BLACK BATTERY
EARTH STRAP 3/8X 3/8
CLIP-J, VYNL COAT 0.625" ID
ASSEMBLY BRUSH HOLDER
TAPE ELEC UL FOAM 1/8 X 1/2
WASHER FLAT .406ID X 1.62OD
WASHER LOCK 3/8
SCREW HHC 3/8-16 X 1-1/4 G5
WASHER FLAT 3/8 ZINC
SCREW HHC M8-1.25 x 55 G8.8
WASHER FLAT 5/16 ZINC
NUT LOCK HEX M8-1.25 NYL INSERT
SCREW TAPTITE M6-1.0X10 BP
WASHER LOCK M8-5/16
NUT HEX 5/16-18 STEEL
SCREW TAPTITE 3/8-16 X 3/4 BP
SCREW 5/16-18X3/4" HH THD ROLL
HOSE RES 1/2 LP GAS
CLAMP HOSE #8 .53 - 1.00
NUT HEX W/TOOTH WSHR M8-1.25
SCREW TAP-R #10-32 x 9/16
U-BOLT 5/16"-18 X 1.25" WITH SADDLE
GASKET, EXHAUST PORT
CLAMP HOSE BAND 1/4"
HOSE 1/4" I.D.
1
1.8 FT
1
5
4
4
4
14
4
2
10
8
2
4
3 FT
4
4
3
1
2
2
1.33 FT
2
1.33 FT
CLAMP HOSE BAND 1/4"
HOSE 1/4" I.D.
®
Generac Power Systems, Inc. 35
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Engine – Drawing No. 0E8774-G Part 1
®
36 Generac Power Systems, Inc.
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Engine – Drawing No. 0E8774-G Part 1
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0C5729
1
ASSEMBLY, CRANKCASE HOUSING
WITH SLEEVE
SEAL, 38 I.D. CRANKSHAFT
SCREW, TAPTITE M6-1.0 X 12 YC
ASSEMBLY, BREATHER
GASKET, BREATHER COVER
SEPARATOR, OIL BREATHER
ASSEMBLY, HEAD #1 G&S
RETAINER, PISTON PIN 20
ROCKER, COVER NO OIL FILL
STUD M8-1.25/10MM X 30 G5 ZINC
PISTON, HC
SET, PISTON RING 90MM
PIN PISTON
ASSEMBLY, CAMSHAFT & GEAR
SHAFT, GOVERNOR
ROLLER BEARING, GOVERNOR PLATE
ROLLER BEARING, GOVERNOR
ASSEMBLY,GOVERNOR GEAR
SPOOL, GOVERNOR MACHINED
GASKET, CRANK CASE
SEAL, OIL PASSAGE
ASSEMBLY, CRANKSHAFT HORIZONTAL
DIRECT DRIVE
ASSEMBLY, CONNECTING ROD
SCREW SHC M6-1.0 X 50 G8.8
SCREEN, OIL PICKUP
ASSEMBLY, OIL PUMP
SLEEVE, SEAMED DOWEL 10 DIA.
