Generac Portable Generator 004692 0 User Manual
®
POWER SYSTEMS, INC.  
Installation and  
Owner’s Manual  
Air-cooled, Prepackaged  
Automatic Standby Generators  
Models:  
004692-0 (8.5 kW)  
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  
3.5 Manual Transfer Operation ........................14  
Introduction ........................Inside Front Cover  
Read This Manual Thoroughly ........................IFC  
Contents ..........................................................IFC  
Operation and Maintenance ............................IFC  
How to Obtain Service ....................................IFC  
3.5.1 Transfer to Generator  
Power Source......................................14  
3.5.2 Transfer Back to Utility  
Power Source......................................15  
Authorized Dealer Locator Number ................IFC  
3.6 Setting the Exercise Timer ..........................15  
3.7 Protection Systems ......................................15  
3.7.1 Low Oil Pressure Switch ..................15  
3.7.2 High Temperature Switch ................15  
3.7.3 Overcrank ........................................16  
3.7.4 Overspeed ........................................16  
Safety Rules ........................................................2  
Standards Index..................................................3  
Section 1 – General Information ..................4  
1.1 Unpacking/Inspection ....................................4  
1.2 Protection Systems ........................................4  
1.3 System Set LED ............................................4  
1.4 Your Generator ..............................................5  
1.5 Specifications ................................................6  
1.5.1 Generator ..........................................6  
1.5.2 Engine ................................................6  
1.6 Fuel Requirements and Recommendations....7  
1.7 Fuel Consumption ........................................7  
1.8 Reconfiguring the Fuel System ......................7  
1.9 Location ........................................................8  
1.9.1 Generator ..........................................8  
1.9.2 Transfer Switch..................................8  
1.10 Battery Installation ........................................8  
1.11 The Battery....................................................8  
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  
4.6 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 ........................9  
2.1 Before Initial Startup ....................................9  
2.2 Check Transfer Switch Operation..................9  
2.3 Electrical Checks ..........................................9  
2.4 Generator Tests Under Load ......................10  
2.5 Checking Automatic Operation....................11  
2.6 Adjusting the Regulator (Natural Gas Only) ..11  
2.7 Engine Governor Adjustment ......................12  
2.7.1 Additional Corrosion Protection ......12  
2.8 Voltage Regulator Adjustment......................12  
Section 3 – Operation ....................................13  
3.1 Break-in Procedure......................................13  
3.2 Using the Auto/Off/Manual Switch ..............13  
3.2.1 “Auto” Position..................................13  
3.2.2 “Off” Position....................................13  
3.2.3 “Manual” Position ............................13  
3.3 Automatic Transfer Operation ....................13  
3.4 Sequence of Automatic Operation................14  
Section 5 – Troubleshooting ........................22  
5.1 Troubleshooting Guide................................22  
Section 6 – Mounting Dimensions..............23  
Section 7 – Electrical Data............................24  
Section 8 – Exploded Views and  
Parts Lists....................................28  
Section 9 – Warranty......................................40  
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IMPORTANT SAFETY INSTRUCTIONS  
Air-cooled 8.5 kW Generator  
SAVE THESE INSTRUCTIONS – Th e m a n u fa ct u r er su ggest s t h a t t h ese r u les for sa fe  
op er a t ion be cop ied a n d p ost ed n ea r t h e u n it ’s in st a lla t ion sit e. Sa fet y sh ou ld be st r essed  
t o a ll op er a t or s a n d p ot en t ia l op er a t or s of t h is equ ip m en t .  
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!
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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 mainte-  
nance 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, you must do nothing that  
might render the system unsafe or in noncompli-  
ance with such codes and standards.  
• Keep hands, feet, clothing, etc., away from drive  
belts, fans, and other moving or hot parts. Never  
remove any drive belt or fan guard while the unit is  
operating.  
• Adequate, unobstructed flow of 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 you  
are physically or mentally fatigued.  
!
!
WARNING:  
known to the state of California to cause  
This product contains or emits chemicals  
cancer, birth defects or other reproductive harm.  
Study these SAFETY RULES carefully before  
installing, operating or servicing this equipment.  
Become familiar with this Ow ner’s Ma nua l and with  
the unit. The generator can operate safely, efficiently  
and reliably only if it is properly installed, operated  
and maintained. Many accidents are caused by failing  
to  
follow  
simple  
and  
fundamental  
rules  
or precautions.  
Generac cannot possibly anticipate every possible  
circumstance that might involve a hazard. The warn-  
ings in this manual, and on tags and decals  
affixed to the unit are, therefore, not all-inclusive. If  
you use a procedure, work method or operating tech-  
nique Generac does not specifically recommend, you  
must satisfy yourself that it is safe for you and others.  
You also must make sure the procedure, work  
method or operating technique that you choose does  
not render the generator unsafe.  
• Inspect the generator regularly, and contact your  
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.  
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 you have any question pertaining to fire  
extinguishers, consult your 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 you must  
work around an operating unit, stand on an insu-  
lated, dry surface to reduce shock hazard.  
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, you must  
inspect the fuel system periodically for leaks. No  
leakage is permitted.  
• 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.  
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  
1.3 SYSTEM SET LED  
The “System Set” LED is lit when all of the following  
conditions are true:  
Only qualified electricians or contractors should  
attempt such installations, which must comply strictly  
with applicable codes, standards and regulations.  
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 volt-  
age 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 genera-  
tor will start.  
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.  
3. The “Not In Auto” dip switch is set to the OFF  
position on the control board.  
4. No alarms are present, for example, low oil pres-  
sure, high temperature, etc.  
• This UL listed, NEMA 1, 2-pole switch is rated at  
100 AC amperes at 250 volts maximum. This  
transfer switch is for indoor use only.  
If this generator is used to power electrical load  
circuits normally powered by a utility power  
source, you are required by code to install a trans-  
fer switch. The transfer switch must effectively iso-  
late the electrical system from the utility distribu-  
tion system when the generator is operating (NEC  
700, 701, and 702). Failure to isolate an electrical  
system by such means will result in damage to the  
generator and also may result in injury or death to  
utility power workers due to backfeed of electrical  
energy.  
If any loss or damage is noted at time of delivery, have  
the person(s) making the delivery note all damage on  
the freight bill or affix his or her signature under the  
consignor's memo of loss or damage.  
If you note loss or damage after delivery, separate the  
damaged materials and contact the carrier for claim  
procedures.  
“Concealed damage” is understood to mean damage  
to the contents of a package that is not in evidence at  
the time of delivery, but is discovered later.  
1.2 PROTECTION SYSTEMS  
Unlike an automobile engine, the generator may have to  
run for long periods of time with no operator present to  
monitor engine conditions. For that reason, the engine is  
equipped with the following systems that protect it  
against potentially damaging conditions:  
1. Low Oil Pressure Sensor  
2. High Temperature Sensor  
3. Overcrank  
4. Overspeed  
There are LED readouts on the control panel to noti-  
fy you that one of these faults has occurred.  
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Section 1 — General Information  
Air-cooled 8.5 kW Generator  
1.4 YOUR GENERATOR  
Figure 1.1 – 8.5 kW, V-Twin GT-990 Engine  
Data  
Decal  
Control  
Panel  
Oil Dipstick  
Air Filter  
Exhaust  
Enclosure  
Fuel Regulator  
12 Volt Battery  
Oil Filter  
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Section 1 — General Information  
Air-cooled 8.5 kW Generator  
1.5 SPECIFICATIONS  
1.5.1 GENERATOR  
ꢀ
Model 0 0 4 6 9 2  
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  
Group 26/26R  
12 Volts and  
550 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 0 0 4 6 9 2  
Type of Engine  
GT-990  
2
26 @ 3,600 rpm  
992cc  
Number of Cylinders  
Rated Horsepower  
Displacement  
Cylinder Block  
Aluminum w/Cast  
Iron Sleeve  
Valve Arrangement  
Ignition System  
Recommended Spark Plug  
Spark Plug Gap  
Compression Ratio  
Starter  
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. Turn off the main gas supply.  
1.6 FUEL REQUIREMENTS  
2. Remove the three carburetor fuel hoses from the  
outlet ports of the demand regulator.  
3. Disconnect wire #0 and wire #14 from the gas  
solenoid located on the top of the demand regu-  
lator.  
AND RECOMMENDATIONS  
Wit h LP gas, u se on ly t h e vapor wit h drawal  
syst em . This type of system uses the vapors formed  
above the liquid fuel in the storage tank.  
The engine has been fitted with a fuel carburetion  
system that meets the specifications of the 1997  
California Air Resources Board for tamper-proof dual  
fuel systems. The unit will run on natural gas or LP  
gas, but it has been factory set to run on natural gas.  
