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Generac 004702-0, 004703-0, 004704-0, 004705-0, 004706-0, 004707

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2. e 9 1 7 1 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below about 10 psi 68 kPa the switch contacts close and the engine shuts down automatically Figure 1 4 Figure 1 4 Low Oil Pressure Switch 1 72 HIGH COOLANT TEMPERATURE SWITCH This normally open N O thermostatic switch has sensing tip which is immersed in captive coolant should coolant temperature exceed about 250 F 121 C the switch contacts close which causes the engine to shut down automatically Figure 1 5 Generac Power Systems Inc 5 1 73 LOW COOLANT LEVEL SWITCH 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 To prevent such overheating without automatic shut down the engine has a low coolant level sensor If the engine coolant drops too low the engine automatically shuts down Figure 1 6 Figure 1 6 Low Coolant Level Sensor 1 74 OVERSPEED SHUTDOWN The Pre pack circuit board on liquid cooled units receives AC frequency rpm signals directly from the stator AC power windings via sensing leads S15 and 16 Should AC frequency exceed about 72 Hz circuit boa
3. 11 2 11 Preparation Before Start Up 12 2 11 1 Prior to Initial Start up 12 2 112 Prarsler Switch uuu cider eruere ai 12 ZA WOL SYEL NI ME 12 2 11 4 Generator Set Lubrication 12 2 11 5 Engine COOL corii a rh 12 2 11 6 BEI ek e NEE 12 2 11 7 Electrical System 12 Table of Contents oi F CONTENTS Section 3 OPERATION 13 3 1 Using a Standard GTS Transfer Switch 13 3 2 Control Console Components 13 azil ECHT u uuu aut raz 13 3 2 2 Auto Off Manual Switch 13 3 2 3 Fault Indicator Lamp 13 32 4 LO Amp FUSE 2 9 L u ua 13 0 2 0 d Ehe Re 14 3 2 6 Set Exercise Time Switch 14 3 3 Manual Transfer and Start up 14 3 4 Automatic Operation 14 3 5 Weekly Exercise Cycle 14 X Engine BIOCK EE ett 14 Section 4 MAINTENANCE 15 4 1 Maintenance Performed by Authorized Service Facilities 15 4 2 Cooling SVSICDUL E 15 4 3 Overload Protection for Engine DC Electrical SYSIEM aa OE AREA 15 4 4 Checking Fluid Levels uzasad it EOG 15 44 1 Check Engine Oil u uu u uuu 15 A42 Battery Flid ME 16 4 4 3 Engine Coolant
4. 16 4 5 Maintenance Owner Operator Can Perform 16 4 5 1 Check Engine Oil Level 16 452 Cheek Batlelyr u yau uuu ku 16 40 9 Exercise System 16 4 5 4 Inspect Cooling System 16 4 5 5 Perform Visual Inspection 16 4 5 6 Inspect Exhaust System 16 40 4 Check Fan aa uuu GR sA 16 4 5 8 Inspect Engine Governor 16 4 5 9 Changing Engine Oil 16 4 5 10 Changing the Engine Air Cleaner 17 4 5 11 Spark Plugs 17 4 5 12 Coolant Change 17 4 6 Miscellaneous Maintenance 17 4 6 1 Cleaning the Generator 17 2 02 Pil i TE 18 4 6 3 Battery Maintenance 18 4 6 4 Battery Replacement 18 4 6 5 Rodent Protection 18 4 7 Out of Service Procedure 19 4 7 1 Removal From Service 19 4 7 2 Return to Service 19 4 8 Fuel Pipe Sizing 19 4 9 Scheduled Maintenance 20 Section 5 TROUBLESHOOTING 23 5 1 Troubleshooting Points 23 Section 6 NOTES
