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Generac 004912-0, 004912-1, 004913-0, 004913-1, 004913-2 manual

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Table of contents for the manual

  • Page 1

    Owner’ s Man ual Liquid-cooled, Prepac kaged Standby Generator s Models: 004912-0, 004912-1 (15 kW LP/15 kW Natural Gas) 120/240V Single-phase w/ 100 Amp T ransfer Switch 004913-0, 004913-1, 004913-2 (25 kW LP/25 kW Natural Gas) 120/240V Single-phase w/ 200 Amp T ransfer Switch ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A TTEMPT INST ALLA[...]

  • Page 2

    Generac ® Pow er Systems, Inc. I NTRODUCTION Thank you for purchasing this model of the standby generator product line by Generac P ower Systems. Every effort was expended to make sure that the information and instructions in this manual are both accurate and current at the time the manual was written. However , the manufacturer reserves the right[...]

  • Page 3

    T able of Contents Centurion Liquid-cooled 1 5 kW and 25 kW Generators Generac ® Pow er Systems, Inc. 1 Introduction ................................Inside Front Cover Read This Manual Thoroughly ............................IFC Operation and Maintenance ................................IFC How to Obtain Service .....................................[...]

  • Page 4

    2 Generac ® Pow er Systems, Inc. Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely , efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to fo[...]

  • Page 5

    Generac ® Pow er Systems, Inc. 3 • Before performing any maintenance on the generator , 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 [...]

  • Page 6

    4 Generac ® Pow er Systems, Inc. 1.1 GEN ER A T OR This equipment is a liquid- cooled, engine - driven generator set. The generator is designed to supply electrical power that operates critical electrical loads during utility power failure. The unit has been factory-installed in a weather resistant, all metal enclosure and is intended for outdoor [...]

  • Page 7

    Generac ® Pow er Systems, Inc. 5 1.5 MAI N CI RCU IT B R EAKER The generator’s main circuit breaker is included with the unit. The breaker for each unit is described in Figure 1.2. 1.6 GEN ER A T OR F U EL S YS TEM The generator has been factory tested and adjusted using a natural gas fuel system. If propane (LP requirements) gas is preferred, c[...]

  • Page 8

    6 Generac ® Pow er Systems, Inc. Figure 1.5- High Coolant T emperature Switch 1.7 .3 L OW C OOL ANT LEVEL SWIT CH Should engine coolant level drop below the level of the high coolant temperature switch, it is possible for the engine to overheat without automatic shutdown. T o prevent such overheating without automatic shut down, the engine has a l[...]

  • Page 9

    1.1 0 SP E CI F ICA TIONS 1.1 0.1 GEN ER A T OR 1.1 0.2 ENGI N E Make ................................................................Mitsubishi Displacement ..................................92 inches 3 (1.5 liters) Cylinder Arrangement ........................................4, in-line V alve Arrangement ....................................Overhe[...]

  • Page 10

    8 Generac ® Pow er Systems, Inc. Serious injury or damage may occur if not configured pr operly . Please consult an authorized Generac Service Dealer with any questions. 1.1 3 T ORQU E SP E CI F ICA TIONS Cylinder Head ................................15 (+ 90° + 90°) ft.lb. Intake Manifold ....................................................13 f[...]

  • Page 11

    Generac ® Pow er Systems, Inc. 9 NOTE: F or more information about the installation of a standby system, you can order Engine - Generator Standby Electric P ower Systems Installer’s Guide and Reference Manual (part #046622) from a Generac Authorized Service Dealer . 2.1.1 N F P A ST A N DAR D S The following published standards booklets pertaini[...]

  • Page 12

    10 Generac ® Pow er Systems, Inc. Figure 2.1 – Basic Standby Electric System NOTE: Generac recommends the use of a Generac P ower Systems transfer switch in conjunction with this generator . 2.5 EM ERGENCY CI RCU IT IS OL A TION M E THOD This prevents overloading the generator by keeping electrical loads below the wattage/amperage capacity of th[...]