Should the primary fuel need to be changed to LP  
gas, the fuel system needs to be reconfigured. See  
Section 1.8 (Page 7) for instructions on reconfigura-  
tion of the fuel system.  
Recommended fuels should have a Btu content of at  
least 1,000 Btus per cubic foot for natural gas; or at  
least 2,520 Btus per cubic foot for LP gas. Ask your  
fuel supplier for the Btu content of your fuel.  
4. Remove the demand regulator from the enclosure  
by rotating counterclockwise.  
5. Remove the small jet (0D5698A) located in the  
side of the regulator housing and install it into the  
small threaded hole in the idle circuit port on the  
regulator.  
7. Refit the brass hose fitting to the idle circuit port  
of the regulator. Use pipe thread sealant to reseal  
the threads on the hose fitting.  
8. Identify both adjustment screws.  
NOTE:  
One adjustment screw can be accessed from the  
front of the unit and the second can be accessed  
from the back of the unit.  
Fuel pressure for both natural gas and liquid  
propane set ups must be 11 inches to 14 inches of  
water column (0.6 psi) at all load ranges.  
9. The unit has been factory set to run on NG fuel.  
To reset the system to run on LP fuel, turn the  
two adjustment screws 1/2 turn clockwise. Use a  
large screwdriver to make this adjustment.  
10. The fuel system will now allow the engine to run  
on LP fuel. It may be necessary to make minor  
adjustments to the preset screw settings to  
achieve maximum power. If you experience prob-  
lems with the unit producing maximum power,  
follow the procedure in Section 2.6, “Adjusting  
the Regulator”.  
NOTE:  
A seperate gas line and regulator may be needed  
to assure proper gas pressure (11-14”) to the gen-  
erator. Low gas pressure can cause hard starting  
and could affect engine durability.  
1.7 FUEL CONSUMPTION  
Model #  
Nat. Gas (*)  
LP Vapor (**)  
1/2 Load Full Load 1/2 Load  
Full Load  
004692-0  
114  
170  
1.33/45.8  
1.98/72.5  
11. Reverse procedure steps 1-4 to reinstall the  
*Natural gas is in cubic feet per hour.  
**LP is in gallons per hour/cubic feet per hour.  
demand regulator.  
Figure 1.2 – Demand Regulator  
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.  
FUEL HOSE  
BRASS HOSE  
FITTING  
IDLE CIRCUIT  
O
BRASS HOSE  
U
T
SMALL  
FUEL JET  
PORT  
PRESSURE  
TAP  
1/8 NPT  
FITTING  
1
REGULATOR  
HOUSING PORT  
ADJUSTER  
SCREWS  
1.8 RECONFIGURING THE  
FUEL SYSTEM  
To reconfigure the fuel system from NG to LP,  
follow these steps:  
NOTE:  
The primary regulator for the propane supply is  
NOT INCLUDED with the generator. You must sup-  
ply a fuel pressure of 11 to 14 inches of water col-  
umn (0.6 psi) to the fuel inlet of the generator.  
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Section 1 — General Information  
Air-cooled 8.5 kW Generator  
1.9 LOCATION  
DANGER  
1.9.1 GENERATOR  
Install the generator set, in its protective enclosure,  
outdoors, where adequate cooling and ventilating air  
is always available. Consider these factors:  
If the Auto/Off/Manual switch is not set to its  
OFF position, the generator can crank and start  
as soon as the battery cables are connected. If  
the utility power supply is not turned off,  
sparking can occur at the battery posts and  
cause an explosion.  
N
• 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, you may need to consider using a windbreak  
to protect the unit.  
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 (—).  
• 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 3 feet of space on all sides.  
• Where strong prevailing winds blow from one  
direction, face the generator air inlet openings to  
the prevailing winds.  
NOTE:  
Damage will result if battery connections are made  
in reverse.  
• Install the generator as close as possible to the fuel  
supply, to reduce the length of piping.  
• Install the generator as close as possible to the  
transfer switch. HOWEVER, REMEMBER THAT  
LAWS OR CODES MAY REGULATE THE DIS-  
TANCE.  
Figure 1.5 – Battery Cable Connections  
1.9.2 TRANSFER SWITCH  
N
The transfer switch shipped with this generator is  
rated 100 amps maximum at 120/240 volts AC single  
phase. The enclosure of the transfer switch is NEMA  
1. This type of enclosure is intended for indoor use  
only. Follow these rules:  
• Install the transfer switch indoors on a firm, stur-  
dy supporting structure.  
• To prevent switch distortion, level the switch if  
necessary. This can be done by placing washers  
between the switch enclosure and mounting sur-  
face.  
• 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.  
NOTE:  
Your generator is equipped with a battery trickle  
charger that is active when your 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 your battery by maintaining  
the battery when the unit is not running. The  
trickle charge feature cannot be used to recharge  
a discharged battery.  
1.10 BATTERY INSTALLATION  
Fill the battery with the proper electrolyte fluid if nec-  
essary and have the battery fully charged before  
installing it.  
1.11 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.  
Before installing and connecting the battery, complete  
the following steps:  
1. Set the generator's Auto/Off/Manual switch to  
OFF.  
When replacing the battery, use the following type of  
battery: Group 26/26R 12VDC, 550 cold-cranking  
2. Turn off utility power supply to the transfer  
switch.  
®
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 8.5 kW Generator  
amps for 8.5 kW at -17.8º C (0º F) minimum. When  
Be sure the Auto/Off/Manual switch is set to  
!
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.  
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  
you attach the cables and cause an explosion.  
2.1 BEFORE INITIAL START-UP  
DANGER  
Before starting, complete the following:  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
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).  
A battery presents a risk of electrical shock  
and high short circuit current. The following  
precautions are to be observed when working  
on batteries:  
3. Turn OFF all loads connected to the tranfer  
switch terminals T1 and T2.  
• 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. 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.  
Do not open or mutilate the battery. Released  
!
electrolyte has been known to be harmful to  
the skin and eyes, and to be toxic.  
Never operate the engine with the oil level  
!
below the “Add” mark on the dipstick. Doing  
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically  
!
this could damage the engine.  
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  
2.2 CHECK TRANSFER SWITCH  
OPERATION  
Refer to Section 3.5 (Page 13), of the owner’s manual  
for manual operation procedures.  
• 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.  
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.  
2.3 ELECTRICAL CHECKS  
Lead-acid batteries present a risk of fire  
because they generate hydrogen gas. The  
following procedures are to be followed:  
Complete electrical checks as follows:  
1. Set the generator's main circuit breaker to its  
OFF (or open) position.  
• DO NOT SMOKE when near the battery;  
• DO NOT cause flame or spark in battery area; and  
• Discharge static electricity from your body before  
touching the battery by first touching a grounded  
metal surface.  
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 8.5 kW Generator  
2. Turn OFF all loads connected to the transfer  
high or low, the engine governor requires adjust-  
ment. If frequency is correct, but voltage is high or  
low, the generator’s voltage regulator requires  
adjustment.  
switch terminals T1 and T2.  
3. Turn on the utility power supply to the transfer  
switch using the means provided (such as a utili-  
ty main line circuit breaker).  
2.4 GENERATOR TESTS UNDER LOAD  
To test the generator set with electrical loads applied,  
proceed as follows:  
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.  
1. Set generator’s main circuit breaker to its OFF  
(or open) position.  
2. Turn OFF all loads connected to the transfer  
switch terminals T1 and T2.  
4. Use an accurate AC voltmeter to check utility  
power source voltage across transfer switch ter-  
minals N1 and N2. Nominal line-to-line voltage  
should be 240 volts AC.  
5. Check utility power source voltage across termi-  
nals 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/Manual  
switch to MANUAL. The engine should crank and  
start.  
8. Let the engine warm up for about five minutes to  
allow internal temperatures to stabilize. Then, set  
the generator’s main circuit breaker to its ON (or  
closed) position.  
3. Set the generator's Auto/Off/Manual switch  
to OFF.  
4. Turn OFF the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
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.  
DANGER  
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.  
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.  
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.  
12. Set the generator's Auto/Off/Manual switch to  
OFF. The engine should shut down.  
NOTE:  
13. Set the generator's main circuit breaker to its  
It is important that you do not proceed until you  
are certain that generator AC voltage and frequen-  
cy are correct and within the stated limits.  
Generally, if both AC frequency and voltage are  
OFF (or open) position.  
14. Let the engine run at no-load for a few minutes.  
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 8.5 kW Generator  
15. Set the Auto/Off/Manual switch to OFF. The  
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.  
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:  
engine should shut down.  
2.5 CHECKING AUTOMATIC  
OPERATION  
To check the system for proper automatic operation,  
proceed as follows:  
1. Check that the Auto/Off/Manual switch is set to  
OFF.  
2. Turn OFF the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
3. Manually set the transfer switch to the UTILITY  
position, i.e., load terminals connected to the util-  
ity power source side.  