5. 24 Section 7 INSTALLATION DIAGRAM 25 Section 8 ELECTRICAL DATA 26 Section 9 EXPLODED VIEWS AND PARTS LISTS 30 Section 10 WARRANTY 48 Generac Power Systems Inc 1 SAFETY RULES IMPORTANT SAFETY INSTRUCTIONS Guardian Liquid cooled 15 kW 20 kW and 25 kW Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe A A A WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING A A This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm 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 follow simple and fundamental rules or precautions Generac cannot possibly anticipate every possible circumstance that might involve a hazard The warning in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that Generac does not specifically recommend satisfy
6. A pan A Serious injury or damage may occur if not configured properly Please consult an authorized Generac Service Dealer with any questions 1 13 TORQUE SPECIFICATIONS Cylinder Head 90 90 ft lb Intake Manifold 13 ft lb Exhaust Manifold 13 ft lb 1 14 ENGINE OIL RECOMMENDATIONS The unit has been filled with 15W 40 engine oil at the factory Use a high quality detergent oil classified For Service CC SD SE SF Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient temperature range anticipated before the next oil change SAE 30W or 15W 40 SAE 20W 20 or 15W 40 SAE 10W or 15W 40 Below 32 F 0 C caution A Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure 1 15 COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is about 8 U S quarts 7 6 liters Use only deionized water and only low silicate anti freeze If desired add a high quality rust inhibitor to the recommended coolant mixture When adding coolant always add the recommended 50 50 mixture caution A Do not use any chromate
7. i NN NO DB HB HS HS a ech D sch eck PO O ND NO a Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators Fuel System Drawing No 0E0774 D DESCRIPTION WELDMENT MOUNTING BASE FLANGE FUEL INLET ASSY REGULATOR 1 5L N G OR LPV SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX M8 1 25 G8 YEL CHR BRACKET RAD HOSE BARBED EL 90 5 16 X 1 8 NPT HOSE 9 32 ID 11 FUEL HOSE ASSM NAT GASIL PV HOSE 9 32 ID 6 5 COVER AIR CLEANER CLAMP HOSE BAND 1 4 DECAL INLET PRESSURE ADAPTER CARB TO AIR CLNR FILTER ELEMENT NUT WING 1 4 20 NYLK CARBURETOR ASSY 1 5L CARBURETOR GASKET SCREW PPHM M5 0 8 X 12 ZNC WASHER LOCK M5 ELBOW 90D STREET 3 4 STUD TH 1 4 20 X 3 G2 ZNC FULL NUT HEX 1 4 20 STEEL NUT HEX 5 16 18 STEEL DECAL FUEL INLET NG STUD 5 16 18 X 1 25 F THR DECAL EMISSION CTRL 1 5 NG 2004 10 15KW NATURAL GAS DECAL EMISSION CTRL 1 5 LP 2004 10 15KW LP VAPOR UNITS GASKET AIR CLEANER ADAPTER O RING 2 028 1 38 X 1 50 X 06 VENTURI 18MM O RING 29 82 X 2 62 SCREW THROTTLE PIN STOP THROTTLE ARM REWORK SCREW HHM 10 32 X 5 8 WASHER LOCK 10 LEVER THROTTLE STOP BARBED STR 3 8NPT X 1 2 W VS HOSE LPG amp NAT GAS 1 2 ID 23 LG CLAMP HOSE 10 56 1 06 PLATE GAS REGULATOR MOUNTING SCREW HHC M8 1 25 X 16 G8 8 SCREW TH FRM M6 1 X 16 N WA Z JS PARTS qea OG Generac Power Systems Inc 4
8. switch to ON position for 20 to 30 seconds and then release Switch will spring back into its original position when released Wait 30 seconds before setting the AUTO OFF MANUAL switch to AUTO position caution A If the AUTO OFF MANUAL switch is switched too soon the engine may start If engine does start it will shut down automatically in about two 2 minutes Set the generator main circuit breaker to its ON or CLOSED position Generator is now programmed to start and exercise every seven days thereafter on day and time of day the switch was actuated Place a sign on