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Generac Power Systems 005223-0 manual

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Table of contents for the manual

  • Page 1

    ST ANDBY GENERA T OR O WNER'S MANU AL This manual should remain with the unit. A ne w standar d of reliability Serial Number QT 3.9L 40kW Model: 005223-0 CENTURION CENTURION C E N T U R I O N ®   N ot i nt ended f or us e i n c r i t i c al l i f e s uppor t appl i c at i ons.  ONL Y QU ALIFIED ELECTRICIANS OR CONTRA CT ORS SHOULD A [...]

  • Page 2

    Standby Generator Sets T able of Contents SECTION P AGE SAFETY RULES ................................................ 1-1 INTRODUCTION ..................................................... 1-3 Read this Manual Thoroughly ................................... 1-3 Operation and Maintenance ...................................... 1-3 How to Obtain Servic[...]

  • Page 3

    Study these SAFETY RULES carefully before install- ing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely , efficiently and reli- ably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental ru[...]

  • Page 4

    • Before performing any maintenance on the gen- erator , disconnect its battery cables to prevent accidental start -up. Disconnect the cable from the battery post indicated by a NEGA TIVE, 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 [...]

  • Page 5

    1-3 I NTRODUCTION Thank you for purchasing this model of the standby generator set product line. Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written. However , the manufacturer reserves the right to change, alter or otherwise improve this produ[...]

  • Page 6

    I DENTIF ICA TION R E C OR D D A T A LA BE L Every generator set has a DA T A LABEL that contains important information pertinent to the generator . The data label, which can be found attached to the gen- erator’s lower connection box, lists the unit ’s serial number and its rated voltage, amps, wattage capacity , phase, frequency , rpm, power [...]

  • Page 7

    E QUIPM ENT DE SCRI PTION This equipment is a revolving field, alternating cur - rent generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers. The unit comes com[...]

  • Page 8

    ENGI NE P RO TE CTIVE DEVICE S The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant tempera- ture, oil pressure or rpm. F or that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shuttin[...]

  • Page 9

    F U E L SYST E M FUE L RE QUIRE MEN T S The standby generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (PV) fuel system The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the uni[...]

  • Page 10

    SP E CIF ICA TIONS GEN ERA T OR T ype ............................................................................. Synchronous Rotor Insulation ................................................................... Class H Stator Insulation .................................................................. Class H T otal Har monic Distor tion .......[...]

  • Page 11

    COLD WEA THER KIT F or cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: • Battery W armer • 4” Junction Box with hardware • 6 qt. pack 5W -30 synthetic oil (engine) R E C ONF IGU RI NG TH E FU EL SY S TEM NOTE: All models are configured for natural gas or LP vapor from the factory . T o reconfi[...]

  • Page 12

    GEN ERA T OR A C LEAD C ON NECTIONS See “V oltage Codes”. This generator may be rated at any one of three voltages, either single -phase or three -phase. The electrical wires in the unit ’s A C con- nection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any q[...]

  • Page 13

    I NS T ALLA TION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. P REP AR A TION BEFOR E ST ART -UP The instructions in this section assume that the standby generator has been properly installed, ser - viced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor . Be[...]

  • Page 14

    S T ART -U P CH E CKLIS T  Before working on the generator , ensure the fol- lowing: • The AUTO/OFF/MANU AL switch is in the OFF position. • The 120V AC supply to the battery charger is switched OFF . P REP AR A TION FOR ST ART -UP • Ensure that the 120V AC circuit breaker to the bat - tery charger is open. • Remove the fuse from the the[...]

  • Page 15

    GEN ERA T OR C ONTROL AN D OP ERA TION Refer to the appropriate control panel operator’s manual for this unit. OP ERA TI NG U N IT WITH MAN U AL TR ANSFER SWIT CH If the generator was installed in conjunction with a transfer switch capable of manual operation only , the following procedure applies. A manually operated transfer switch is one that [...]

  • Page 16

    MAI NTENANCE PER FOR M ED B Y AUTHOR IZED SERVICE F ACILITI ES  Before working on the generator , ensure the fol- lowing: • The AUTO/OFF/MANU AL switch is in the OFF position. • The 15A fuse has been removed from the con- trol box. • The 120V AC supply to the battery charger is switched OFF . EVER Y TH R EE MONTHS 1. Check battery state of[...]

  • Page 17

    ENGI NE COOLANT Check coolant level in coolant recovery bottle. See the “Specifications” section. • Add recommended coolant mixture as necessary . • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly . Coolant should be at bottom of radiator filler neck. If coolant level is low , inspe[...]

  • Page 18

    7. Start engine and check for oil leaks. Figure 10.2 - Oil Filter Oil Filter CHANGI NG THE ENGI NE AI R CLEAN ER T o replace the engine air cleaner , (part number 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover . See the “Service Schedule” section for air cleane[...]

