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Generac Power Systems 004987-2, 005396-0 manual

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Table of contents for the manual

  • Page 1

    • Safety • Assembly • Operation • Maintenance • Troubleshooting • Electrical Data • Par ts • W arranty FOR THE NEAREST A UTHORIZED SER VICE CENTER 1-800-333-1322 Owner ’s Man ual MODELS: 004987-2 (15,000 W att) 005396-0 (17,500 W att) www .centuriongenerators.com COMMERCIAL • INDUSTRIAL • RESIDENTIAL[...]

  • Page 2

    T able of Contents Introduction .................................................................. 1 Read This Manual Thor oughly ..................................... 1 Safety Rules .................................................................. 2 Standards Index ........................................................................... 3 Sect[...]

  • Page 3

    INTRODUCTION Thank you f or purchasing this model b y Generac P o wer Systems, Inc. ® This model is a compact, high perf ormance, air-cooled, engine driven generator designed to supply electrical power to oper ate electrical loads where no utility power is av ailab le or in place of utility due to a power outage . READ THIS MANU AL THOR OUGHL Y If[...]

  • Page 4

    2 Nev er start or stop the unit with electr ical loads connected to receptacles AND with connected devices turned ON. Star t the engine and let it stabilize bef ore connecting electrical loads. Disconnect all electr ical loads before shutting do wn the generator . Do not inser t objects through unit's cooling slots. Never operate generator: In[...]

  • Page 5

     ELECTRICAL HAZARDS  All generators cov ered b y this manual produce dangerous electrical voltages and can cause f atal electrical shock. Utility power deliv ers extremely high and dangerous v oltages as does the gener ator when it is in operation. Av oid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure[...]

  • Page 6

    4 1.1 UNP A CKING Set the palleted car ton on a rigid flat surface. Remov e staples along bottom of car ton that fasten carton to pallet. Open car ton from top. Remov e all packaging material. Remov e separate accessory box. Lift car ton off the generator . Remov e generator from shipping pallet b y removing bolts through the shipping brack ets (Fi[...]

  • Page 7

    5 5 1.2.3 B A TTER Y CONNECTION The battery shipped with the generator has been provided fully charged. Caution m ust be taken when connecting the battery . NO TE: A battery may lose some of it’ s charge when not in use for prolonged periods of time. Cut the tie wrap cable holding the RED and BLA CK battery cables to the stator . Connect the RED [...]

  • Page 8

    6 6 Section 2 – Operation 2.1 KNO W THE GENERA T OR Read the Owner’ s Man ual and Safety Rules before operating this generator . Compare the generator to Figures 4 through 6 to become f amiliarized with the locations of various controls and adjustments. Sav e this manual f or future ref erence. Figure 4 - Control P anel 1. 12 V olt DC, 10 Amp R[...]

  • Page 9

    7 2.2 CORD SETS AND CONNECTION PLUGS 2.2.1 120 V A C, 20 AMP , DUPLEX RECEPT A CLE This is a 120 V olt outlet protected against overload by a 20 Amp push-to-reset circuit breaker (Figure 7). Use each socket to po wer 120 V olt AC , single phase, 60 Hz electrical loads requiring up to a combined 2400 watts (2.4 kW) or 20 Amps of current. Use only hi[...]

  • Page 10

    8 Use this receptacle to operate 120 V olt AC , 60 Hz, single phase loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps . The outlet is protected by a 30 Amp push-to-reset circuit break er . 2.2.4 120/240 V A C, 30 AMP RECEPT A CLE Use a NEMA L14-30 plug with this receptacle. Connect a suitable 4- wire grounded cord set to the plug and to[...]

  • Page 11

    9 Proper gr ounding of the generator will help prevent electrical shock in the e v ent of a ground f ault condition in the generator or in connected electrical devices. Proper grounding also helps dissipate static electricity , which often builds up in ungrounded de vices . 2.3.2 CONNECTING ELECTRICAL LO ADS DO NO T connect 240 V olt loads to 120 V[...]

