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Generac Power Systems 004692-2 Installation And Owner's Manual

8.5 kw liquid-cooled, prepackaged automatic standby generator
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CENTURION
CENTURION
CENTURION
®
!
Not intended for use as Primary Power in place of utility or
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!!
*This manual should remain with the unit.*
in life-support applications.
DANGER
Installation and
Owner's Manual
Air-cooled, Prepackaged
Automatic Standby Generators
Models:
004692-2 (8.5 kW)
GENERAC
POWER SYSTEMS, INC.
CENTURION
CENTURION
CENTURION
®
R
R
!

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Summary of Contents for Generac Power Systems 004692-2

  • Page 1 Not intended for use as Primary Power in place of utility or DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!! Installation and Owner’s Manual Automatic Standby Generators ® in life-support applications. DANGER Air-cooled, Prepackaged Models: 004692-2 (8.5 kW) GENERAC POWER SYSTEMS, INC. CENTURION CENTURION CENTURION...

  • Page 2: Introduction

    This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views and lists of repair parts, for Centurion model: • 004692-2 – 8.5 kW NG, 8.5 kW LP , V-twin GT-990 Engine OPERATION AND MAINTENANCE It is the operator's responsibility to perform all safe-...

  • Page 3: Table Of Contents

    Section 5 – Troubleshooting ...22 Troubleshooting Guide ...22 Section 6 – Mounting Dimensions...23 Section 7 – Electrical Data ...24 Section 8 – Exploded Views and Parts Lists...32 Section 9 – Notes ...46 Section 10 – Warranty ...48 Generac ® Power Systems, Inc.

  • Page 4: Safety Rules

    Generac ® Power Systems, Inc. GENERAL HAZARDS • 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.

  • Page 5: Standards Index

    NANCE OF FARM STANDBY ELECTRICAL SYS- TEMS, available from the American Society of Agricultural Engineers, 2950 Niles Road, St. Joseph, MI 49085. 9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE, available same as Item 1. Generac ® Power Systems, Inc.

  • Page 6: Section 1 - General Information

    1. Low Oil Pressure Sensor 2. High Temperature Sensor Generac ® Power Systems, Inc. There are LED readouts on the control panel to noti- fy personnel that one of these faults has occurred.

  • Page 7: The Generator

    Figure 1.1 – 8.5 kW, V-Twin GT-990/760 Engine Exhaust Enclosure Section 1 — General Information Air-cooled 8.5 kW Generator Data Decal Oil Dipstick Air Filter Oil Filter Control Panel Fuel Regulator Fuel Inlet Battery Compartment Generac ® Power Systems, Inc.

  • Page 8: Specifications

    -20°F (28.8°C to 104°F (40°C) Model 004692 GT-990/760 26 @ 3,600 rpm 992cc Aluminum w/Cast Iron Sleeve Overhead Valves Solid-state w/Magneto RC12YC 0.50 mm (0.020 inch) 9.5:1 12 Vdc Approx. 1.7 Qts Generac Part # 70185 Generac Part # 0C8127 3,600...

  • Page 9: System Set Led

    LP Vapor (**) Full Load 1.98/72.5 RECONFIGURING THE FUEL SYSTEM NOTE: Figure 1.4 - Demand Regulator OUTLET PORTS FUEL HOSE BRASS HOSE FITTING BRASS HOSE FITTING 1/8 NPT ADJUSTER SCREWS Generac ® Power Systems, Inc. SMALL FUEL JET REGULATOR HOUSING PORT...

  • Page 10: Location

    • Install the generator as close as possible to the transfer switch. HOWEVER, REMEMBER THAT LAWS OR CODES MAY REGULATE THE DIS- TANCE. Generac ® Power Systems, Inc. ◆ 1.10.2 TRANSFER SWITCH The transfer switch shipped with this generator is rated 100 amps maximum at 120/240 volts AC single phase.

  • Page 11: The Battery

    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. Generac ® Power Systems, Inc.

  • Page 12: Section 2 - Post Installation Start-Up And Adjustments

    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. 10 Generac ® Power Systems, Inc. 4. Use an accurate AC voltmeter to check UTILITY power source voltage across transfer switch ter- minals N1 and N2.