  • Page 19

    BA TTER Y MAI NTENANCE The battery should be inspected per the “Service Schedule” section. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary . 2. Check the battery fluid level of unsealed batteries and, if necessary , fill with DISTILLED[...]

  • Page 20

    SERVICE S CH EDULE 30 KW - 1 5 0 KW ST ANDBY GAS ENGIN E DRIVEN GEN ER A T OR SET S The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will nee[...]

  • Page 21

    Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask Required T ask Required T ask T ask Required T ask mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Init[...]

  • Page 22

    Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask Required T ask Required T ask T ask Required T ask mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Init[...]

  • Page 23

    Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask Required T ask Required T ask T ask Required T ask mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Init[...]

  • Page 24

    TROU BLESHOO TI NG GU IDE P ROBLEM CAUSE C OR RECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse . 2. Loose or corroded or defectiv e 2. Tighten, clean or replace batter y cab les. batter y cab les as necessar y . 3. Defectiv e star ter contactor . 3. Replace contactor .* 4. Defectiv e star ter motor . 4. Replace starter motor .* 5[...]

  • Page 25

    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    [...]

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    1 0F3137 1 PAN CB CO NN BOX 2 0F3 1 88 1 STAN D RH CO NT R OL 3 0F3 189 1 ST AND LH CONTR O L 4 023484N 1 BU SHING SNAP SB-2.5-31 5 *** 0F6366B 1 / 2 XFMR DUAL 120V/1 6 V (FOR 120/240 V & 277/480 V UNITS) 0F636 6A 1 XFMR DUAL 104V/16 V (FOR 120/208 V UNITS) 6 *** 043180 2 / 4 W ASHER FLAT M 4 7 *** 022264 2 / 4 WASHER L OCK #8-M4 8 ** * 0C39 90[...]

  • Page 30

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  • Page 31

    1 0F343 8 1 RTR 390 30 AD1 CPL 0F344 0 1 RTR 390 40 AD2 C PL HI-EF 0F61 88 1 AS S Y RTR 39 0 30 KD 1 CP L 0F61 90 1 AS S Y RTR 39 0 40 KD 2 CP L 2 0F3 4 39 1 S TR 39 0 30 AD 1 CP L 0F34 41 1 S TR 39 0 40 AD 2 CP L 0F61 89 1 S T R 390 30 G D 1 CPL 0F61 99 1 S T R 390 40 G D 2 CPL 0F665 5 1 ASSY STR 390 30KD1 C PL 0F665 6 1 ASSY STR 390 40KD2 C PL 3 [...]

  • Page 32

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  • Page 33

    1 0F327 0 1 MTG BASE 3. 9L 40KW C2 2 0528 6 0 4 NUT FLANGE D HE X M12-1 .75 3 05225 1 4 DAM PENE R VIBR ATION 40 B LUE 4 052257 4 SPACER .49 X .62 X 1.87 PWDR/ZNC 5 05225 2 4 DAM PENE R VIBR ATION 6 05225 9 4 WAS HER FL AT M 12 7 0528 91 4 S CREW HH C M12- 1.75 X 80 G8. 8 8 053621 0410 1 ASSY WIRE 14 .0 0 " 9 0429 0 9 1 SCREW HH C M 8-1. 25 X [...]

  • Page 34

    [...]

  • Page 35

    1 0F3408 1 TRA Y BAT TER Y 2 0F 3 4 11 1 STRAP BA TTERY RET AINMENT 3 0582 08 REF BATT 12VDC 24 F 62 5 4 0368 3 3 1 SCREW HH C 3/ 8- 1 6 X 1 G8 5 02223 7 1 WASHE R LOCK 3/8 6 0221 31 1 WASHE R FLAT 3/8-M1 0 ZINC 7 050331A 1 BATT POST COVER RED + 8 050331 1 BATT POST COVER BLK - 9 038805 H 1 CAB LE BA TT BL K #1 X 2 3.00 10 0388 04Y 1 CABLE BATT RE [...]

  • Page 36

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  • Page 37

    1 0E5048A 1 FLEXPLATE HSB 3.9L CHRYSL ER (1800RPM) 0F3903A 1 FLEX PLATE 2 POLE 3.9L CHR Y (360 0R PM) 2 0F2982 1 ENG ADAPTER MACH 3.9L HSB NSPS 3 0E67 03 1 COVER FLYWH EEL ACCESS 4 0F3795 REF ENGIN E INSER T ED VAL VE 3.9L (3600 RPM) 0E8336 REF MAKE 3.9L CHRY SLER ENGINE (1800 RP M) 5 0E78 41 2 GASKET THERMOSTAT ADAPTOR 6 0E7254 1 MACH THE RM ADAPT[...]