  • Page 12

    10 10 Section 2 – Operation 2.6 BEFORE ST ARTING THE GENERA T OR Prior to operating the generator , engine oil and gasoline will need to be added, as follo ws: 2.6.1 ADDING ENGINE OIL NO TE: When adding oil to the engine crankcase in the future, use only high quality detergent oil rated with API service classification SG, SH or SL. Use no special[...]

  • Page 13

    11 2.7 T O ST AR T THE ENGINE  Never start or stop engine with electrical devices plugged into the receptacles AND de vices turned on. Unplug all electrical loads from the unit's receptacles before star ting the engine. Make sure the unit is in a le v el position. Open the fuel shut-off valv e (Figure 15). Figure 15 - Fuel Shut-off V alve L[...]

  • Page 14

    12 2.9 A UT OMA TIC IDLE CONTROL This feature is designed to g reatly improv e fuel economy . When this switch is turned “ On , ” the engine will only run at its normal fast gov erned engine speed when electr ical load is connected. When the load is remov ed, the engine will run at a reduced speed of 2100 RPM. With the switch “ Off , ” the [...]

  • Page 15

    13 13 Section 3 — Maintenance 3.1 MAINTENANCE SCHEDULE Follo w the calendar intervals. More frequent ser vice is required when operating in adv erse conditions noted below . Maintenance Daily Every Season Check Oil Le v el  Ser vice Air Pre-Cleaner  ** Change Oil and Oil Filter‡  * Clean Spark Arrestor Screen  Check V alve Clearance[...]

  • Page 16

    14 14 Section 3 — Maintenance NO TE: DO NO T use a garden hose to c lean generator . W ater can enter the engine fuel system and cause problems. In addition, if water enters the generator through cooling air slots, some water will be retained in voids and cre vices of the rotor and stator winding insulation. W ater and dirt buildup on the generat[...]

  • Page 17

    15 15 T o clean or replace foam pre-c leaner: Remov e air cleaner cov er , then f oam pre-filter . W ash pre-cleaner in soap y water . Squeeze pre-filter dry in clean cloth (DO NO T TWIST). Clean air cleaner cov er bef ore re-installing it. T o clean or replace paper air filter: Remov e air cleaner cov er; then remo v e f oam pre-filter (ser vice i[...]

  • Page 18

    16 When valv e clearance is correct, hold the piv ot ball stud in place with the allen wrench and tighten the rock er arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam n ut, recheck v alv e clearance to make sure it did not change . Install new v alv e cov er gasket. Re-attach the valv e cov er . NO TE: Start all four[...]

  • Page 19

    17 17 Section 4 — T r oubleshooting 4.1 TROUBLESHOO TING GUIDE PROBLEM CA USE CORRECTION Engine is running, but no A C output is av ailable. 1. Circuit break er is open. 2. P oor connection or defectiv e cord set. 3. Connected de vice is bad. 4. F ault in generator . 1. Reset circuit break er . 2. Chec k and repair . 3. Connect another de vice th[...]

  • Page 20

    18 Section 5 — Notes[...]

  • Page 21

    19 Section 6 — Electrical Data Schematic – Drawing No. 0G2894-A[...]

  • Page 22

    20 20 Section 6 — Electrical Data Wiring Diagram – Drawing No. 0G2892-A[...]

  • Page 23

    21 21 Section 6 — Electrical Data Wiring Diagram – Drawing No. 0G2892-A[...]

  • Page 24

    22 Section 7 — Exploded Views and P arts Lists GT -990 Engine – Drawing No. 0G2963-G (Part 1)[...]

  • Page 25

    23 Section 7 — Exploded Views and P arts Lists GT -990 Engine – Drawing No. 0G2963-G (Part 1) ITEM P ART NO. QTY . DESCRIPTION 1 0C5729 1 ASSY , CRANKCASE WITH SLEEVE 2 0E9843A 1 SEAL, 38 I.D . CRANKSHAFT GREEN 3 0G0919 7 SCREW , HHFCS M6-1.0 X 12 G8.8 4 0C5372 1 ASSEMBL Y , BREA THER 5 0C3005 1 GASKET , BREA THER CO VER 6 0E3372B 1 SEP ARA T O[...]