the generator control panel and the transfer switch indicating the day and time the generator will be exercising NOTE If battery terminals are disconnected the exercise timer needs to be reset for correct automatic exercise operation Figure 3 2 Set Exercise Switch SET EXERCISE TIME ON FAULT AUTO INDICATOR Oe O MANUAL 3 6 ENGINE BLOCK HEATER This standby generator comes equipped with a block heater Figure 3 3 similar to the block heaters used in automotive applications The block heater is wired to a grounded plug Centurion Liquid cooled 15 kW and 25 kW Generators 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 MAINTENANCE PER
9. CENTURION Owner s Manual Liquid cooled Prepackaged Standby Generators Models 004912 0 004912 1 15 kW LP 15 kW Natural Gas 120 240V Single phase w 100 Amp Transfer Switch 004913 0 004913 1 004913 2 25 kW LP 25 kW Natural Gas 120 240V Single phase w 200 Amp Transfer Switch UN a I w A OO IIIIIIIIII OU III III JI UI PANAMY This manual should remain with the unit ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY INTRODUCTION Thank you for purchasing this model of the standby generator product line by Generac Power 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 to change alter or otherwise improve this product s at any time without prior notice READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the nearest Generac Authorized Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular service or operation that may be hazardous if performed incorrectly or carelessly Obse
10. Section 2 Installation WARNING A Do not dispose of the battery in a fire The battery is capable of exploding Do not open or mutilate the battery Released electrolyte can be toxic and harmful to the skin and eyes A The battery represents a risk of high short circuit current When working on the battery always remove watches rings or other metal objects and only use tools that have insulated handles 2 10 1 VENTED BATTERIES caution A A 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 Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbonate of soda to one gallon 4 liters of water The bicarbonate 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 Lead acid batteries present a risk of fire f because they generate hydrogen gas The following procedure are to be followed DO NOT SMOKE when near batteries DO NOT cause fl
11. 4 5 10 CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner part number 059402 remove the air cleaner cover and remove air cleaner Clean bottom plate and install the air filter making sure it is positioned properly before reattaching the cover Figure 4 3 Figure 4 3 Engine Air Cleaner Air Cleaner 0700000022 RY aA m de LF AM H ech L 6 o Doors Removed for Clarity MAINTENANCE 5 Section 4 Maintenance See Scheduled Maintenance Section 4 7 for air cleaner maintenance 4 5 11 SPARK PLUGS Reset the spark plug gap or replace the spark plugs as necessary See Section 4 7 1 Clean the area around the base of the spark plugs 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 plugs to clean 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See Scheduled Maintenance Section 4 7 for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 5 0 6 mm 0 020 0 025 inch by carefully bending the ground electrode Figure 4 4 Figure 4 4 Setti