COVER, OIL RELIEF
SPRING, OIL RELIEF
BALL, 1/2D OIL RELIEF
37
38
39
40
41
0C3971C
0C5305
0C3027
0E9842
0C5731
1
1
1
1
1
ASSEMBLY, DIPSTICK WITH HANDLE
TUBE, DIPSTICK
O-RING, OIL CLR 3/8 X 1/2
SEAL, 42 I.D. CRANKSHAFT
ASSEMBLY, HOUSING COVER WITH
SLEEVE
SCREW, HHFC M10-1.5 X 55
SCREW HHFC M6-1.0 X 25
ASSEMBLY, OIL FILL CAP
HOOK, LIFTING
ROCKER, COVER WITH OIL FILL
GASKET, VALVE COVER
KEEPER, VALVE SPRING
RETAINER, VALVE SPRING
SPRING, VALVE
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16A
16B
17
18
19
20
21
0E9843
090388
1
3
1
1
3
1
4
1
4
2
2
2
1
1
2
1
1
1
1
1
1
0C5372
0C3005
0E3372B
0D8067A
071983
0C2981C
045761A
0E2985
021533
0E1466
0D4041
0C2983
0C2985A
0C2985B
0D4042
0A7811
0C2977
0C5943
0E4357E
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
0C3006
080318
093064
0C8808
0D2723B
0C2979
086515
0D2274
0D3867
078672
0C5371
072694
0D3998
0C3027
0D5313
0D6024
0C2976
086516
0C2229
083897
0D8067B
0D9853D
0C2978
043790A
9
8
1
2
1
2
8
4
4
2
4
4
4
2
4
2
12
2
2
4
1
4
2
1
SEAL, VALVE STEM D7
WASHER, VALVE SPRING
STUD, ROCKER ARM PIVOT
NUT HEX M8-1.0 G8 YEL CHR
O-RING, 3/8" X 1/2"
ROCKER ARM
PLATE, PUSH ROD GUIDE
SCREW HHFC M8-1.25 X 65
VALVE, EXHAUST
VALVE, INTAKE
TAPPET, SOLID
ASSEMBLY, HEAD #2 G&S
PUSHROD, 147
GASKET, HEAD
BARBED ELBOW 90 3/8NPT X 3/8
L0CKTITE
KIT GASKET
KIT PISTON & RINGS
KIT BREATHER ASSEMBLY
KIT GOVERNOR ASSEMBLY
KIT HEAD ASSEMBLY CYLINDER 1
KIT HEAD ASSEMBLY CYLINDER 2
KIT OIL RELIEF
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
0E3223
0D2157
0E6098
0D4123A
078699E
0C3011
0C3009
0C3010
093873
0C5315
0C5998
0D1667
0C2991
0C2988
0C2992
2
2
1
1
2
2
2
2
2
1
1
1
2
1
1
66
67
68
69
70
71
72
73
0D4010
0D4011
0D4012
0D4013
0D8675A
0D8675B
0D4015
0D4016
1
1
1
1
1
1
1
1
WASHER, LOCK RIB M6
GEROTOR, OUTER
CLAMP, OIL TUBE
ARM, GOVERNOR
E-RING, GOVERNOR ARM
THRUST WASHER, GOVERNOR
BUSHING, GOVERNOR LOWER
KIT GEAR COVER
®
Generac Power Systems, Inc. 37
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Engine – Drawing No. 0E8774-G Part 2