4. Turn ON the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
Unit  
8.5 kW  
120 Volts  
70.8 amps  
240 Volts  
35.4 amps  
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).  
5. Set the Auto/Off/Manual switch to AUTO. The sys-  
tem is now ready for automatic operation.  
6. Turn OFF the utility power supply to the transfer  
switch.  
Figure 2.1 — Dual Fuel Regulators  
990  
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.  
Adjustment  
Screw  
(Both sides)  
With the generator running and loads powered by  
generator AC output, turn ON the utility power sup-  
ply to the transfer switch. The following should  
occur:  
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.  
• 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.  
Figure 2.2 — Placement of Regulator  
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 you experience engine problems at high or full load  
conditions follow these steps. It will require a fre-  
quency meter to perform this procedure.  
1. Turn off utility power to the main distribution  
panel in the house. This can be done by switching  
the service main breaker to the off or open posi-  
tion.  
Adjustment Screw  
7. Turn utility power to the main distribution panel  
back on. This can be done by switching the serv-  
ice main breaker to the on or closed position.  
Allow the generator to shut down.  
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 8.5 kW Generator  
2.7.1 ADDITIONAL CORROSION  
N
PROTECTION  
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.  
Periodically spray all engine linkage parts and brack-  
ets with corrosion inhibiting spray such as WD-40 or  
a comparable product.  
!
If this procedure or equipment are not available to  
you, locate the Generac Dealer nearest you and they  
can perform the adjustments.  
2.8 VOLTAGE REGULATOR  
ADJUSTMENT  
With the frequency between 62-63 Hertz, slowly turn  
the slotted potentiometer (Figure 2.5) until line volt-  
age reads 244-252 volts.  
NOTE:  
A service fee may be charged for this adjustment.  
NOTE:  
2.7 ENGINE GOVERNOR ADJUSTMENT  
If both AC frequency and voltage are correspondingly  
high or low, adjust the engine governor as follows:  
You must remove the access panel on top of the  
control panel to adjust the voltage regulator.  
1. Loosen governor clamp bolt.  
Figure 2.5 – Voltage Adjustment Potentiometer  
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 your hand, push the governor arm to the  
closed throttle position. Make sure the idle spring  
does not stretch at all.  
7. Restart the unit.  
8. Slowly turn the idle adjust screw to adjust the no-  
load idle frequency to 63-63.5 Hz.  
9. The governor is now set.  
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.  
Figure 2.4 — Full Load Speed Adjust Screw  
Full Load Speed Adjust Screw  
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Section 3 — Operation  
Air-cooled 8.5 kW Generator  
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.  
ꢀ
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.  
Figure 3.1 – Generator Control Panel  
1. Set the generator’s Auto/Off/Manual switch to  
AUTO.  
2. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as a utili-  
ty main line circuit breaker).  
FUSE  
R
L o c a t  
e
y o u r n e a r e s t  
d e a le r a t  
:
R
POWER SYSTEMS, INC.  
5A  
AUTO OFF MAN.  
SYSTEM SET  
LOW OIL  
3. The unit will start, and the transfer switch will  
transfer to standby.  
HIGH TEMP.  
OVER SPEED  
OVER CRANK  
FUSE  
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.  
F L A  
S
H
IN  
N
H
G
O
IN  
G R E E N L E D  
=
SET  
EXERCISE  
TIME  
15A  
U
G
T
IL IT  
E D L E D  
IS E R  
Y
S
E N  
S
S
=
E
4
F L A  
S
R
E X E R  
C
N
O
T
S
E T  
5. Run the unit for one hour at 50% rated load.  
6. Run the unit for one hour at 75% rated load.  
7. Run the unit for one hour at 100% rated load.  
8. Turn ON the utility power supply to the transfer  
switch, which will allow the transfer switch to  
transfer back to utility power. The unit will con-  
tinue to run for one minute and then shut down.  
9. Allow the unit to cool.  
10. Drain the oil and remove the oil filter. Replace the  
oil filter according to Section 4.4, “Changing the  
Oil Filter” (Page 16). Replace the oil with synthet-  
ic oil as recommended in Section 4.3, “Changing  
the Engine Oil” (Page 15).  
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.  
!
11. The generator is now ready for service.  
3.3 AUTOMATIC TRANSFER  
3.2 USING THE AUTO/OFF/MANUAL  
SWITCH (FIGURE 3.1)  
OPERATION  
To select automatic operation, do the following:  
1. Make sure the transfer switch main contacts are  
set to their “Utility” position, i.e., loads connected  
to the utility power source (Figure 3.2, Page 14).  
2. Be sure that normal utility power source voltage  
is available to transfer switch terminal lugs N1  
and N2.  
3.2.1 “AUTO” POSITION  
ꢀ
Selecting this switch position activates fully automatic  
system operation. It also allows you to start and exercise  
the engine every seven days with the setting of the exer-  
cise timer (see Section 3.6, Page 14). This position also  
is used for remote starting, when it is set up.  
3. Set the generator’s Auto/Off/Manual switch to  
AUTO.  
3.2.2 “OFF” POSITION  
This switch position shuts down the engine. This  
position also prevents automatic operation.  
ꢀ
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  
“Sequence of Automatic Operation” (Page 14).  
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Section 3 — Operation  
Air-cooled 8.5 kW Generator  
3.4 SEQUENCE OF AUTOMATIC  
3.5 MANUAL TRANSFER OPERATION  
OPERATION  
3.5.1 TRANSFER TO GENERATOR  
ꢀ
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).  
POWER SOURCE  
To start the generator and activate the transfer switch  
manually, proceed as follows:  
1. Set the generator’s Auto/Off/Manual switch  
to OFF.  
2. Set the generator’s main circuit breaker to its  
OFF (or open) position.  
3. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as a  
utility main line circuit breaker).  
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.  
DANGER  
The actual sequence of operation is controlled by  
sensors and timers on a control logic circuit board,  
as follows:  
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.  
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.  
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).  
B.Engine Warm-up Time Delay  
Figure 3.2 – Manual Transfer Switch Operation  
• 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.  
D.Utility Voltage Pickup Sensor  
• This sensor monitors utility power supply volt-  
age. When that voltage is restored above 80 per-  
cent of the nominal source voltage, a retransfer  
time delay starts timing.  
E.Retransfer Time Delay  
• This timer runs for about 15 seconds.  
• At end of a 15-second delay, circuit board action  
de-energizes transfer relay in the transfer switch.  
• Retransfer to utility power source then occurs.  
F. Engine Cool-down Timer  
• When the load is transferred back to utility power  
source, the engine cool-down timer starts timing.  
• The timer will run for about one minute, and the  
generator will then shut down.  
5. To crank and start the engine, set the  
Auto/Off/Manual switch to MANUAL.  
6. Let the engine stabilize and warm up for a few  
minutes.  
7. Set the generator’s main circuit breaker to its ON  
(or closed) position. The standby power source  
now powers the loads.  
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Section 3 — Operation  
Air-cooled 8.5 kW Generator  
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  
When utility power has been restored, you will want  
to transfer back to that source and shut down the  
generator. This can be accomplished as follows:  
ꢀ
NOTE:  
The exerciser will only work in the AUTO mode  
and will not work correctly unless this procedure  
is performed. The exerciser will need to be reset  
every time the 12-volt battery is disconnected and  
then reconnected. The exerciser WILL NOT work  
if dip switch 2 on the controller printed circuit  
board (“Remote Not Auto”) is ON.  
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.  
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.  
3.7 PROTECTION SYSTEMS  
3.7.1 LOW OIL PRESSURE SWITCH  
ꢀ
This switch (Figure 3.3) has normally closed contacts  
that are held open by engine oil pressure during crank-  
ing 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.  
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 util-  
ity power source (Figure 3.2 on page 14).  
6. Turn ON the utility power supply to the transfer  
switch using the means provided.  
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. Your generator will  
automatically restart and the LED on the generator  
control panel will reset once the temperature has  
returned to a safe operating level.  
7. Set the system to automatic operation as outlined  
in “Automatic Transfer Operation,” Section 3.3  
(Page 13).  
3.6 SETTING THE EXERCISE TIMER  
Your 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 you complete the following sequence.  
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 3.3 – Low Oil Pressure and  
High Temperature Switches  
Low Oil Switch  
High Temp Switch  
A switch on the control panel (see Figure 3.1, Page  
13) allows you to select the day and time for system  
exercise. To select the desired day and time of day,  
you must perform the following sequence at that  
time.  
Oil  
Drain  
Hose  
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.  
Oil Filter  
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Section 4 — Maintenance  
Air-cooled 8.5 kW Generator  
Figure 4.1 – Generator Control Panel  
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.  
FUSE  
R
L o c a t  
e
y o u r n e a r e s t  
d e a le r a t  
:
R
POWER SYSTEMS, INC.  