12. A Uy n LOL 31VNH3LTV rm sa dA 9 S GE kin G Lu 91S SWALSAS 11 AOpe HOS JYIM 30 1d ASN R a z e l Lu u aou fet il Lee EH NOILLOANNO9 HOLIMS N H3JSNVH I OVH3N39 5 SV GHVGNVLS HOS LYVLS I l I FYIM c CSL LL s Si edo qaq o z LL SIS 9 esl Gem R m u S 91S Si ama vsze SL vi 9 4 Vv a A lt 9 ez ez De F L v6L v T S FGES d 91 9L 3 dod Q WR LOL sh osL OSL J ZL a z 9 Bv 7 vsi Olo gsi 10L 6 H ag Z S l x 971 74 Gl Ld Q P p NA ei Jo vszz Das 8 1 ezz 96 0 m S val p 0 I 9 03 OSL H an 662 L S8 v 03 ON ZMS oft 11 l 3 6 94 OSI DG Sg S8 9 04 v v vs v 8 03 S 23 M NOUISOd Am YO Sk 9g 9g 1 93 NI NMOHS L MOVIB 0 Z1 03 0 WH rL rL LA LL O3 SEI qau 01 93 l l 6 03 J ezz 6220 vl LSL dvo ee Generac Power Systems Inc TO CONTROL PANEL TO CONTROL PANEL TO DC VOLTAGE REGULATOR GOVERNOR CONTROL UNIT TERMINAL STRIP TO 120V 15A UTILITY FED CIRCUIT Section 8 Electrical Data Centurion Liquid cooled 15 kW and 25 kW Generators i ELECTRICAL Electrical Schematic 1 5L Drawing No 0A7182 B DATA lt WTS 12V BATTERY RED uiu BLACK LEGEND EH CC CONTROL CONTACTOR ACTUATOR CONNECTOR GOVERNOR ACTUATOR DCA DC ALTERNATOR EH ENGINE HEATER FS FUEL SOLENOID GRD GROUND ISC IGNITION SYSTEM CONTACT LOS
13. ADAPTER THERMOSTAT GASKET THERMOSTAT THERMOSTAT 195 DEG GASKET INLET MANIFOLD MANIFOLD INTAKE MACHINED ASSY WATER LEVEL SENSOR C E PL SW TMP 245 DEG 3 8 NPT BARBED EL 90 3 8 NPT X 5 8 PLUG STD PIPE 3 8 STEEL SQ HD Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators Engine Drawing No 0E1228 E PART NO QTY 061012 039253 0A5110 0A7006 025507 022500B 0A8584 036277 042574 026073A 0A6701 039414 0A5568 051769 0A4804 0A4804A 0A4800 0A4800A 0A5839 0A1354B 0A4839 055816 049811 0E1936 0A2628 0A5275 0A5586 0A4814 0A45310244 001852 0912970066 070928 069860C 069811 075443 po A A A cl cl M5 N a a sch sch a O A ma sch PARTS qea OG DESCRIPTION PLUG STD PIPE 1 8 SCKT HD SCREW HHC M8 1 25 X 20 G8 8 PIPE WATER INLET O RING 1 1 16 X 1 5 16 X 1 8 WASHER SHAKEPROOF EXT 7 16 SIL SPACER 41 X 75 X 25 ST ZNC SWITCH OIL PRESSURE ELBOW 90D STREET 1 8 ADAPTOR 1 8 NPTF TO 1 8 28 PLUG STD PIPE 1 4 STEEL SQ HD SCREW HHC M10 1 5 X 110 G8 8 SCREW HHC M8 1 25 X 35 G8 8 SCREW HHC M12 1 25 X 55 G8 8 WASHER LOCK M12 PULLEY CRANKSHAFT 1800 RPM BUILT PRIOR TO 11 20 02 PULLEY CRANKSHAFT 1800 RPM BUILT AFTER 11 20 02 PULLEY CRANKSHAFT 3600 RPM BUILT PRIOR TO 11 20 02 PULLEY CRANKSHAFT 3600 RPM BUILT AFTER 11 20 02 BRACKET ALT SUPPRT DC ALTERNATOR 12V ARM ADJUST ALTERNATOR SCREW HHC M6
14. Drawing No 0E0771 E DESCRIPTION ROOF ACSTC amp STND CMPRTMNT 1 5L DUCT CENTER 1 5L SUPPORT RADIATOR 1 5L MITSU BRACE SIDE 1 5L MITSU DOORWELDMENT 1 5EPS CORNER POST REAR RH SIDE 1 5L DOOR REAR COMPARTMENT 1 5L BRACE REAR 1 5L MITSU CORNER POST REAR LH SIDE 1 5L LATCH amp CAM SCREW TH FRM M6 1 X 16 N WA Z JS SCREW PHM 10 32 X 5 8 ZINC NUT HEX M5 0 8 G8 YEL CHR WASHER LOCK 10 ASSEMBLY BASE DOOR GROUND WIRE WASHER SHAKEPROOF EXT 10 STL GRD WIRE ASS Y 99HSB WASHER LOCK 8 M4 SCREW PPHM 8 32 X 5 16 NUT HEX 1 4 20 STEEL ASSEMBLY COVER ACCESS WASHER FLAT 1 4 ZINC WASHER LOCK M6 1 4 GASKET CLIP ON SELF GRIPPING LATCH AND CAM NUT HEX JAM 3 8 24 SS GASKET CLIP ON SELF GRIPPING DUCT LH SIDE 1 5L DUCT RH SIDE 1 5L age LISTS Generac Power Systems Inc 33 iews and Parts Section 9 Exploded V LISTS OG PARTS 0E0772 G ing No cooled 25 kW Generator Draw Acoustic Compartment Centurion Liquid s FYIM ON OU k ZGGZE0 LAN 24938 ou H3N31SV3 NO 3111901 3SN H91V1uooq 3Sn LI NMOHS SV JUNIIS TANVd 4004 8 LONG LNOHd dO WOldAL M NN d M NNNM k AN NON Aa NN AAA AN Li ki NEN NN 40IS uv4 NO SI NVO4 SALVLS C JIS HV3N NO SI WYO4 SALVLS C 3J318V9 H4409 SS400V YOF TANVd JOOd d3dNn GNLS QHA L 34 Generac Power Systems Inc ITEM CONDOR NN PART NO 008666 0D8664C 0D8657 0D866