74
138
75
139
135
122
124
125
123, 145
125
76
77
136
137
120
79
124
133
116
134
142
78
32
119
143
80
115
127
114
11
121
118
8
81
29
8
130
126
99
96
95
83
84
109
103
105
86
85
88
110
99
1
89
90
101
89
91
107
108
112
92
112
113
111
®
38 Generac Power Systems, Inc.
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Engine – Drawing No. 0E8774-G Part 2
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
74
75
76
77
78
0C5136A
0C3024
0C3040
0C8127
0D8564A
0D8564B
0D2595
0D4417
0C3025
0D3083
0C7292
070185B
075281
0F2094
2
1
1
1
1
1
4
4
1
1
1
1
1
2
KNOB, AIR CLEANER
COVER, AIRBOX NG/LP
PRE-CLEANER,
ELEMENT, AIR CLEANER
ASSEMBLY, MIXER/AIRBOX 990
ASSEMBLY, MIXER/AIRBOX 760
SCREW SHOULDER (8MM) M6-1.0 X 18
WASHER,RUBBER 1/4" X 1/8" THICK
SWITCH, OIL PRESS
ASSEMBLY, OIL DRAIN HOSE
NIPPLE, 3/4"-16 UNF
OIL FILTER
SWITCH, THERMAL 284F
SCREW, M3-0.5 X 6 SEMS
110
111
112
0C3022A
0D1131
045756
1
1
25
HOUSING, BLOWER NG COOLER
GUARD, FAN
SCREW TAPTITE M6-1X10 YELLOW
CHROME
NUT, GROMMET 1/4 PLUG
HOSE, BREATHER
WASHER FLAT 5/16-M8 ZINC
WASHER LOCK M8-5/16
WRAPPER, UPPER CYLINDER 1
WRAPPER, LOWER CYLINDER 1
WRAPPER, LOWER CYLINDER 2
WRAPPER, UPPER CYLINDER 2
SCREW TAPTITE M5-0.8 X 8 ZP
ASSEMBLY, GROUND WIRE
ASSY, IGN COIL W/DIODE NO ADV
WASHER LOCK M6-1/4
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
0C9763
0C3036A
022145
022129
0C3018
0C3019
0D1142A
0D1143
0E6043
0F1177
0F1338B
022097
092079
0E4271
0D4529
022129
061906
082774
0E5343
0C8468
0C3048
0D3754
0D3742
0C8482
0E0486
0D3743
0D3705
4
1
1
1
1
1
1
1
2
1
1
4
4
1
2
2
2
1
1
1
1
1
1
1
1
1
1
79
80
81
82
83
84
85
86
87
88
035461A
2
BARBED STR 1/4NPT X 3/8 WITH VIBRA
SEAL
CLAMP HOSE .38-.87
HOSE, 3/8" I.D. X 6" LONG
COOLER, OIL
PLASTITE,1/4-15 X 3/4
GASKET, MANIFOLD / PORT
MANIFOLD CYLINDER 2
MANIFOLD CYLINDER 1
SLEEVE, RUBBER
WASHER FLAT M8 SS
WASHER LOCK M8 SSTL
SCREW SHC M8-1.25 X 20 G12.9
PLATE, BACKING WITH OIL COOLER
GROUND WIRE CONNECTOR
FLYWHEEL ASSEMBLY
FAN, NYLON
SCREW TAPTITE M6-1.0 X 25 BP
STARTER
SPARKPLUG
89
90
91
92
93
94
95
96
97
0C7649
0C9806
0C3026
0C9764
0C3043
0C7694
0C7693
0C3041A
070008
070006
040976
0C3016A
0E4997
0C3725B
0C3031
0C3032
0A5992
051754
0C3033
0C3034
0C8549A
4
2
1
4
2
1
1
2
4
4
4
1
1
1
1
1
2
2
1
1
1
WASHER LOCK M8-5/16
SCREW HHC M8-1.25 X 85 G8.8
KEY, WOODRFF 4 X 19D
NUT HEX LOCK M10-1.50
SPRING, ANTI-LASH
ROD, GOVERNOR CONTROL
ASSEMBLY, GOVERNOR LEVER
SPRING, GOVERNOR
ASSEMBLY, GOVERNOR ADJUSTER
SCREW SHC M10-1.5 X 75 G10.9
SPRING, GOVERNOR IDLE
ASSEMBLY, GOVERNOR ADJUSTER
BRACKET
SEAL, GOVERNOR SHAFT
NUT HEX M8-1.25 G8
SCREW HHFC M6-1.0 X 10mm
O-RING 0.49" I.D. X 0.07" THICK
ASSY, IGN COIL W/DIODE NO ADV
98
99
100
101
102
103
104
105
106
107
108
109
PLATE, FAN
140
142
143
144
145
0C2993
045771
0D6147
0E8152
0F1338A
1
1
7
1
1
WASHER SHAKEPROOF INT M8 SS
SCREW HHC M8-1.25 X 12 G8.8
WASHER, 25mm I.D.