5A  
AUTO OFF MAN.  
SYSTEM SET  
LOW OIL  
HIGH TEMP.  
OVER SPEED  
OVER CRANK  
FUSE  
F L A  
S
H
IN  
N
H
G
O
IN  
G R E E N L E D  
=
SET  
EXERCISE  
TIME  
15A  
U
G
T
IL IT  
E D L E D  
IS E R  
Y
S
E N  
S
S
=
E
4
F L A  
S
R
E X E R  
C
N
O
T
S
E T  
NOTE:  
If the fault is not repaired, the overcrank feature  
will continue to activate.  
4.2 CHECKING THE ENGINE  
OIL LEVEL  
For oil capacities, see “Specifications,” Section 1.5  
(Page 6). For engine oil recommendations, see  
Section 4.3.1. To check the engine oil level, proceed  
as follows (Figure 4.2, on page 17):  
3.7.3.1 Approximate Crank Cycle Times  
• 15 seconds ON  
• 7 seconds OFF  
• 7 seconds ON  
• 7 seconds OFF  
• Repeat for 45 seconds  
Approximately 90 seconds total  
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.  
2. Remove the dipstick and wipe it dry with a  
clean cloth.  
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 your nearest Generac Authorized Dealer  
if this failure occurs.  
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.  
Never operate the engine with the oil level  
!
below the “Add” mark on the dipstick. Doing  
4.1 FUSE  
this could damage the engine.  
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, you can-  
not crank or start the engine. You should replace the  
fuse using only an identical 15-amp replacement.  
4. Install the dipstick.  
5. Reset the Auto/Off/Manual switch to its original  
position.  
Figure 4.2 — Oil Dipstick and Fill, 8.5 kW  
The generator panel’s 5 amp fuse protects the battery  
charge circuit against overload. If the fuse element  
has melted open, you will not have battery charging  
capability. You should replace the fuse using only an  
identical 5 amp replacement. To remove fuse, push  
cap down and rotate counterclockwise.  
Oil Dipstick  
Oil Fill  
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Section 4 — Maintenance  
Air-cooled 8.5 kW Generator  
Figure 4.3 – Oil Drain Hose and Filter  
4.3 CHANGING THE ENGINE OIL  
4.3.1 ENGINE OIL RECOMMENDATIONS  
ꢀ
Use oil of American Petroleum Institute (API) Service  
Class SG, SH or SJ. Use all season SAE 5W-30  
Synthetic oil. Organic break-in oil is required before  
using synthetic oil.  
NOTE:  
Oil  
Drain  
Hose  
The unit is supplied with “break-in” oil. See the  
“Break-in Procedure,” Section 3.1 (Page 13), for  
the first required oil change.  
Oil Filter  
Any attempt to crank or start the engine before  
!
it has been properly serviced with the recom-  
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 (Page 6) for oil  
capacities.  
mended oil may result in an engine failure.  
4.3.2 OIL CHANGE PROCEDURE  
To change the oil, proceed as follows:  
ꢀ
1. Run the engine until it is thoroughly warmed up  
then shut OFF the engine.  
2. Immediately after the engine shuts OFF, pull the  
oil drain hose (Figure 4.3) free of its retaining  
clip. Remove the cap from the hose and drain the  
oil into a suitable container.  
4.4 CHANGING THE OIL FILTER  
Change the engine oil filter as follows:  
1. With the oil drained, remove the old oil filter by  
turning it counterclockwise.  
2. Apply a light coating of clean engine oil to the gas-  
ket of the new filter. See Section 1.5.1 (Page 6) for  
recommended filter.  
3. Screw the new filter on by hand until its gasket  
lightly contacts the oil filter 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 (Page 6) for oil  
capacities.  
5. Start the engine and check for leaks.  
4.5 CHANGING THE ENGINE  
AIR CLEANER  
4.5.1 8.5 KW GENERATORS  
ꢀ
See Figure 1.2, (Page 5), for the location of your air  
cleaner. Use the following procedure:  
1. Turn the two screws counterclockwise to loosen.  
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.  
5. Install the cover. Turn the two cover screws clock-  
wise to tighten.  
See the “Service Schedule,” Section 4.11 (Page 19) for  
air cleaner maintenance. See Section 1.5.1 (Page 6)  
for air filter replacement part number.  
®
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Section 4 — Maintenance  
Air-cooled 8.5 kW Generator  
Figure 4.4 — 12 kW and 15 kW Engine  
Air Cleaner  
4.7 BATTERY MAINTENANCE  
The battery should be inspected per the “Service  
Schedule,” Section 4.11 (Page 19). The following pro-  
cedure should be followed for inspection:  
Screw  
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.  
Cover  
Filter  
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:  
• 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 (Page 19) for  
maintenance requirements.  
1. Clean the area around the base of the spark  
plug(s) to keep dirt and debris out of the engine.  
Clean by scraping or washing using a wire brush  
and commercial solvent. Do not blast the spark  
plug(s) to clean.  
2. Remove the spark plug(s) and check the condi-  
tion. Replace the spark plug(s) if worn or if reuse  
is questionable. See Section 4.11 (Page 19) for  
recommended inspection.  
3. Check the spark plug gap using a wire feeler  
gauge, carefully bending the ground electrode  
(Figure 4.5).  
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  
Figure 4.5 – Setting the Spark Plug Gap  
SET PLUG GAP AT 0.50 mm  
(0.020 inch)  
• 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.  
®
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Section 4 — Maintenance  
Air-cooled 8.5 kW Generator  
Lead-acid batteries present a risk of fire  
because they generate hydrogen gas. The  
following procedures are to be followed:  
Figure 4.6 - Valve Clearance Adjustment  
Rocker  
Arm  
Pivot Ball  
Stud  
• DO NOT SMOKE when near the battery;  
• DO NOT cause flame or spark in battery area; and  
• Discharge static electricity from your body before  
touching the battery by first touching a grounded  
metal surface.  
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  
you attach the cables and cause an explosion.  
• Install new valve cover gasket.  
• Re-attach the valve cover.  
NOTE:  
4.8 ADJUSTING VALVE CLEARANCE  
After the first 50 hours of operation, you should  
adjust the valve clearance in the engine.  
St art all fou r screws before t igh t en in g or you  
will n ot be able t o get all t h e screws in place.  
Mak e su re t h e valve cover gask et is in place.  
Important: If you feel uncomfortable about doing this  
procedure or you don't have the proper tools, please  
contact your Generac Authorized Dealer for service  
assistance. This is a very important step to insure  
the longest life for your engine.  
• Re-attach the spark plug wire to the spark plug.  
• Repeat the process for the other cylinder.  
To adjusting valve clearance:  
• Make sure the engine is at room temperature.  
• Make sure that the spark plug wire is removed  
from the spark plug and out of the way.  
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.  
• Remove the four screws attaching the valve cover  
with a #2 or #3 phillips screwdriver.  
Without sufficient cooling and ventilating air flow, the  
engine/generator quickly overheats, which causes it to  
quickly shut down. (See Figure 4.7 for vent locations.)  
• 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:  
You m u st h old t h e rock er arm jam n u t in place  
as you t u rn t h e pivot ball st u d.  
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.  
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.  
®
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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:  
The maximum ambient temperature for your  
generator is 48.9° C (104° F).  
!
1. Verify that utility power is turned off and that the  
Auto/Off/Manual switch is set to OFF.  
2. Check the tag on the engine for oil viscosity and  
classification. Verify that the correct recommend-  
ed oil is used in the engine (see Section 4.3.1,  
Page 17). If necessary, drain and refill with the  
proper oil.  
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.  
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 (Page 6), for type  
and size.  
4. Clean and wipe the entire generator.  
5. Reconnect the battery. Observe battery polarity.  
Damage may occur if the battery is connected  
incorrectly.  
4.11 OUT OF SERVICE PROCEDURE  
4.11.1 REMOVAL FROM SERVICE  
ꢀ
If you cannot exercise the generator 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  
6. Open the fuel shutoff valve.  
oil fault.  
7. Start the unit by moving the Auto/Off/Manual  
switch to MANUAL. Allow the unit to warm up  
thoroughly.  
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 (Page 17).  
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. Stop the unit and set the Auto/Off/Manual switch  
to AUTO.  
9. Turn on the utility power to the transfer switch.  
10. Your generator is now ready for service.  
NOTE:  
If the battery was dead or disconnected, you must  
reset the exercise timer.  
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.  
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.  
9. Clean and wipe the entire generator.  
®
20 Generac Power Systems, Inc.  
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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 your 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 generator  
is 11-14” WC (0.6 PSI)  
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)  
*Con t act you r n earest Gen erac Au t h orized Dealer for assist an ce.  