  • Page 13

    Generac ® Pow er Systems, Inc. 11 2.8 GEN ER A T OR A C N EUTR AL CO N N EC T I O N S Generac uses an UNGROUNDED AC neutral. Grounding is recommended only at the main service entrance. If the neutral wire is grounded and one of the phase loads becomes grounded, the excessive current opens the load circuit breaker or collapses the generator field. [...]

  • Page 14

    12 Generac ® Pow er Systems, Inc. When using maintenance -free batteries, it is not necessary to check the specific gravity or electrolyte level. Have these procedures performed at the intervals specified in Section 4, “Maintenance.” A negative ground system is used. Battery connections are shown on the wiring diagrams. Make sure all batteries[...]

  • Page 15

    Generac ® Pow er Systems, Inc. 13 3.1 USI NG A S T AN D AR D “GT S” TR ANSF ER SWIT CH When required, the pre -packaged standby generator can be installed with an engineered Generac “GTS” type engineered automatic transfer switch. When a GTS type transfer switch is used, it controls automatic operation and automatic transfer as follows: ?[...]

  • Page 16

    14 Generac ® Pow er Systems, Inc. 3.2.5 7 .5 AM P I N-LI N E FUSE This in-line fuse is connected in wire 15A which runs between the A UTO/OFF/MANUAL switch and position 10 of the 076009A PCB. This fuse protects the start, fuel, field boost, and transfer outputs from the PCB and will open if there is excessive current draw on any one of these outpu[...]

  • Page 17

    Generac ® Pow er Systems, Inc. 15 Figure 3.3 - Engine Block Heater Refer to applicable wiring diagram(s) and electrical schematic(s) at back of manual for wiring connections. Customer supplies a 120V 15A Utility fed circuit for the block heater . 4.1 MAI NTENANCE P ER FOR M ED B Y AUTHOR IZED SERVICE F A CI LITI E S A. EVER Y TH R EE MONTHS 1. Che[...]

  • Page 18

    16 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Centurion Liquid-cooled 1 5 kW and 25 kW Generators Figure 4.1 - Oil Dipstick and Oil Fill Cap 4.4.2 BA T TER Y F L U I D Check battery electrolyte fluid at least once weekly . Fluid should cover separators in all battery cells. If fluid level is low , add distilled water to cover tops of[...]

  • Page 19

    Generac ® Pow er Systems, Inc. 17 1. Remove OIL DRAIN HOSE from its retaining clip. 2. Loosen and remove OIL DRAIN HOSE CAP . Drain oil completely into suitable container . 3. When all oil has drained, install and tighten OIL DRAIN HOSE CAP , and re -install into its retaining clip. 4. T urn OIL FIL TER (F igure 4.2) counterclockwise and remove. D[...]

  • Page 20

    18 Generac ® Pow er Systems, Inc. Once each year , have the generator cleaned and inspected by an Authorized Service Dealer . That dealer will use dry , low pressure air to clean internal windings. P arts inside the control console should be cleaned and inspected at this time as well. Finally , have the insulation resistance of stator and rotor wi[...]

  • Page 21

    Generac ® Pow er Systems, Inc. 19 1. The base frame of the unit contains an optional fuel inlet location that is capped at the factory . Check that it is secured in place. The same applies for any access ports in the roof of the enclosure. If any of these caps are missing, contact a Generac Authorized Dealer . 2. Inside the generator set, the chan[...]

  • Page 22

    20 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Centurion Liquid-cooled 1 5 kW and 25 kW Generators 4.9 S CH EDU LED MAI NTENANCE The following is a recommended maintenance schedule for Centurion small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in [...]

  • Page 23

    Generac ® Pow er Systems, Inc. 21 Section 4 — Maintenance Centurion Liquid-cooled 1 5 kW and 25 kW Generators Maintenance Le vel 1 Le vel 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp. Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- mont[...]

  • Page 24

    22 Generac ® Pow er Systems, Inc. Section 4 — Maintenance Centurion Liquid-cooled 1 5 kW and 25 kW Generators Maintenance Le vel 1 Le vel 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp. Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- mont[...]