NUT,HEX M24
SNORKEL, AIR INTAKE
®
Generac Power Systems, Inc. 39
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Control Panel Assembly – Drawing No. 0E7974-F
®
40 Generac Power Systems, Inc.
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Control Panel Assembly – Drawing No. 0E7974-F
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
0E7886A
0E7886C
1
1
CIRCUIT BREAKER 30A X 2P 240V (7KW)
CIRCUIT BREAKER 40A X 2P 240V
(8.5KW)
CIRCUIT BREAKER 45A X 2P 240V
(11KW)
CIRCUIT BREAKER 50A X 2P 240V
(12KW)
CIRCUIT BREAKER 60A X 2P 240V
(13KW)
CIRCUIT BREAKER 70A X 2P 240V
(15KW)
ASSEMBLY, BATTERY CHARGER
ENGINE
ASSEMBLY, POTTED REGULATOR
RELAY, 12V 25A SPST
BLOCK 1 POSITION
22
23
0D5240
0D9784
0D9784
1
6
4
SWITCH, SPST (ON)-ON N/O
NUT HEX LOCK M3-0.5 NYLON INSERT
NUT HEX LOCK M3-0.5 NYLON INSERT
(7KW)
NEUTRAL CONNECTOR
HARNESS, CONTROL PANEL (NOT
SHOWN)
HARNESS, CONTROL PANEL WIRE (NOT
SHOWN) (7KW)
SCREW TAPTITE, M5-0.8 x 10 BP
NUT HEX LOCK M5-0.8 NYLON INSERT
TRANSFORMER
SCREW HHC 1/4"-20 x 1/2"
FUSE 5A X AGC5
BLOCK TERMINAL STRIP 20A 4 X 6 X
1100V
RELAY PANEL 12VDC DPDT 10A 240VAC
SCREW PPHM M4-0.7 x 10mm
WASHER FLAT M4
COVER, CONTROL PANEL COMPONENT
COVER, CONTROL PANEL COMPONENT
(7KW)
SCREW PPHMS/LW #6-32 x 1/4"
SCREW HHC M5-0.8 x10mm
COVER, CONTROL PANEL
COVER, CONTROL PANEL (7KW)
NUT FLANGE M6-1.0 NYLOK
ASSEMBLY, ROOF/DOOR GROUND WIRE
SCREW HHTR 1/4"-20 X 3/4"
WASHER LOCK SPECIAL 1/4"
WASHER FLAT 1/4"-M6
0E7886D
0E7886E
0E7886F
0E7886G
0A1801
1
1
1
1
1
24
26
0D8502
0D8441
1
1
0E0120
1
27
29
30
31
32
33
074908
082025
0C3910
022507
099727
046689
4
6
1
2
1
1
2
3
4
5
6
7
083049
0C2174
075210A
0D3062
0D8615
1
1
1
4
1
HEX STAND-OFF #6-32 x 3/8"
ASSEMBLY, HOME STANDBY
CONTROLLER
ASSEMBLY, HOME STANDBY
CONTROLLER (7KW)
34
35
36
37
063617
075475
043180
0D8439
0E0119
1
4
2
1
1
0D8615A
1
8
9
10
11
032300
022676
0E4494
0E7890
2
1
1
1
HOLDER, FUSE
FUSE, 15AMP X AGC15
SWITCH, ROCKER DPDT ON-OFF-ON
CIRCUIT BREAKER MOUNTING
BRACKET
38
39
40
092036
045770
0E7866
0E7867
0D3700
0912970069
0E2874
0A1658
022473
038750
022097
049813
031879
031879
023897
8
2
1
1
8
1
1
2
3
1
3
1
6
4
2
12
13
15
17
18
19
023484E
075476
0E6480
0C1085
0D8443
054502
053623
1
4
6
4
1
1
1
SNAP BUSHING
41
42
43
44
45
46
47
48
49
SCREW PPHM M4-0.7 x 16mm
NUT HEX LOCK M4-0.7 NYLON INSERT
SCREW PPHM M3-0.5 X 8mm
DECAL, CONTROL PANEL (NOT SHOWN)
CIRCUIT BREAKER 3 X 1 ETA 46-500-P
CIRCUIT BREAKER 2.5 X 1 ETA 46-500-P
(7KW)
CONTROL, PANEL BOTTOM
CONTROL, PANEL BOTTOM (7KW)
SCREW HHC M5-0.8 x 30mm
SCREW HHC M6-1.0 x 30mm
WASHER LOCK M6-1/4"
NUT HEX M6-1.0
WASHER FLAT #4
WASHER FLAT #4 (7KW)