15. O CO COo CO O1 Oo NO OI OO IS O1 cO O10O 0O 0O 0O O O1 O O N co LO A N e oo no no no N I 00 o o a co co NM p RE sss p az po MEM NE PERIODIC REPLACEMENT PARTS Generac s Part Number 0445310244 046627 059402 Spark Plug 0A45310275 Generac Power Systems Inc 19 gt Section 4 Maintenance MAINTENANCE Centurion Liquid cooled 15 kW and 25 kW Generators o 49 SCHEDULED MAINTENANCE 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 an average service application They will need to be decreased performed more frequently if the unit is used in a severe application Use the unit hour meter or calendar time whichever occurs first from the previous maintenance interval to determine the next required maintenance interval Service Maintenance Interval Information The various service maintenance intervals are designated by interval numbers as follows 1 An early inspection of the generator set to insure it is ready to operate when required and to identify any potential problem areas Performed monthly or following each 10 hours of operation of the unit and requires approximately 5 man hours per unit to complete This inspection may be performe
16. yourself that it is safe for others Also make sure the procedure work method or operating technique chosen does not render the generator unsafe A Dan A A 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 install operate or maintain this equipment A 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 2 Generac Power Systems Inc operation be copied and posted in potential hazard areas Safety should be stressed to all operators potential operators and service and repair technicians for this equipment SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries A 4 GENERAL HAZARDS For safety reasons Generac recommends that this equipment be installed serviced and repaired by a Generac Authorized Service Dealer or other competent qualified electrician or installation technician who is familiar with applicable codes standards and regulations The operator also must comply with all such codes standards and regulations I
17. 1 0 X 70 G8 8 WASHER FLAT M6 FAN COOLING 15 PULLEY FAN 95 DIA V BELT 3 8 X 32 1 8 1 5L V BELT 3 8 X 28 9 1 5L SPACER PULLEY FILTER OIL ADAPTER DRAIN OIL GROUND WIRE STARTER CLAMP HOSE OIL DRAIN HOSE ASM OIL DRAIN CAP HEX 1 4NPT BRASS SCREW CRMPTIT 1 4 20 X 5 8 Generac Power Systems Inc 39 es Section 9 Exploded Views and Parts O Centurion Liquid cooled 15 kW and 25 kW Generators 0 Radiator Drawing No 0E0769 H TO ENGINE BYPASS ON INTAKE MANIFOLD TO THERMOSTAT MIDWAY UP ENGINE BLOCK ADAPTER TO WATER INLET TUBE TO BASE OF WATER INLET 35 BOTTOM ONLY 40 Generac Power Systems Inc PART NO 0D8657 0A5734 0A6237 0A6238 084918 051520N 048031C 099502 083709 052250 047411 022097 049813 022473 084427 0515202 075443 056892 0A6284 0A6258 029032 031669 060035 022127 046627 007649 002454 076749 0E0726 035461 0A7275 0A2111 065852 047290A QTY NN PO GO A A m BH O ON CO Z NN A AB HS HS HS a Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators Radiator Drawing No 0E0769 H DESCRIPTION SUPPORT RADIATOR 1 5L MITSU RADIATOR 1 5L VENTURI 1 5L MODINE GUARD FAN 1 5L MODINE HEATER ENGINE 0500W 120V TUBING 5 8 ID X 12 CLAMP HOSE BAND 1 4 CLAMP HOSE 24 B1 06 2 00 CLAMP WIRE HOSE 573 551 TAPE FOAM 1 X 1 12 LG SCRE