  • Page 25

    Generac ® Pow er Systems, Inc. 23 Section 5 — T roubleshooting Centurion Liquid-cooled 1 5 kW and 25 kW Generators 5.1 TROU B LE SHOO TI NG POI NTS P ROBLEM CAUSE CORR E CTION Engine won’t crank. 1. 15 amp fuse blo wn. 1. Replace fuse. 2. Loose or corroded or def ective 2. Tighten, clean or replace batter y cables . batter y cables as necessar[...]

  • Page 26

    24 Generac ® Pow er Systems, Inc. Section 6 — Notes Centurion Liquid-cooled 1 5 kW and 25 kW Generators[...]

  • Page 27

    Generac ® Pow er Systems, Inc. 25 Section 7 - Installation Diagram Centurion Liquid-cooled 1 5 kW and 25 kW Generators Drawing No. 0E1 533-A[...]

  • Page 28

    NB S ET EXER C I S E S WIT CH TERMINAL S TRIP 7 P OS. V O LTA G E RE GU LAT OR VR T S3 - - S W 2 - FL - SU PRE SS I O N A SS EMBL Y NE U TRAL BL OCK FA U LT LI G H T H OU R METE R F US E 1 5 AMP S FIELD BREAKER LED G EN D F T S1 FL T S2 S W 2 F1 C B 2 P CB C B 1 T S1 A S ALTERNAT O R S TAT OR - C APA C IT OR TR1 C A P GCU A S 1 2 4 X 1 1 4 1 11 44 [...]

  • Page 29

    Generac ® Pow er Systems, Inc. 27 Section 8 - Electrical Data Centurion Liquid-cooled 1 5 kW and 25 kW Generators Wiring Diagram — 1.5L Engine — Drawing No. 0E0343-A 4 3 2 1 5 6 9 8 1 0 11 12 CO NNE C TI ON PANEL CO NTR OL LE G EN D EH U TILITY FE D C IR CU I T T O 12 0 V / 1 5A GO VERN OR CO NTR O LLE R T O ELE C TR O NI C L OS WL S BLA CK G [...]

  • Page 30

    28 Generac ® Pow er Systems, Inc. Section 8 - Electrical Data Centurion Liquid-cooled 1 5 kW and 25 kW Generators Wiring Diagram — 1.5L Guardian — Drawing No. 0E1 52 5 FL 3 4 1 5 6 1 13 2 5 7 D 11 9 B A 17 16 10 12 E 4 3 15 14 GCU S W1 S W2 A LTERNATE TR1 2 2 5 N2 N1A ( BLUE ) ( RED ) A A B ( BLACK ) ( BLACK ) + - 14 S A VR S H O WN IN O FF P [...]

  • Page 31

    Generac ® Pow er Systems, Inc. 29 Section 8 - Electrical Data Centurion Liquid-cooled 1 5 kW and 25 kW Generators Electrical Schematic — 1.5L — Drawing No. 0A7 182-B WT S - WATER TEMPERAT U RE S WIT C H WL S - WATER LEVEL S WIT CH F S - F U EL SO LEN O I D S M - S TARTER M O T OR L OS - L O W O IL S WIT CH I SC - I G NITI O N S Y S TEM CO NTA [...]

  • Page 32

    ITEM P AR T NO . QTY . DESCRIPTION 1 098290 1 ASM MO T OR STEPPER 2 098941A 1 HOUSING GO VERNOR CONNECT OR 3 098958A REF CONNECT OR INTERF ACE ASSEMBL Y 4 098942A 1 CO VER CONNECTOR HOUSING 5 098225 2 SCREW FHM #2 X 5/8 SELF T AP 6 043146 3 SCREW HHC M6-1.0 X 10 G8.8 7 022097 5 W ASHER LOCK M6-1/4 8 084543A 1 SCREW PHM M3-0.5 X 12MM 9 098783 1 LEVE[...]