  • Page 38

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    1 0F18 23A 1 E NCL HS B CONT ROL PANEL 2 0F30 78 1 CO VE R CO NTR O L P ANEL 3 0F26 06 1 HIN GE C ONTINUO US H-P NL 4 036261 6 RIVET POP .125 X .27 5 SS 5 0F26 27 A 1 COVER CONTR OL P ANEL SIDE 6 043181 4 SCREW PHM M3-0 .5 X 10MM 7 052777 7 WAS HER FL AT M 3 8 0F42 45A 1 AA SY PCB CO MM CTR LR 1 80 0 RPM 9 * 0F126 2 4 HOLDER FUSE WI CKMA NN 178 .61[...]

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  • Page 41

    1 0F32 03 1 WELDME NT R AD SUPP ORT 3.9L C2 2 03 5685 4 CLAMP HO SE #2 8 1. 32-2. 25 3 0F260 8 1 RADIAT OR 598 X 568 X 49 C PL RH 4 0F4 413 1 HOSE UP PER R AD CP L C2 3.9L 5 0F4 4 14 1 HO SE LOWE R RAD CPL C2 3. 9L 6 0E7854 1 CLUTC H COOLING FAN 7 0F282 0 1 FAN 22 " DIA 10 BL AD E 8 05 1756 4 SCREW HHC M 10-1. 5 X 20 G8.8 9 0 4652 6 4 WASHE R [...]

  • Page 42

    [...]

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    1 0F65 04 1 PIP E R/H S IDE MU FFLER 2 0F 3127 1 PIPE L/H SI D E 3.9L C PL 3 0F2808B 1 PIPE EXHAUST M UFFLER OUT 4 0F07 38 1 MUFF LER 7" X 9"-(2) 2" I N/2.5" OUT 5 0F29 62 1 MUFF LER STR AP 6 0F28 30 1 MUFF LER B RACKET STIF FENER 7 047411 2 SCREW HHC M6-1 .0 X 16 G8.8 8 02 2097 2 WAS HER LO CK M6- 1/4 9 02 2473 2 WAS HER FL AT [...]

  • Page 44

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  • Page 45

    1 0F6322 1 BOTTOM PLATE, AIR CLEANE R 3.9L 2 0F5418 1 ELEMENT AIR FILTE R 3 0E6406 1 HOLDER VE NTURI 4 0E 770 2 1 HOL D D OWN AI R CLE AN ER 5 0F6323 1 PLATE, AIR CLEANER TOP 3.9L 6 03756 1 1 NUT WING 1/4-20 NYLK 7 04981 5 4 SCREW HHC M5-0.8 X 16 G 8.8 8 04922 6 4 WASHER LOCK M5 9 05171 3 4 WASHER FLAT M 5 10 0E6586 1 GASKET BOS CH 32 & 40[...]

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    1 03 321 2 4 SCRE W HH C 5/ 16- 18 X 1-1/ 4 G 5 2 075580 1 FLANGE FUEL IN LET 3 0F6 3 90 1 RE GU L AT O R AS S EM BLY DU AL FUE L 4 03 9253 2 S CREW HHC M 8-1.2 5 X 20 G8.8 5 02 2145 2 W ASHE R FLAT 5/16-M 8 ZI NC 6 02 2129 6 WAS HER L OCK M 8-5/ 16 7 04 5771 2 NUT HEX M 8-1. 25 G8 CLEA R ZIN C 9 0E8 28 6 1 STREE T EL 4 5 DE G 1/2" NP T BR A S[...]

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    1 0F585 3 (XX) 1 RE AR WR AP C2 2 0C 24 5 4 68 S CR EW T HF M6- 1 X 16 N WA Z/ JS 3 0F584 9 (XX) 2 DO OR C2 4 087233 2 RIVET POP .1875 X .4 50 SS 5 0E3 257 4 SCREW TH-F RM M 6 W/CA P SHK PRF W 6 0F 5 85 2 (X X) 2 DIS C H A RG E DU CT , L H & RH SID E C2 7 0F585 0 (XX) 2 FRO NT CO RNER S C2 8 0F585 1 (XX) 1 DIS CHAR GE CE NTER DUCT C2 9 0F33 13 [...]

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    Standby Generator Sets W arranty Printed in U.S.A. GENERA C PO WER SYSTEMS ST ANDARD LIMITED W ARRANTY FOR HOME ST ANDBY/LIGHT COMMERCIAL PRODUCT 45kW AND BELO W For a period of two (2) y ears from the date of sale, or start-up by A uthorized/Cer tified Generac P ower Systems Dealer , or branch thereof , Generac P ow er Systems, Inc. will, at its o[...]