18. 10 hrs hrs Initiate an automatic start and transfer of the unit to site load and exercise it for at least one hour looking for leaks loose connections or components and abnormal operating conditions Correct as necessary Start and exercise the unit at full rated load use a load bank if the site load is not enough for at least two hours looking for leaks loose connections components and abnormal operating conditions Correct as necessary Change the engine oil Replace the engine oil filter s Replace the engine air filter s Check the engine spark plugs on gas engine driven units Clean and re gap or replace as necessary Perform a five minute no load operational run of the unit looking for any post service problems Return the unit to standby setup for operation when required 5 o ee Generac Power Systems Inc Task Comp Date Initials Section 5 Troubleshooting TROUBLESHOOTING Centurion Liquid cooled 15 kW and 25 kW Generators 5 1 TROUBLESHOOTING POINTS CAUSE PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts then shuts down AUTO OFF MANUAL Switch at OFF engine continues to run No AC output from generator 1 2 W JO OT Co DP R OO MN 15 amp fuse blown Loose or corroded or defective battery cables Defective starter contactor Defective starter motor Dead or Def
19. 2 2 8 12 16 4 4 4 1 2 2 12 1 1 1 1 1 1 Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators Mounting Base Drawing No 0E0768 B DESCRIPTION BASE MOUNTING 1 5L STNRD amp ACSTC WASHER SHAKEPROOF EXT 5 16 STL DAMPENER VIBRATION VIB ISO 70 75 DURO SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK Me 5 16 NUT HEX M8 1 25 G8 YEL CHR WASHER FLAT M8 SCREW HHC M8 1 25 X 60 G8 8 EARTH STRAP PANEL SUPPORT PANEL BRACKET SCREW TH FRM M6 1X16 N WA Z JS SCREW HHC M6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC LUG SLDLSS 42 48 X 17 64 CU NUT HEX M6 X 1 0 G8 YEL CHR WASHER SHAKEPROOF EXT 1 4 STL LISTS age Generac Power Systems Inc 31 Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW Generator Standard Compartment Drawing No 0E0771 E WELD STUD UNDER ROOF PANEL FOR ACCESS COVER USE DOOR LATCH FASTENER TO SECURE GROUND WIRE USE LOCTITE ON NUTS ITEM 26 32 Generac Power Systems Inc ITEM CONDOR NN PART NO QTY 008666 0D8664C 0D8657 0D8660 0A7568 0D8659 0D8662 0D8661 0D8658 067042 0C2454 033530 051716 022152 0912970064 023762 0912970063 022264 067035 022127 0C2634A 022473 022097 0D2023 0F3390 037337 0D2023 OD8664A 0D8664B Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW Generator Standard Compartment