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Section 6 — Mounting Dimensions  
Air-cooled 8.5 kW Generator  
Drawing No. 0D3739-A  
M
0
P
2
1
T Y  
2
0
P
E
4
H
v
M
M
0
P
2
1
T Y  
2
0
P
E
4
H
v
M
M
O
v 0  
H
E
0
Y T  
2 1  
2
Y
M
0
P
2
1
T Y  
2
0
P
E
4
H
v
M
M
0
P
Y T  
2 1  
2
Y
0
P
E
4
H
v
M
M
0
P
2
1
T Y  
2 0 P / E 2 4 H 0 v O M  
CBHOM-F  
Y2P0E//  
CBHOM-F  
Y2P0E//  
CBHOM-F  
Y2P0E//  
CBHOM-F  
Y2P0E//  
CBHOM-F  
Y2P0E//  
CBHOM-F  
224H40OOH0vv  
Y2P0E// M  
TY  
1
2
 v
MM  
TY  
1
2
 v
MM  
TY  
1
2
 v
MM  
TY  
1
2
 v
MM  
TY  
1
2
 v
MM  
TY  
1
®
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Section 7 — Electrical Data  
Air-cooled 8.5 kW Generator  
Wiring Diagram - Drawing No. 0D8500  
ENGINE WIRING  
3
2
1
BATTERY  
CHARGER  
DIAGRAM KEY  
BA - BRUSH ASSEMBLY  
BCR - BATTERY CHARGE RELAY  
CB1 - MAIN OUTPUT BREAKER  
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION  
14  
2
1
0
D
-
DIODE  
225B  
DSW - PCB MOUNTED DIP SWITCH  
FS  
FS - FUEL SOLENOID  
F1 - FUSE 15 AMP  
F2 - FUSE 5 AMP  
GRD - CONTROL PANEL GROUND  
224B  
13A  
0
HTO - HIGH OIL TEMPERATURE SWITCH  
IC - INLINE CONNECTOR  
ICT - INTERCONNECTION TERMINALS  
0
IM1 - IGNITION MODULE, CYLINDER #1  
IM2 - IGNITION MODULE, CYLINDER #2  
LOP - LOW OIL PRESSURE SWITCH  
SC - STARTER CONTACTOR  
SCR - STARTER CONTACTOR RELAY  
SP1, SP2 - SPARK PLUGS  
0
14  
SW1 - AUTO / OFF / MANUAL SWITCH  
SW2 - SET EXERCISE SWITCH  
SM - STARTER MOTOR  
14  
TB - INSULATED TERMINAL BLOCK  
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)  
IC  
TB  
D
SP1  
6
5
0
0
14  
IM1  
18  
85  
4
3
86  
2
1
13  
13  
D
16  
IC  
IC  
SP2  
C1  
16  
SCR  
IM2  
13  
18  
85  
A
B
86  
351  
HTO  
0
14  
86  
56  
0
85  
56  
1
16  
13  
86  
2
3
4
5
J2  
LOP  
0
J1  
CONTROL  
PRINTED CIRCUIT BOARD  
RED  
BLACK  
DSW  
1
2
3
4
ON  
ON - INDICATES  
1 - 20 Vac Sense Transformer  
2 - Remote Not Auto  
3 - 50 Hz Operation  
4 - SPARE  
SM  
-
+
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  
CONTROL PANEL BOX  
225  
224  
224A  
225A  
CLOSEST TO BEARING  
BA  
224A  
4
0
225A  
TX  
BCR  
CB2  
162  
1
4
7
3
6
9
STATOR  
N1 N2  
77  
A
B
66  
2
225B  
4
10  
9
224B  
0
2
11  
6
77  
8
2
14  
55  
4
7
6
22  
6
66A  
11  
0
11  
11  
22  
5
4
3
22  
77  
11  
66  
66  
13A  
225  
22  
4
77  
0
4
0
6
0
2
6
44  
1
224  
162  
162  
55  
C2  
VOLTAGE  
REGULATOR  
66A  
0
0
66A  
4
55  
N2  
33  
N1  
13  
13  
22  
13  
225  
GRD  
351  
224  
194  
23  
N2  
4
N1  
13  
44  
351  
23  
56  
11  
13  
13A  
351  
CUSTOMER  
CONNECTION  
194  
15A  
23  
22  
N2  
18  
13  
33  
N1  
194  
0
14  
13  
66A  
F2  
F1  
239  
CB1  
0
15A  
17  
OFF  
17  
15  
13  
239  
17  
0
SW1  
225  
15  
224  
1a  
1
15  
1b  
SW2  
240V GENERATOR  
AUTO  
OUTPUT TO TRANSFER  
SWITCH CONTACTOR  
MANUAL  
®
Generac Power Systems, Inc. 25  
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Section 7 — Electrical Data  
Air-cooled 8.5 kW Generator  
Electrical Schematic - Drawing No. 0D8501  
11  
22  
3
2
1
225A  
224A  
BATTERY  
CHARGER  
225B  
F2  
13A  
13  
224B  
13A  
2
1
F1  
7
7
9
9
BCR  
1
4
3
6
11  
0
13A  
77  
C2-1  
0
77  
14  
BATTERY CHARGE  
WINDING  
66  
0
66  
C2-2  
22  
0
0
0
C2-4  
55  
HTO  
0
C2-11  
0
LOP  
11  
22  
ENGINE RUN  
WINDING  
BA  
FIELD  
SW2  
C1-4  
0
14  
(STATOR)  
C1-3  
0
C2-9  
C2-3  
4
0
ELECTRONIC  
VOLTAGE  
REGULATOR  
C2-10  
4
4
66A  
0
85  
6
86  
162  
C1-6  
4
6
CB2  
0
351  
C2-7  
C2-8  
66A  
2
DPE WINDING  
(STATOR)  
1
2
3
4
5
J2  
23  
18  
1
2
4
J1  
194  
86  
3
4
5
6
7
8
9
23  
194  
56  
DIAGRAM KEY  
BA - BRUSH ASSEMBLY  
14  
BCR - BATTERY CHARGE RELAY  
CB1 - CIRCUIT BREAKER, MAIN OUTPUT  
CB2 - CIRCUIT BREAKER, ALT. EXCITATION  
D - DIODE  
66A  
239  
15A  
17  
CONTROL  
PRINTED CIRCUIT  
BOARD  
10  
11  
12  
13  
14  
15  
16  
17  
FS - FUEL SOLENOID  
F1 - FUSE 15 AMP  
F2 - FUSE 5 AMP  
15  
0
225  
224  
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  
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)  