  • Page 33

    ITEM P AR T NO . QTY . DESCRIPTION 1 0D8656 1 BASE,MOUNTING 1.5L STNRD&ACSTC 2 027482 2 W ASHER SHAKEPROOF EXT 5/16 STL 3 070936 2 D AMPENER VIBRA TION 4 070936C 2 VIB. ISO. 70-75 DURO 5 039253 8 SCREW HHC M8-1.25 X 20 G8.8 6 022145 12 WASHER FLA T 5/16 ZINC 7 022129 16 WASHER LOCK M8-5/16 8 045771 4 NUT HEX M8-1.25 G8 YEL CHR 9 071956 4 W ASHE[...]

  • Page 34

    32 Generac ® Pow er Systems, Inc. N U T S ITEM #2 6. US E L OC TITE ON PANEL FOR ACCESS COVER E WELD S T U D U NDER R OOF 17 G R OU ND WIRE . FA S TENER T O S E CU R E US E D OO R LAT CH N O TE : 11 24 7 10 4 9 2 4 26 1 5 2 5 19 8 5 11 1 0 5 N O TE : 11 1 9 2 6 6 1 0 4 2 6 18 1 0 1 5 " Y" 2 6 14 13 1 7 2 6 11 17 1 5 1 21 24 3 2 3 22 11 2[...]

  • Page 35

    ITEM P AR T NO . QTY . DESCRIPTION 1 0D8666 1 ROOF A CSTC&STND CMPR TMNT 1.5L 2 0D8664C 1 DUCT CENTER 1.5L 3 0D8657 1 SUPPORT RADIA T OR 1.5L MITSU 4 0D8660 2 BRACE SIDE 1.5L MITSU 5 0A7568 2 DOORWELDMENT 1.5EPS 6 0D8659 1 CORNER POST REAR RH SIDE 1.5L 7 0D8662 1 DOOR REAR COMP AR TMENT 1.5L 8 0D8661 1 BRACE REAR 1.5L MITSU 9 0D8658 1 CORNER PO[...]

  • Page 36

    34 Generac ® Pow er Systems, Inc. T YPI C AL O F FR O NT D UC T & R OOF P ANEL. S E CU RE A S S H O WN. PANEL FOR ACCESS COVER CABLE W ELD S T U D U NDER R OO F US E D OO R LAT C H NO TE: 24 38 42 7 45 36 9 43 8 10 4 1 9 3 9 18 6 22 23 1 11 5 40 25 42 1 11 11 26 4 35 3 10 3 2 "Y" 10 "Y " 14 15 17 18 1 9 15 17 3 4 2 9 3 1 21[...]

  • Page 37

    Generac ® Pow er Systems, Inc. 35 ITEM P AR T NO . QTY . DESCRIPTION 1 0D8666 1 ROOF A CSTC & STND CMPR TMNT 1.5L 2 0D8664C 1 DUCT CENTER 1.5L 3 0D8657 1 SUPPORT RADIA T OR 1.5L MITSU 4 0D8660 2 BRACE SIDE 1.5L MITSU 5 0A7568 2 DOOR WELDMENT 1.5 EPS 6 0D8659 1 CORNER POST REAR RH SIDE 1.5L 7 0D8662 1 DOOR REAR COMP AR TMENT 1.5L 8 0D8661 1 BRA[...]

  • Page 38

    36 Generac ® Pow er Systems, Inc. Section 9 - Exploded Views and P arts Centurion Liquid-cooled 1 5 kW and 25 kW Generators Control Panel — Drawing No. 0E0 7 7 8-G A 22 28 5 1 26 29 T O 'A' 26 25 10 27 33 9 3 1 53 5 2 55 5 4 58 8 6 7 5 3 1 50 3 4 49 12 28 42 3 40 39 38 41 11 2 30 5 7 17 16 18 28 28 'A ' 2 1 56 14 38 13 40 24 [...]