WASHER FLAT #10
20
21
0E7870
0E7871
075235
1
1
4
50
®
Generac Power Systems, Inc. 41
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
GTS Load Center – Drawing No. 0E7973-B
12
31
37
7
9
6
11
5
2
3A
22
3
39
9
27
36
15
24
20
10
13
1
19
3B
16
22
26
17
40
21
23
18
38
14
8
33
32
34
38
34
®
42 Generac Power Systems, Inc.
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
GTS Load Center – Drawing No. 0E7973-B
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
3A
3B
3C
3D
4
5
6
7
8
0D3086
0D3092
0C2237
077220
077220A
082574
084464
074908
024912
0A1658
063617
0E7889
0A1495
0A1661
022473
055450
0D4684
0E7900
056326
022152
064526
0E6155
063378
0D3094
074138
036933
077033
048850
028739
0A2110
0D3191
0D3088
073591
073590A
040213B
0E7888C
0E7888
0E7888B
0E7888A
0D3320
0D3093
0D8597
075475
0A7215
0E6193
1
1
1
1
1
1
1
6
1
1
1
1
4
2
1
1
1
BOX GTS LOAD CENTER
COVER, 12 POSITION GTS LOAD CENTER
TRANSFER SWITCH HOME STANDBY 100A 2P 250V
COIL UTILITY
COIL STANDBY
INSULATOR-SIDEWALL (NOT SHOWN)
LIMIT SWITCH OPERATION (NOT SHOWN)
SCREW HHTT M5-0.8 X 10
SCREW HHTT 1/4-20 X 5/8
LOCK WASHER, SPECIAL-1/4"
RELAY PANEL 12VDC DPDT 10A@240VAC
12 CIRCUIT LOAD CENTER 125A/240V
SCREW HHTT M4-0.7 X 10
RIVET POP .156" X .675"
WASHER FLAT 1/4-M6 ZINC
PLUG PLASTIC 1.375
HARNESS ADAPTER PLATE
SUBPLATE, LOAD CENTER
TRIM VINYL BLACK 1/8"GP
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1
10.5"
6
2
1
4
1
2
6
6
1
4
4
1
1
2
2
4
3
1
5
1
1
1
1
2
WASHER LOCK #10
SCREW HWHS #6-25 X 3/8"
ARM EXTENDER PIN
HOLDER CABLE TIE
HARNESS,GTS TO MAIN PANEL
LUG QUICK DISCONNECT NI-S 10X45 DEG BRASS / TIN
SCREW PPHM #10-32 X 3/8"
LUG SLDLSS 1/0-#14X9/16 AL/CU
BLOCK TERMINAL 20A 5 X 6 X 1100V
TIE WRAP 3.9" X .10"
SCREW SWAGE 1/4-20 X 1/2" ZINC
COVER, RELAY & TERMINAL BLOCK
WIRE HARNESS,GTS LOAD CENTER (NOT SHOWN FOR CLARITY)
FUSE HOLDER
FUSE 5A X BUSS
PCB SUPPORT SNAP-IN 1-3/8"
CIRCUIT BREAKER 20A 1P
CIRCUIT BREAKER 20A 2P
CIRCUIT BREAKER 15A 1P
CIRCUIT BREAKER 30A 2P
COVER - HARNESS ENTRY
HARNESS, GTS TO EXT CONN BOX
HARNESS, GTS TO EXT CONN BOX (8.5KW)
SCREW PPHM M4-0.7 X 10
SCREW SW 1/4"-20 X 5/8" WITH WASHER
BRACKET, ARM EXTENDER
38
39
40
4
1
®
Generac Power Systems, Inc. 43
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Regulator – Drawing No. 0D8720-D