20. 5 8 ZYC 58 0E3783 1 DECAL WARNING REMOVE FUSE NOT SHOWN Generac Power Systems Inc 37 Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators Engine Drawing No 0E1228 E 38 Generac Power Systems Inc PART NO QTY 0A4531 022473 0A45310258 0A4355 0E2632 022097 022507 052212 046526 022131 002499 055993 045772 023586 020692 0A7005 052243 0A4772 070901 051735 056768 022145 022129 022259 052213 047411 052830 045771 058306 030795 0A2711A 048665 075885 0445310257 0E1100 0E0561 0A6751 034339 026925 h em c gt com pO ro r ro ro eo r Samo PO OI DESCRIPTION ENGINE 1 5L WASHER FLAT 1 4 ZINC GASKET EXHAUST MANIFOLD MANIFOLD EXHAUST HEAT SHIELD EXH 1 5L WASHER LOCK M6 1 4 SCREW HHC 1 4 20 X 1 2 G5 SCREW HHC M10 1 25 X 25 G8 8 WASHER LOCK M10 WASHER FLAT 3 8 ZINC STAMPING ENG FOOT SPACER 41 X 75 X 12 STL ZNC NUT HEX M10 1 5 G8 YEL CHR SCREW SHC 5 16 18 X 2 G8 8 NZ STARTER 12V SPACER 56 X 1 X 37 ST ZNC SCREW HHC M10 1 5 X 60 G8 8 ENGINE PLATE SLEEVE DOWEL BLHSG SCREW HHC M10 1 5 X 70 G8 8 SCREW HHC M10 1 5 X 90 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK M8 5 16 NUT HEX 5 16 18 STEEL SCREW HHC M10 1 25 X 20 G8 8 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHC M10 1 25 X 45 G8 8 NUT HEX M8 1 25 G8 YEL CHR SCREW SHC M8 1 25 X 25 612 9 SCREW HHC 5 16 18 X 1 G5
21. LOW OIL SWITCH SM STARTER MOTOR WTS WATER TEMPERATURE SWITCH WLS WATER LEVEL SWITCH Generac Power Systems Inc 29 PARTS qp is 0 17 TO A AY 18 S pa en SY 11 ITEM PART NO I 098290 2 098941A 3 098958A 4 098942A 5 098225 6 043146 7 022097 8 084543A 9 098783 10 037398 11 0E1326 12 0A7106 13 074031 14 029333A 15 022507 16 022473 17 064526 18 0E1694 Gen amp Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators Governor Assembly Drawing No 0E1331 B 4 3 2 ITEM 13 NEOPRENE L COATING W QD SECURE WIRE HARNESS WITH TIE WRAP AS SHOWN 8 INTAKE MANIFOLD 10 r CARBURETOR ARM E REF QTY DESCRIPTION ASM MOTOR STEPPER HOUSING GOVERNOR CONNECTOR CONNECTOR INTERFACE ASSEMBLY COVER CONNECTOR HOUSING SCREW FHM 2 X 5 8 SELF TAP SCREW HHC M6 1 0 X 10 G8 8 WASHER LOCK M6 1 4 SCREW PHM M3 0 5 X 12MM LEVER STEPPER MOTOR NUT LOCK HEX 10 32 NYL INS ASSY CARBURETOR LINKAGE ROD BRACKET STEPPER MOTOR LIQUID NEOPRENE TIE WRAP 7 4 X 19 BLK UL SCREW HHC 1 4 20 X 1 2 G5 WASHER FLAT 1 4 ZINC SCREW TAP HWH 6 25 X 3 8 ZINC SPRING ANTI LASH JJ M 30 Generac Power Systems Inc ITEM CONDOR NN PART NO 008656 027482 070936 0709360 039253 022145 022129 045771 071956 051730 021991 0D9335 0D9336 002454 047411 022097 022473 055414 049813 026850 QTY 1 2
22. base rust inhibitor with ethylene glycol base anti freeze or chromiumhydroxide green slime forms and will cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base anti freeze Using any high silicate anti freeze boosters or additives will also cause overheating Generac also recommends that any soluble oil inhibitor is NOT used for this equipment s Generac Power Systems Inc Centurion Liquid cooled 15 kW and 25 kW Generators 1 16 BEFORE INSTALLATION Before installing this equipment check the ratings of both the generator and the transfer switch Read Emergency Isolation Method and Total Circuit Isolation Method in the installation manual Part No 079699 The generator s rated wattage amperage capacity must be adequate to handle all electrical loads that the unit will power You may have to group the critical essential loads together and wire them into a separate emergency distribution panel This generator can be installed in conjunction with a Generac GTS type engineered transfer switch if desired The standard transfer switch included has no adjustable sensing or controlling circuit boards Instead the generator control console houses a Printed Circuit Board Assembly which controls all phases of operation including engine start up and load transfer 2 1 GENERATOR INSTALLATION A