®
26 Generac Power Systems, Inc.  
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Section 7 — Electrical Data  
Air-cooled 8.5 kW Generator  
Electrical Schematic - Drawing No. 0D8501  
11  
C2-6  
22  
C2-5  
TX  
225A  
N2  
56VA  
1VA  
224A  
225  
224  
N1  
194  
23  
CUSTOMER  
CONNECTIONS  
N2  
N2  
13  
N1  
N1  
15  
17  
11  
NEUTRAL  
17  
23  
0
22  
15A  
33  
0
SW1  
194  
120V  
15  
120V  
POWER WINDING  
(STATOR)  
239  
15  
44  
CB1  
23  
15  
194  
239  
11  
225  
14  
224  
0
240V  
14  
15A  
15  
239  
13  
RED  
0
C2-1  
66A  
17  
13  
SC  
SCR  
56  
16  
16  
0
14  
C1-1  
BATTERY  
12V  
0
SC  
0
FS  
0
SM  
BLACK  
CUSTOMER  
SUPPLIED  
IM1  
SP1  
SP2  
D
18  
C1-5  
IM2  
D
®
Generac Power Systems, Inc. 27  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 8.5 kW Generator  
Compartment – Drawing No. 0D8445-A  
76  
85  
44  
77  
71  
40  
68  
69  
82  
48  
84  
80  
82  
41  
73  
78  
81  
80  
30  
17  
79  
72  
51  
86  
72  
5
52  
18  
A
6
29  
45  
31  
12  
49  
47  
44  
16  
19  
66  
47  
28  
55  
75  
64  
65  
47  
54  
50  
35  
46  
74  
11  
25  
49  
51  
14  
8
57  
49  
51  
9
35  
27  
50  
22  
34  
56  
49  
49  
67  
58  
1
59  
49  
62  
13  
35  
59  
38  
26  
3
51  
70  
39  
23  
58  
37  
42  
24  
43  
48  
51  
36  
51  
A
21  
49  
43  
46  
47  
7
83  
33  
2
32  
10  
49  
50  
53  
52  
20  
51  
4
15  
62  
63  
71  
69  
35  
25  
60  
68  
®
28 Generac Power Systems, Inc.  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 8.5 kW Generator  
Compartment – Drawing No. 0D8445-A  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
0D8312  
0C6735  
0C7061  
0C7062  
0C7063  
0C7064  
0D8333  
0C8101A  
0C8101B  
0C8283  
0C8284A  
0C8284B  
0C8284C  
0C8285  
0C8899A  
0D1128  
0D1605  
0D2538A  
0D1839  
0D1840  
0D2425  
0D2588  
0D2676  
0D2677  
0D2979B  
0D2979C  
0D2979D  
0D3057A  
0D3057B  
0D3057C  
0D3057D  
0D3059A  
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  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61*  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
0A2115  
022097  
022473  
036261  
047411  
043116  
0D3700  
083512  
090388  
092120  
0D1606  
0D3167  
0A3328  
055414  
092079  
0A1658  
0C3906  
045771  
0388040AJ0  
022145  
022129  
074908  
0D2346  
023484F  
043107  
0A7836  
0A8475  
0912970069  
0912970070  
055450  
0D2023  
0D3701  
0D3472  
0C8742  
0C8911  
0D8442  
4
7
4
14  
14  
5
18  
12  
33  
2
1
1
1
1
1
2
2
4
1
8
4
8
1
1
4
2
2
1
2
2
10.5  
1
1
1
1
WASHER NYLON .250"  
WASHER LOCK M6-1/4"  
WASHER FLAT ¼" ZINC  
RIVET POP .125 X .129-.133/#30  
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 TAPTITE M8-1.25 X 16 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"  
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, CLIP-ON SELF GRIPPING  
PLATE, "HOT"  
GROMMET 2.75 X 1/16  
EXTERNAL CONNECTION BOX  
POWER BLOCK  
HARNESS GENERATOR TO EXTERNAL  
CONNECTION BOX  
SCREW PPHM #10-32 X 1  
WASHER LOCK #10  
WASHER FLAT #10 ZINC  
NUT HEX #10-32 STEEL  
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  
FOAM, EXHAUST SIDE ENCLOSURE  
FRONT  
SCREW SWAGE 1/4-20 X 1  
WASHER, SELF LOCKING  
FOAM, FRONT EXHAUST ENCLOSURE  
COVER  
33  
0D3059B  
1
34  
35  
36  
0A2311  
0D7176  
0D3059D  
1
24  
1
1
79  
80  
81  
82  
83  
84  
85  
86  
036937  
022152  
023897  
022158  
0D3059C  
026850  
049813  
0D2537A  
2
5
2
5
1
1
1
1
37  
0D3059E  
1
FOAM, BACK EXHAUST ENCLOSURE  
COVER  
DOOR, PAWL  
LATCH, QUARTER TURN LOCKING  
HINGE, LIFT OFF, TYPE A PIN  
HINGE, LIFT OFF, TYPE B PIN  
LATCH, QUARTER TURN NON-LOCKING  
38  
39  
40  
41  
42  
0C7781  
0D3037  
0D2537  
0D2538  
0D3037A  
2
1
1
1
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  
*
NOT SHOWN  
** ITEMS INCLUDED IN KIT 0D3057  
®
Generac Power Systems, Inc. 29  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 8.5 kW Generator  
Engine & Alternator – Drawing No. 0D8446  
®
30 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  
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  
083512  
074994  
057822  
052858  
0C2824  
025145  
0C4138  
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, IHCS 3/8"-24 x 14.2"  
BOLT, IHCS M8-1.25 x 345mm  
BRACKET, ALTERNATOR MOUNTING  
DUCT, ALTERNATOR AIR  
GASKET, ALTERNATOR AIR DUCT  
BRACKET, ENGINE MOUNTING  
RUBBER MOUNT  
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 YC  
WASHER LOCK M8-5/16  
NUT HEX 5/16-18 STEEL  
SCREW TAPTITE 3/8-16 X 3/4 CZ  
SCREW TAPTITE M8-1.25 X 16 YC  
HOSE RES 1/2 LP GAS  
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  
4
1
1
1
1
1.8 FT  
1
5
4
4
4
14  
4
2
10  
8
2
4
2.83 FT  
4
4
3
1
2
2
CLAMP HOSE #8 .53 - 1.00  
NUT LOCK M8  
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.  
1.33 FT  
®
Generac Power Systems, Inc. 31  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 8.5 kW Generator  
Engine – Drawing No. 0D8674-C Part 1  
66 2, 5, 19, 20, 39, 40, 47, 64, 93, 140  
67 8, 11, 12, 13  
68 4, 5, 6  
34  
36  
69 16A, 16B, 17, 18  
37  
70 7, 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59, 60  
71 48, 49, 50, 51, 52, 53, 54, 55, 56, 58, 59, 60, 62  
72 27, 28, 29  
35  
3
38  
140  
39  
73 3, 32, 33, 34, 35, 36, 40, 72  
34  
22  
40  
33  
32  
3
9
41  
21  
12  
10  
31  
13  
42  
29  
43  
25  
30  
28  
27  
11  
3
26  
15  
16A  
14  
16B  
23  
24  
44  
16A  
8
53  
55  
56  
54  
17  
7
18  
45  
20  
19  
6
57  
46  
5
4
47  
48  
49  
62  
63  
50  
3
64  
51  
52  
1
2
65  
58  
59  
60  
61  
®
32 Generac Power Systems, Inc.  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 8.5 kW Generator  
Engine – Drawing No. 0D8674-C 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 D20  
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 (GT-990)  
ASSEMBLY, CRANKSHAFT HORIZONTAL  
DIRECT DRIVE (GT-760)  
ASSEMBLY, CONNECTING ROD (GT-990)  
ASSEMBLY, CONNECTING ROD (GT-760)  
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  
36  
37  
38  
39  
40  
41  
0C2992  
0C3971C  
0C5305  
0C3027  
0C3007  
0C5731  
1
1
1
1
1
1
BUSHING, GOVERNOR LOWER  
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 20  
ASSEMBLY, OIL FILL CAP  
HOOK, LIFTING  
ROCKER, COVER WITH OIL FILL  
GASKET, VALVE COVER  
KEEPER, VALVE SPRING  
RETAINER, VALVE SPRING  
SPRING, VALVE  
SEAL, VALVE STEM D7  
WASHER, VALVE SPRING  
NUT, JAM ROCKER ARM  
STUD, ROCKER ARM M8-1.0 x 57mm  
PIVOT, ROCKER ARM  
ROCKER ARM  
PLATE, PUSH ROD GUIDE  
SCREW HHFC M8-1.25 X 65  
VALVE, EXHAUST  
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16A  
16B  
17  
18  
19  
20  
21  
0C3008  
090388  
0C5372  
0C3005  
0C3003  
0D8067A  
071983  
0C2981C  
045761A  
0C5848  
021533  
071980  
0D4041  
0C2983  
0C2985A  
0C2985B  
0D4042  
0A7811  
0C2977  
0C5943  
0D4040E  
1
8
1
1
3
1
4
1
4
2
2
2
1
1
2
1
1
1
1
1
1
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  
0C8566  
093064  
0C8808  
0D2723B  
0C2979  
086515  
0D2274  
0D3867  
078672  
0C5371  
0D5326  
0D6023  
0D5354  
0D5313  
0D6024  
0C2976  
086516  
0C2229  
083897  
0D8067B  
088396D  
0C2978  
043790A  
9
8
1
2
1
2
8
4
4
2
4
4
4
4
4
2
12  
2
2
4
1
4
2
1
21  