®
44 Generac Power Systems, Inc.
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Section 8 — Exploded Views and Parts Lists
Air-cooled 8.5 kW Generator
Regulator – Drawing No. 0D8720-D
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
0D5694
0F3154
0C4647
0D4166
0C6070
043180
022264
075475
0C5760E
0C6606
097934
0C4645
0C5761
0C5968
0C6066
0C5759
0C5764
0C5764A
070728
0C6069
0C5762
045764
0C6731
0C6067
0C4706
0C6068
0C4643A
026073
026073
0A4032
0D3308
024310
028414A
0D5698A
0D3973
1
1
1
1
1
4
4
4
1
2*
2*
2*
2
2
2
2
2
2
4
2
2
16
2
2
2
2
2
1
2
2*
4
1
1
CASTING, TWIN REGULATOR HOUSING
SOLENOID COIL, 12VDC
GASKET , SOLENOID
PLUNGER, LP REGULATOR ASSEMBLY
SPRING-SOLENOID, PLUNGER
WASHER, FLAT M4
WASHER, LOCK M4
SCREW PPHM M4-0.7 X 10
JET, GN 410 ENGINE LP (7KW)
BARBED STRAIGHT 1/2NPT x 1/2
O-RING, CHECK VALVE
ADJUSTER SCREW, TWIN REGULATOR
LEVER, REGULATOR
SUPPORT, INLET SEAL
SEAL, INLET
PIN, PIVOT ARM
SPRING, REGULATOR
SPRING, REGULATOR (7KW)
SCREW, PFHMS M3-0.5 x 5
GASKET, DIAPHRAGM
COVER, TWIN REGULATOR
SCREW, TAPTITE M4X8 BP
18
19
20
21
22
23
24
25
26
27
RIVET, POP .118 X .125
SUPPORT, DIAPHRAGM
DIAPHRAGM, TWIN REGULATOR
CAP, D I APHRAGM SUPPORT
INLET, TWIN REGULATOR 11.11 DIA.
PLUG, STANDARD PIPE 1/8" STEEL SQUARE HEAD
PLUG, STANDARD PIPE 1/8" STEEL SQUARE HEAD (7KW)
PIN, LIMITED ADJUSTMENT
WASHER, FLAT M3 X 10mm O.D.
PLUG, STANDARD PIPE 1/2" STEEL SQUARE HEAD (7KW)
BARBED STRAIGHT 1/8"NPT X 1/4"
JET IDLE PRIMER PHILLIPS HD (V-TWIN ONLY)
PLUG, EXPANSION 16mm
28
29
30
31
32
37
1
1
* A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY
®
Generac Power Systems, Inc. 45
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Section 9 — Notes
Air-cooled 8.5 kW Generator
®
46 Generac Power Systems, Inc.
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Section 9 — Notes
Air-cooled 8.5 kW Generator
®
Generac Power Systems, Inc. 47
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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.
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 modifi-
cation 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, dur-
ing 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 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 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 impor-
tant 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 serv-
ice, 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 fol-
lowing address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part 1
®
48 Generac Power Systems, Inc.
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Section 10 – Warranty
Air-cooled 8.5 kW Generator
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 con-
tinue 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 man-
ufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsi-
ble for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac
ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterfeit and/or “grey market” part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
3) Ignition System including:
a) Spark plug
b) Ignition module
1.2) LPG/Natural Gas carburetion assembly and its internal
components.
a) Fuel controller (if so equipped)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
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)
5) Crankcase Breather Assembly including:
a) Breather connection tube
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
*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
®
Generac Power Systems, Inc. 49
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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 pur-
chaser/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 main-
tenance 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, freez-
ing, 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 replace-
ment 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. SPECIFICALLY, GENERAC MAKES
NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
®
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Revision 10/01/04
Part No. 0F0091
Revision B (11/15/04)
Printed in U.S.A.
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