  • Page 39

    Generac ® Pow er Systems, Inc. 37 ITEM P AR T NO . QTY . DESCRIPTION 1 0D9322 1 P ANEL BACK & BO TTOM GU ARDIAN 2 0D9332 1 P ANEL LH SIDE GUARDIAN & SPRN 3 0D9325A 1 P ANEL FRONT CONTR OL GU ARDIAN W/ SILKSC 4 0D9330 1 P ANEL RH SIDE C-P ANEL SML BRK 5 0C1457 1 HOURMETER 6 064009 1 LIGHT 12VDC .02A LED RED PILO T 7 032300 1 HOLDER FUSE 8 0[...]

  • Page 40

    6 1 WATERPUMP HARDWARE 13 9 10 11 2 8 7 12 24 10 14 15 16 6 32 5 4 1 24 39 41 30 17 11 10 14 11 19 17 18 20 26 21 20 25 22 24 5 7 33 1 1 14 9 24 72 10 11 10 14 1 24 35 3 4 36 44 45 14 71 12 46 11 10 49 47 70 11 10 6 69 56 55 6 7 59 5 2 58 6 4 63 65 6 2 60 7 Section 9 - Exploded Views and P arts Centurion Liquid-cooled 1 5 kW and 25 kW Generators En[...]

  • Page 41

    ITEM P AR T NO . QTY . DESCRIPTION 1 0A4531 1 ENGINE-1.5L 2 022473 2 W ASHER FLA T 1/4 ZINC 4 0A45310258 1 GASKET -EXHAUST MANIFOLD 5 0A4355 1 MANIFOLD-EXHA UST 6 0E2632 1 HEA T SHIELD EXH 1.5L 7 022097 8 W ASHER LOCK M6-1/4 8 022507 2 SCREW HHC 1/4-20 X 1/2 G5 9 052212 2 SCREW HHC M10-1.25 X 25 G8.8 10 046526 4 W ASHER-LOCK-M10 11 022131 20 W ASHE[...]

  • Page 42

    14 11 17 28 ( BOTTOM ONLY ) "A " 28 22 9 30 3 2 29 10 2 21 1 3 2 3 35 18 14 12 33 17 34 4 TO WATER INLE T ( MIDWAY UP ENGINE BLOCK ) 14 TUBE (ON BLOCK) TO THERM OS TAT 3 1 10 23 26 8 20 WATER INLET 8 19 8 8 6 ADAPTER 12 24 7 16 7 7 15 13 TO EN G INE BYPA SS 33 3 4 11 12 Section 9 - Exploded Views and P arts Centurion Liquid-cooled 1 5 kW [...]

  • Page 43

    ITEM P AR T NO . QTY . DESCRIPTION 1 0D8657 1 SUPPORT RADIA T OR 1.5L MITSU 2 0A5734 1 RADIA T OR 1.5L 3 0A6237 1 VENTURI 1.5L MODINE 4 * 0A6238 1 GUARD F AN 1.5L MODINE 5 084918 1 HEA TER ENGINE 0500W 120V 6 051520N 1 TUBING 5/8 ID X 12 7 048031C 4 CLAMP HOSE BAND 1/4 8 099502 4 CLAMP HOSE #24 B1.06 - 2.00 9 083709 1 CLAMP WIRE HOSE .573 - .551 10[...]

  • Page 44

    42 Generac ® Pow er Systems, Inc. 2 9 33 32 31 1 8 2 0 1 0 1 9 L.P. VAP OR P O R T " OU T 2 " 41 4 0 11 14 9 " C" 12 14 1 6 17 8 4 3 1 5 " D" 4 5 27 42 2 3 2 7 6 4 0 21 39 36 38 2 8 30 34 24 2 5 6 6 41 26 37 35 22 1 3 ( NATURAL GAS ) " OU T 1 " P O R T 41 3 11 " D" Section 9 - Exploded Views and P [...]

  • Page 45

    Generac ® Pow er Systems, Inc. 43 ITEM P AR T NO . QTY . DESCRIPTION 1 * --------- 1 WELDMENT MOUNTING BASE 2 075580 1 FLANGE FUEL INLET 3 0E1006 1 ASSY REGULA T OR 1.5L N.G.OR LPV 4 039253 2 SCREW HHC M8-1.25 X 20 G8.8 5 022145 2 W ASHER FLA T 5/16 ZINC 6 022129 6 W ASHER LOCK M8-5/16 7 045771 2 NUT HEX M8-1.25 G8 YEL CHR 8 0A7040 1 BRACKET -RAD [...]