0D4122E  
1
VALVE, INTAKE  
TAPPET, SOLID  
ASSEMBLY, HEAD #2 G&S  
PUSHROD, 144.6  
GASKET, HEAD  
BARBED ELBOW 90 3/8NPT X 3/8  
L0CKTITE  
KIT GASKET  
22  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
0C2969  
0D3961  
0D2157  
0C5313  
0D4123  
078699E  
0C3011  
0C3009  
0C3010  
093873  
0C5315  
0C5998  
0D1667  
0C2991  
0C2988  
2
2
2
1
1
2
2
2
2
2
1
1
1
2
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
KIT PISTON & RINGS  
KIT BREATHER ASSEMBLY  
KIT GOVERNOR ASSEMBLY  
KIT HEAD ASSEMBLY CYLINDER 1  
KIT HEAD ASSEMBLY CYLINDER 2  
KIT OIL RELIEF  
WASHER, LOCK RIB M6  
GEROTOR, OUTER  
CLAMP, OIL TUBE  
ARM, GOVERNOR  
E-RING, GOVERNOR ARM  
THRUST WASHER, GOVERNOR  
KIT GEAR COVER  
®
Generac Power Systems, Inc. 33  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 8.5 kW Generator  
Engine – Drawing No. 0D8674-C Part 2  
74  
138  
75  
139  
135  
122  
124  
125  
76  
77  
136  
123  
125  
137  
120  
79  
124  
133  
134  
78  
132  
131  
119  
80  
116  
115  
127  
114  
117  
121  
118  
97  
128  
129  
81  
98  
130  
126  
99  
82  
96  
95  
83  
100  
102  
84  
109  
103  
105  
104  
93  
87  
86  
85  
94  
91  
110  
97  
98  
99  
88  
106  
112  
89  
90  
101  
89  
107  
108  
112  
92  
112  
113  
111  
®
34 Generac Power Systems, Inc.  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 8.5 kW Generator  
Engine – Drawing No. 0D8674-C 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  
070185  
075281  
0C1085  
043182  
035461A  
2
1
1
1
1
1
4
4
1
1
1
1
1
2
2
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  
FILTER, OIL D 69 X 64 LONG  
SWITCH, THERMAL 284F  
SCREW PPHM M3-0.5 X 8  
WASHER LOCK M3  
BARBED STR 1/4NPT X 3/8 WITH VIBRA  
SEAL  
CLAMP HOSE #5.5 .62 - .62  
HOSE, 3/8" I.D. X 6" LONG  
COOLER, OIL  
108  
109  
110  
111  
112  
0C3034  
0C8549  
0C3022A  
0D1131  
045756  
1
1
1
1
27  
NUT,HEX M24  
SNORKEL, AIR INTAKE  
HOUSING, BLOWER NG COOLER  
GUARD, FAN  
SCREW TAPTITE M6-1X10 YELLOW  
CHROME  
NUT, GROMMET 1/4 PLUG  
HOSE, BREATHER  
BRACKET, STARTER  
SCREW HHC M6-1.0 x 16 WITH LOCK-  
WASHER  
WRAPPER, UPPER CYLINDER 1  
WRAPPER, LOWER CYLINDER 1  
WRAPPER, LOWER CYLINDER 2  
WRAPPER, UPPER CYLINDER 2  
SCREW TAPTITE M5-0.8 X 8 BP  
ASSEMBLY, GROUND WIRE  
ASSEMBLY, IGNITION COIL  
WASHER LOCK M6-1/4  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
113  
114  
115  
116  
0C9763  
0C3036  
0C8919  
079246  
4
1
1
1
117  
118  
119  
120  
121  
122  
123  
124  
125  
126  
127  
128  
129  
130  
131  
132  
133  
134  
135  
136  
137  
138  
139  
0C3018  
0C3019  
0D1142A  
0D1143  
066849B  
0C3053  
0C3052  
022097  
092079  
0C3017  
0D4529  
022129  
061906  
082774  
052859  
0C8468  
0C3048  
0D3754  
0D3742  
0C8482  
0D2576  
0D3743  
0D3705  
1
1
1
1
2
1
2
4
4
1
2
2
2
1
1
1
1
1
1
1
1
1
1
89  
90  
91  
92  
93  
94  
95  
96  
97  
040173  
0C9806  
0C3026  
0C9764  
0C3043  
0C7694  
0C7693  
0C3041  
070008  
070006  
040976  
0C3016A  
085011  
0C3725B  
0C3031  
0C3032  
0A5992  
051754  
0C3033  
4
2
1
4
2
1
1
2
4
4
4
1
1
1
1
1
2
2
1
SCREW TAPTITE M6-1.0 X 25 BP  
STARTER  
SPARKPLUG  
PLASTITE,1/4-15 X 3/4  
GASKET, MANIFOLD / PORT  
MANIFOLD CYLINDER 2  
MANIFOLD CYLINDER 1  
SLEEVE, RUBBER  
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 70 G10.9  
SPRING, GOVERNOR IDLE  
ASSEMBLY, GOVERNOR ADJUSTER  
BRACKET  
WASHER FLAT M8 SS  
98  
99  
WASHER LOCK M8 SSTL  
SCREW SHC M8-1.25 X 20 G12.9  
PLATE, BACKING GT990 WITH OIL COOL  
INSULATOR ASSEMBLY IGNITION  
FLYWHEEL ASSEMBLY  
FAN, NYLON  
PLATE, FAN  
WASHER SHAKEPROOF INT M8 SS  
SCREW HHC M8-1.25 X 12 G8.8  
WASHER, 25mm I.D.  
100  
101  
102  
103  
104  
105  
106  
107  
140  
0C2993  
1
SEAL, GOVERNOR SHAFT  
®
Generac Power Systems, Inc. 35  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 8.5 kW Generator  
Control Panel Assembly – Drawing No. 0D8503-B  
41  
8,9  
40  
27  
8,32  
10  
22  
38  
1
43  
25  
7
6
31  
33  
42  
23  
45  
44  
37  
47  
45  
16  
4
29  
28  
29  
28  
49  
20  
12  
2
24  
48  
11  
47  
27  
38  
45  
21  
44  
17  
45  
47  
15  
14  
30  
35  
39  
36  
46  
31  
29  
28  
3
19  
14  
15  
35  
49  
23  
16  
21  
17  
34  
15  
14  
13  
5
®
36 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. 0D8503-B  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
0A9947E  
0A9947G  
0A9947F  
0A9947C  
1
1
1
1
CIRCUIT BREAKER 30 X 2 240V SQD  
QOU230 (7KW)  
CIRCUIT BREAKER 40 X 2 240V SQD  
QOU240 (8.5KW)  
CIRCUIT BREAKER 50 X 2 240V SQD  
QOU250 (12KW)  
CIRCUIT BREAKER 60 X 2 240V SQD  
QOU260 (13KW)  
22  
23  
24  
25  
26  
0D5240  
051714  
0D8502  
0A1661  
0D8441  
1
4
1
2
1
SWITCH, SPDT ON-MOM-ON  
NUT HEX M3-0.5  
NEUTRAL ISOLATOR  
RIVET POP .156 X .160-.164/#20  
HARNESS, CONTROL PANEL WIRE (NOT  
SHOWN)  
SCREW TAPTITE, M5-0.8 x 10 BP  
WASHER LOCK M5  
NUT HEX M5-0.8  
TRANSFORMER  
SCREW HHC 1/4"-20 x 1/2"  
FUSE 5A X AGC5  
TERMINAL STRIP  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
43  
44  
45  
46  
47  
48  
49  
074908  
049226  
051716  
0C3910  
022507  
099727  
046689  
063617  
075475  
022985  
0D8439  
092036  
045770  
0C7171  
0D3700  
0A2311  
0A1658  
022473  
038750  
022097  
049813  
031879  
4
6
6
1
2
1
1
1
4
2
1
8
2
1
10  
1
2
3
1
3
1
4
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
0A18010SRV  
0830490SRV  
0C2174  
075210A  
0D3062  
0D8615  
032300  
022676  
033873  
0D5045  
023484E  
075476  
022264  
051715  
043182  
043181  
0D8443  
054502  
0D8438  
075235  
1
1
1
1
4
1
2
1
1
1
1
2
6
6
4
4
1
1
1
4
ASSEMBLY, BATTERY CHARGER ENGINE  
ASSEMBLY, POTTED REGULATOR  
RELAY, 12V 25A SPST  
BLOCK 1 POSITION  
HEX STAND-OFF #6-32 x 3/8"  
ASSEMBLY, HOME STANDBY CONTROLLER  
HOLDER, FUSE  
FUSE, 15AMP X AGC15  
SWITCH, ROCKER  
RELAY PANEL 12VDC DPDT 10A 240VAC  
SCREW PPHM M4-0.7 x 10mm  
WASHER FLAT #6  
COVER, CONTROL PANEL COMPONENT  
SCREW PPHMS/LW #6-32 x 1/4"  
SCREW HHC M5-0.8 x10mm  
COVER, CONTROL PANEL  
NUT FLANGE M6-1.0 NYLOCK  
SCREW SWAGE 1/4"-20 x 1"  
LOCKWASHER SPECIAL 1/4"  
WASHER FLAT 1/4"  
DIN RAIL  
SNAP BUSHING SB-687-8  
SCREW PPHM M4-0.7 x 16mm  
WASHER LOCK M4  
NUT HEX M4-0.7  
WASHER LOCK M3  
SCREW PHM M3-0.5 x 10mm  
DECAL, CONTROL PANEL (NOT SHOWN)  
CIRCUIT BREAKER 3 X 1 ETA 46-500-P  
CONTROL, PANEL BOTTOM  
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  
®
Generac Power Systems, Inc. 37  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 8.5 kW Generator  
GTS Load Center – Drawing No. 0D3996-C  
12  
31  
37  
7
9
6
11  
5
2
4
17  
18  
4
3
39  
22  
16  
29  
9
30  
23  
27  
36  
15  
24  
42  
10  
13  
1
19  
25  
16  
22  
40  
21  
23  
26  
38  
14  
41  
8
33  
32  
35  
34  
34  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
2
3
0D3086  
0D3092  
0C2237  
1
1
1
BOX GTS LOAD CENTER  
22  
23  
24  
25  
26  
27  
28  
036933  
077033  
048850  
028739  
038150  
0D3191  
0D3088  
6
6
1
4
2
1
1
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" NAT'L UL  
WASHER FLAT #8 ZINC  
COVER, RELAY & TERM BLOCK  
WIRE HARNESS,GTS LOAD CENTER  
(NOT SHOWN FOR CLARITY)  
FUSE HOLDER  
ASSEMBLY FUSE 5A X BUSS HLDR73591  
PCB SUPPORT SNAP-IN 1-3/8"  