  • Page 13: Generator Tests Under Load

    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. CHECKING AUTOMATIC OPERATION ADJUSTING THE REGULATOR (NATURAL GAS ONLY) Generac ® Power Systems, Inc. 11...

  • Page 14: Engine Governor Adjustment

    35.4 amps If this procedure or equipment are not available, locate the nearest Generac Dealer and they can per- form the adjustments. A service fee may be charged for this adjustment. ENGINE GOVERNOR ADJUSTMENT...

  • Page 15: Additional Corrosion Protection

    L o c a t e y o u r n e a r e s t AUTO MAN. FUSE EXERCISE TIME Generac ® Power Systems, Inc. 13 d e a le r a t : POWER SYSTEMS, INC. SYSTEM SET LOW OIL HIGH TEMP.

  • Page 16: Off" Position

    (load terminal lugs T1/T2 connect to terminal lugs E1/E2). 14 Generac ® Power Systems, Inc. Upon restoration of utility source voltage above a pre-...

  • Page 17: Transfer Back To Utility Power Source

    2 on the controller printed circuit board (“Remote Not Auto”) is ON. If the exerciser is not set using the “Set Exercise Time Switch”, the generator will automatically exercise 7 days after the battery connection was made. Generac ® Power Systems, Inc. 15...

  • Page 18: Protection Systems

    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. The generator panel’s 15 amp fuse (Figure 4.1) pro- tects the DC control circuit against overload.

  • Page 19: Changing The Engine Oil

    2. Remove the cover and air filter. 3. Wipe away dust or debris from inside of the air box and around edges. 4. Install the new air cleaner into the air box. Oil Filter Generac ® Power Systems, Inc. 17...

  • Page 20: Spark Plug(S)

    (Figure 4.5). Figure 4.5 – Setting the Spark Plug Gap SET PLUG GAP AT 0.50 mm (0.020 inch) 18 Generac ® Power Systems, Inc. The battery should be inspected per the “Service Schedule,” Section 4.11. The following procedure should be followed for inspection: 1.

  • Page 21: Adjusting Valve Clearance

    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.

  • Page 22: Attention After Submersion

    4.10 ATTENTION AFTER SUBMERSION If the generator has been submerged in water, it must not be started and operated. Following any submersion in water, have a Generac Authorized Dealer thoroughly clean and dry the generator. 4.11 OUT OF SERVICE PROCEDURE 4.11.1 REMOVAL FROM SERVICE...

  • Page 23: Service Schedule

    4.13 SERVICE SCHEDULE ATTENTION: It is recommended that all service work be performed by the nearest Generac Authorized Dealer. SYSTEM/COMPONENT X = Action R = Replace as Necessary * = Notify Dealer if Repair is Needed. FUEL Fuel lines and connections*...

  • Page 24: Section 5 - Troubleshooting

    There is no transfer to standby after utility source failure. Unit consumes large amounts of oil. *Contact the nearest Generac Authorized Dealer for assistance. 22 Generac ® Power Systems, Inc. CAUSE 1. Fuse blown 2. Loose, corroded or defective battery cables 3.

  • Page 25: Section 6 - Mounting Dimensions

    Section 6 — Mounting Dimensions Air-cooled 8.5 kW Generator Drawing No. 0D3739-B Generac ® Power Systems, Inc. 23...