  • Page 46

    44 Generac ® Pow er Systems, Inc. 8 36 13 3 12 5 9 15 14 17 T o Blow e r H ousin g 3 2 2 3 24 35 1 21 28 7 22 33 10 29 16 30 18 2 6 19 20 3 1 2 1 4 T o En g ine C rankshaf t 26 Section 9 - Exploded Views and P arts Centurion Liquid-cooled 1 5 kW and 25 kW Generators Alternator — Drawing No. 0A93 48-F[...]

  • Page 47

    Generac ® Pow er Systems, Inc. 45 ITEM P AR T NO . QTY . DESCRIPTION 1 098671 1 ASSY RO TOR 10KW 098681 1 ASSY RO TOR 15KW 098675 1 ASSY RO TOR 20KW 098936 1 ASSY RO TOR 25KW 2 0A5336A 1 HOUSING BLOWER 3 0A1659 1 SCREEN AIR OUTLET 4 071912 4 SCREW PPHM M5-0.8 X 8 SS 5 049226 4 W ASHER LOCK M5 6 051713 4 W ASHER FLA T M5 7 022129 4 W ASHER LOCK M8-[...]

  • Page 48

    ITEM P AR T NO . QTY . DESCRIPTION 1 077483 1 BA TT 12VDC 75-AH 26 2 038804D 1 CABLE BA TT RED #4 X 20.00 3 038805B 1 CABLE BA TT BLK #4 X 23.00 4 0742600131 1 ASSY ,WIRE#16 RED 1.6 5 022131 1 W ASHER FLA T 3/8 ZINC 6 046526 1 W ASHER LOCK M10 7 052213 1 SCREW HHC M10-1.25 X 20 G8.8 8 075763 3 BOO T , BA TTER Y CABLE 9 0D8668 1 BRACKET , BA TTER Y [...]

  • Page 49

    Generac ® Pow er Systems, Inc. 47 ITEM P AR T NO . QTY . DESCRIPTION 1 0A4355 1 MANIFOLD EXHAUST 1.5L 2 0E2844 1 NIPPLE T OE 1.5NPTX5.5 BLK IRON 3 036434 3 BOL T U 5/16-18 X 2.09 036449 3 SADDLE 2 INCH 4 0E0109 1 PIPE,EXHAUST 1.5L STNDRD&A CSTC 5 0C1318 1 FLEX PIPE EXHA UST 6 0D8657 1 SUPPORT , RADIA T OR 1.5L MITSU 7 0E0170 1 BLANKET , EXHA U[...]

  • Page 50

    48 Generac ® Pow er Systems, Inc. CALI FOR N IA EM ISSION C ONTROL W AR R ANT Y ST A TEM ENT Y OU R W AR R ANT Y R IGHT S AN D OBLIGA TIONS The California Air Resources Board (CARB) and Generac P ower Systems, Inc. (Generac) are pleased to explain the Emission Control System W arranty on your new engine. * In California, new utility , and lawn and[...]

  • Page 51

    Generac ® Pow er Systems, Inc. 49 EM IS SION CONTROL S YS TEM W AR R ANT Y Emission Control System W arranty (ECS W arranty) for 1995 and later model year engines: (a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS W arranty P eriod shall begin on the date the new engine or equipment is purchased by/delivere[...]

  • Page 52

    Part No. 0E5129 Revision G (12/20/04) Printed in U.S.A. Section 1 0 – Warranty Centurion Liquid-cooled 1 5 kW and 25 kW Generators GENER AC PO WER SY STEMS "TWO YEAR" LI MITED W AR RANT Y FOR CENTU R ION "PR EP ACKAGED EMERGENCY AUT OMA TIC ST AN DBY GENER A T ORS" F or a period of two years from the date of original sale, Gen[...]