CIRCT BRK 20 X 1 HOM120  
CIRCT BRK 20 X 2 HOM220  
CIRCT BRK 15 X 1 HOM115  
CIRCT BRK 30 X 2 HOM230  
COVER - HARNESS ENTRY  
HARNESS, GTS TO EXT CONN BOX  
(10KW / 12KW / 13KW)  
COVER, 12 POSITION GTS LOAD CENTER  
TRANSFER SWITCH HOME STANDBY  
100A2P250V  
4
5
6
7
8
074908  
024912  
0A1658  
063617  
0D3030  
0A1495  
0A1661  
022473  
055450  
6
1
1
1
1
4
2
1
1
SCREW TAPTITE M5-0.8 X 10 BP  
SCREW TAPTITE 1/4-20 X 5/8 BP  
LOCK WASHER, SPECIAL-1/4"  
RELAY PANEL 12VDC DPDT 10A@240VAC  
BASE, MOUNTING 6 POLE 125A/240V  
SCREW TAPTITE M4-0.7X10 BP  
RIVET POP .156 X .160-.164/#20  
WASHER FLAT 1/4 ZINC  
29  
30  
31  
32  
33  
34  
35  
36  
37  
073591  
073590A  
040213B  
0C8037  
0D3190  
0C8036  
0C8035  
0D3320  
0D3093  
2
2
4
3
1
5
1
1
1
9
10  
11  
12  
PLUG HEYMAN DP1375  
(10KW / 12KW / 13KW)  
025034  
1
PLUG STEEL 1.0625 STMPSN 3811  
(14KW / 15KW / 16KW)  
HARNESS ADAPTER PLATE  
PANEL-SUB BREAKER BASE  
TRIM VINYL BLACK 1/8GP  
WASHER LOCK #10  
NUT WING M6-1.0  
HANDLE, TRANSFER SWITCH HOME  
STANDBY  
13  
14  
15  
16  
17  
18  
0D4684  
0D3319  
056326  
022152  
087680  
077441  
1
1
1 FT  
6
1
1
0D3926  
1
HARNESS, GTS TO EXT CONN BOX  
(14KW / 15KW / 16KW)  
WASHER LOCK M4  
SCREW SW 1/4-20X5/8 N WA JS500  
SCREW SWAGE 1/4-20 X 1/2 ZINC  
SCREW PPHM M4-0.7 X 10  
HARNESS,GTS TO MAIN PANEL  
38  
39  
40  
41  
42  
022264  
0A7215  
0A2110  
075475  
0D3094  
2
4
4
2
1
19  
21  
063378  
074138  
4
2
HOLDER CABLE TIE  
LUG DIS QK NI-S 10X45 DEG BR/T  
®
38 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-B  
10  
8
7
34  
33  
2
6
36  
21  
5
4
10  
37  
32  
20  
3
37  
25  
24  
FOR GT 760  
ENGINE ONLY  
1
22  
19  
23  
35  
10  
16  
29  
18  
26  
15  
14  
12  
19  
11  
17  
28  
13  
27  
31  
32  
23  
24  
22  
12  
26  
20  
25  
15  
14  
29  
18  
11  
16  
17  
28  
13  
9
21  
ITEM  
PART NO.  
QTY. DESCRIPTION  
ITEM  
PART NO.  
QTY. DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
0D5694  
0C5765  
0C4647  
0C4680  
0C6070  
022985  
022264  
075475  
0C5760A  
0C6606  
097934  
0C4645  
0C5761  
0C5968  
0C6066  
0C5759  
0C5764  
0C5764A  
070728  
070728  
0C6069  
0C5762  
1
1
1
1
1
4
4
4
1
2*  
2*  
2*  
2*  
2*  
2*  
2*  
2
1
4
2
2*  
2*  
CASTING, TWIN REGULATOR HOUSING  
SOLENOID, TWIN REGULATOR  
GASKET , SOLENOID  
PLUNGER, LP REGULATOR ASSEMBLY  
SPRING-SOLENOID, PLUNGER  
WASHER, FLAT #6  
21  
045764  
045764  
0C6731  
0C6067  
0C4706  
0C6068  
0C4643A  
026073  
16  
8
SCREW, TAPTITE M4X8 BP  
SCREW, TAPTITE M4X8 BP (7KW)  
RIVET, POP .118 X .125  
22  
23  
24  
25  
26  
27  
2*  
2*  
2*  
2*  
2*  
1
SUPPORT, DIAPHRAGM  
DIAPHRAGM, TWIN REGULATOR  
CAP, DIAPHRAGM SUPPORT  
INLET, TWIN REGULATOR 11.11 DIA.  
PLUG, STANDARD PIPE 1/8 STEEL  
SQUARE HEAD  
PIN, LIMITED ADJUSTMENT  
WASHER, FLAT M3 X 10mm O.D.  
WASHER, FLAT M3 X 10mm O.D. (7KW)  
INLET, TWIN REGULATOR NO HOLE -  
NOT SHOWN (7KW)  
BARBED STRAIGHT 1/8"NPT X 1/4"  
JET IDLE PRIMER PHILLIPS HD  
JET, GT760 CYL 1 NAT GAS  
JET, GT760 CYL 2 NAT GAS  
JET, GT 760 LP CYL 1  
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  
28  
29  
0A4032  
0D3308  
0D3308  
0C4643  
2*  
4
2
30  
1
31  
32  
33  
34  
35  
36  
37  
028414A  
0D5698A  
0C5760B  
0C5760C  
0C5760D  
0C5760E  
0D3973  
1
1
1
1
1
1
2
SPRING, REGULATOR (7KW)  
SCREW, PFHMS M3-0.5 x 5  
SCREW, PFHMS M3-0.5 x 5 (7KW)  
GASKET, DIAPHRAGM  
18  
JET, GT760 LP CYL 2  
PLUG, EXPANSION 16mm  
19  
20  
COVER, TWIN REGULATOR  
* A QUANTITY OF 1 IS TO BE USED ON 7KW HOME STANDBY  
®
Generac Power Systems, Inc. 39  
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Section 9 – 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 Ow ner’s Ma nua l. 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 respon sible for con t act in g a Gen erac Au t h orized Warran t y Service Facilit y as soon as a problem occu rs.  
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 on ly 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 h ave an y qu est ion s regardin g you r warran t y righ t s an d respon sibilit ies, you sh ou ld con t act Gen erac at t h e  
followin g address:  
ATTENTION WARRANTY DEPARTMENT  
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 297  
WHITEWATER, WI 53190  
Pa r t 1  
®
40 Generac Power Systems, Inc.  
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Section 9 – 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 Ow ner’s  
Ma nua l 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 Ow ner’s Ma nua l  
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 Ow ner’s  
Ma nua l 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  
Pa r t 2  
®
Generac Power Systems, Inc. 41  
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Section 9 – Warranty  
Air-cooled 8.5 kW Generator  
GENERAC POWER SYSTEMS "TWO YEAR" STANDARD WARRANTY FOR ®  
"PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS"  
For a period of two years or 2000 hours of operation from the date of original sale, whichever occurs first, 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 accor-  
dance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be  
returned to and examined by the nearest Generac Authorized Warranty Service Dealer. All transportation costs under the war-  
ranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to  
Generac prepackaged emergency automatic standby generators sold and rated for use in "Standby" applications.  
WARRANTY SCHEDULE  
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and  
maintenance is required):  
• Engine - All Components  
• Alternator - All Components  
• Transfer System - All Components  
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 Guardian generators that utilize non-Generac replacement parts.  
• Any Generac Guardian generators used as rental or trailer mounted applications.  
• 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.  
• Costs of normal maintenance, adjustments, installation and start-up.  
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.  
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with  
all mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty  
will not cover repair when normal use has exhausted the life of a part(s) or engine.  
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,  
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.  
• Damage related to rodent infestation.  
• Products that are modified or altered in a manner not authorized by Generac in writing.  
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or  
replacement of the defective part(s).  
• Failure due to misapplication.  
• Telephone, cellular phone, facsimile, internet access or other communication expenses.  
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit  
warranty period.  
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.  
• Rental equipment used while warranty repairs are being performed.  
• 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 conse-  
quential 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  
Part No. 0D8444  
Revision 0 (04/03/02)  
Printed in U.S.A.  
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