  • Page 26

    24 Section 7 — Exploded Views and P arts Lists GT -990 Engine – Drawing No. 0G2963-G (Part 2)[...]

  • Page 27

    25 Section 7 — Exploded Views and P arts Lists GT -990 Engine – Drawing No. 0G2963-F (Part 2) ITEM P ART NO. QTY . DESCRIPTION 66 0D6592 1 WINGNUT , AIRBO X 67 0D4511 1 PRECLEANER, AIR 68 0D9723 1 ELEMENT , AIR CLEANER 69 0E5302 1 STUD M6-1.0 X 73 70 0D4183 1 ADAPT OR, SPIT BA CK 71 0D6327 1 GASKET , SPITBACK 72 0D2774B 1 BASE, AIRBO X 73 0D512[...]

  • Page 28

    26 Section 7 — Exploded Views and P arts Lists Generator – Drawing No. 0G2964[...]

  • Page 29

    27 Section 7 — Exploded Views and P arts Lists Generator – Drawing No. 0G2964 ITEM P ART NO . QTY . DESCRIPTION 1 066849 2 SCREW HHTT M5-0.8 X 16 2 0G2921 1 ST A T OR 15KW 0G2923 ST A TOR 17.5KW 3 0G29220SR V 1 ASSEMBL Y , RO T OR WITH F AN 15KW 0G29240SR V ASSEMBL Y , ROT OR WITH F AN 17.5KW 4 0C6043B 1 CARRIER, REAR BEARING 5 0D2492 1 EXHA US[...]

  • Page 30

    28 Section 7 — Exploded Views and P arts Lists Control P anel – Drawing No. 0G2965-B[...]

  • Page 31

    29 Section 7 — Exploded Views and P arts Lists Control P anel – Drawing No. 0G2965-B ITEM P ART NO. QTY . DESCRIPTION 1 0G28880ST03 1 CONTROL P ANEL BOX (15 KW & 005396) 0G28900ST03 1 CONTROL P ANEL BO X (17.5 KW) 2 0D4409 1 ELECTRONIC GO VERNOR / IDLE CONTROLLER 3 0F9719 1 ASSY PCB VREG AIR COOLED 4 0F3100 1 RELA Y 3PDT 12VDC 5 0F3101 1 RE[...]

  • Page 32

    30 Section 7 — Exploded Views and P arts Lists Frame, Handle & Wheel Kit – Drawing No. 0E0695-B[...]

  • Page 33

    31 ITEM P ART NO . QTY . DESCRIPTION 1 057058 4 SCREW HHC M6-1.0 X 55 2 0D5315 4 R UBBER T ANK MOUNT 3 0D4570 1 CAP , FUEL WITH GA UGE & VENT 4 0D22850SR V 1 KIT , FUEL T ANK 5 045771 4 NUT HEX M8-1.25 6 022129 10 WASHER LOCK M8-5/16 7 022145 14 WASHER FLA T 5/16 8 0D4565 1 BRACKET BA TTERY 9 0D3545 2 BOL T ,BA TTERY J-BOL T 10 022287 2 SCREW H[...]

  • Page 34

    32 CALIFORNIA EMISSION CONTROL W ARRANTY ST A TEMENT Y OUR W ARRANTY RIGHTS AND OBLIGA TIONS The Calif ornia Air Resources Board (CARB) and Generac P ow er Systems, Inc. (Generac) are pleased to e xplain the Emission Control System warranty on y our ne w engine. In California, new off-road Large Spark-Ignition (LSI) engines must be designed, b uilt[...]

  • Page 35

    33 Section 8 – Warranty EMISSION CONTROL SYSTEM W ARRANTY Emission Control System W arr anty (ECS warranty) f or 2001 and later model y ear LSI engines: (a) Applicability: This warranty shall apply to 2001 and later model y ear engines. The ECS W arranty period shall begin on the d ate the new engine or equipment is purchased by/deliv ered to its[...]

  • Page 36

    Section 8 – Warranty P ar t No . 0G2955 Re v . B GENERA C PO WER SYSTEMS “TWO YEAR” LIMITED W ARRANTY FOR CENTURION ® “15,000 AND 17,500 W A TT PORT ABLE GENERA T ORS” For a period of two y ears from the date of original sale, Generac P o wer Systems, Inc. (Generac) warrants its Centurion generator will be free from def ects in materials[...]