  • Page 26: Section 7 - Electrical Data

    SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TB - INSULATED TERMINAL BLOCK TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) BLACK BATTERY CUSTOMER SUPPLIED 24 Generac ® Power Systems, Inc. ENGINE WIRING BATTERY CHARGER 225B...
  • Page 27 Wiring Diagram - 8.5 kW – Drawing No. 0D8500-B CONTROL PANEL BOX 224A 225A AUTO MANUAL Section 7 — Electrical Data Air-cooled 8.5 kW Generator CLOSEST TO BEARING 240V GENERATOR OUTPUT TO TRANSFER SWITCH CONTACTOR CUSTOMER CONNECTION Generac ® Power Systems, Inc. 25 STATOR...
  • Page 28 SP1, SP2 - SPARK PLUGS SW1 - AUTO / OFF / MANUAL SWITCH SW2 - SET EXERCISE SWITCH SM - STARTER MOTOR TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.) 26 Generac ® Power Systems, Inc. BATTERY 225B...
  • Page 29 Electrical Schematic - Drawing No. 0D8501-B C2-6 C2-5 POWER WINDING (STATOR) C2-1 Section 7 — Electrical Data Air-cooled 8.5 kW Generator 240VAC UTILITY INPUT 12Vdc TRANSFER RELAY COIL CUSTOMER CONNECTIONS NEUTRAL 120V 120V 240V BATTERY BLACK CUSTOMER SUPPLIED Generac ® Power Systems, Inc. 27...
  • Page 30 Electrical Schematic - 12 Circuit Load Center - Drawing No. 0E7815 LEGEND 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 XA,XB-LIMIT SWITCHES 28 Generac ® Power Systems, Inc. NEUTRAL CONNECTION INSIDE SWITCH BRN/WHT YEL/WHT VIO/WHT ORG/WHT...
  • Page 31 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 Generac ® Power Systems, Inc. 29 TS TO GENERATOR CONTROL PANEL TO GENERATOR OUTPUT CIRCUIT BREAKER...
  • Page 32 Section 7 — Electrical Data Air-cooled 8.5 kW Generator Wiring Diagram - 12 Circuit Load Center - Drawing No. 0E7687 30 Generac ® Power Systems, Inc.
  • Page 33 Section 7 — Electrical Data Air-cooled 8.5 kW Generator Wiring Diagram - 12 Circuit Load Center - Drawing No. 0E7687 Generac ® Power Systems, Inc. 31...

  • Page 34: Section 8 - Exploded Views And Parts Lists

    Section 8 — Exploded Views and Parts Lists Air-cooled 8.5 kW Generator Enclosure – Drawing No. 0F0100-A 32 Generac ® Power Systems, Inc.
  • Page 35 049813 0D2537A 0E4321 0E1330A 0E9692 042907 Generac 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...
  • Page 36 Section 8 — Exploded Views and Parts Lists Air-cooled 8.5 kW Generator Engine & Alternator – Drawing No. 0D8446-C 34 Generac ® Power Systems, Inc.
  • Page 37 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" 1.33 FT HOSE 1/4" I.D. CLAMP HOSE BAND 1/4" 1.33 FT HOSE 1/4" I.D. Air-cooled 8.5 kW Generator Generac ® Power Systems, Inc. 35...
  • Page 38 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.
  • Page 39 0D4010 0D4011 0D4012 0D4013 0D8675A 0D8675B 0D4015 0D4016 Generac 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...
  • Page 40 Section 8 — Exploded Views and Parts Lists Air-cooled 8.5 kW Generator Engine – Drawing No. 0E8774-G Part 2 38 Generac ® Power Systems, Inc. 123, 145...

  • Page 41: Washer Lock

    0D3742 0C8482 0E0486 0D3743 0D3705 0C2993 045771 0D6147 0E8152 0F1338A Generac 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...
  • Page 42 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.
  • Page 43 0E2874 0A1658 022473 038750 022097 049813 031879 031879 023897 Generac 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...
  • Page 44 Section 8 — Exploded Views and Parts Lists Air-cooled 8.5 kW Generator GTS Load Center – Drawing No. 0E7973-B 42 Generac ® Power Systems, Inc.
  • Page 45 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 Air-cooled 8.5 kW Generator Generac ® Power Systems, Inc. 43...
  • Page 46 Section 8 — Exploded Views and Parts Lists Air-cooled 8.5 kW Generator Regulator – Drawing No. 0D8720-D 44 Generac ® Power Systems, Inc.
  • Page 47 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 Air-cooled 8.5 kW Generator Generac ® Power Systems, Inc. 45...

  • Page 48: Section 9 - Notes

    Section 9 — Notes Air-cooled 8.5 kW Generator 46 Generac ® Power Systems, Inc.
  • Page 49 Section 9 — Notes Air-cooled 8.5 kW Generator Generac ® Power Systems, Inc. 47...

  • Page 50: Section 10 - Warranty

    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.

  • Page 51: Emission Control System Warranty

    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”...
  • Page 52 "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.

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