23. 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 4 6 4 BATTERY REPLACEMENT When replacing batteries use the same number and the type of battery BCI Group No 26 26R with 525 CCA 0 degrees F BCI Group No CCA 26 26R 525 0 deg F NOTE The BCI number should be located directly on the battery 4 6 5 RODENT PROTECTION The intrusion of rodents into the generator set can cause a wide range of problems from failure of the unit to start to personal injury and in extreme circumstances short circuit or fire Although the unit was designed to limit this problem further precautions can be taken by the owner to help minimize both the chance of rodent entry and the extent of any damage The following inspection should be performed Centurion Liquid cooled 15 kW and 25 kW Generators 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 chance of rodent entry into the control panel is greatly reduced by the inclusion of adjustable wire connectors Check that the wire connector screws are tight thus closing off any gap between the access holes and the wires
24. 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 the fuel supplier for the Btu content of the fuel being used Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE A seperate gas line and regulator may be needed to assure proper gas pressure to the generator Improper gas pressure can cause hard starting and affect engine durability WARNING amp Gaseous fuels such as natural and LP propane 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 1 7 ENGINE PROTECTIVE DEVICES The engine has several safety switches which cause the engine to automatically shut down under the following conditions low oil pressure high coolant temperature engine overspeed low coolant level or overcrank Figure 1 3 A Figure 1 3 Engine Protective Devices HIGH COOLANT TEMPERATURE SWITCH LOW COOLANT LEVEL SWITCH LOW OIL z D L E Aye J AP J WITCH
25. has 30 50 psi Crankcase Oil Capacity 4 0 U S quarts 3 8 liters Recommended Engine Oil SAE 15W 40 Type of Cooling System Pressurized closed recovery Coona PAM EE Pusher Type Cooling System Capacity 2 U S gallons 7 6 liters Recommended Coolant Use a 50 50 mixture of ethylene glycol base and deionized water 1 11 FUEL CONSUMPTION 25 kW Models Using Natural Gas 441 cu ft per hour Using LP Gas 175 cubic ft 4 8 gal per hour 15 kW Models Using Natural Gas 277 cu ft per hour Using LP Kaes gees 110 cubic ft 3 1 gal per hour NOTE Fuel consumption is given at rated maximum continuous power output when using natural gas rated at 1000 Btu per cubic foot or LP gas rated 2520 Btu per cubic foot Actual fuel consumption obtained may vary depending on such variables as applied load ambient temperature engine conditions and other environmental factors Section 1 General Information Centurion Liquid cooled 15 kW and 25 kW Generators GENERAL INFORMATION Fuel pressure for a natural gas set up should be five inches to 14 inches of water column 0 18 to 0 5 psi at all load ranges Fuel pressure for an LP vapor set up should be 11 inches to 14 inches of water column 0 4 to 0 5 psi at all load ranges NOTE A seperate gas line and regulator may b
26. i W3LSAS GNNOND 3AILIVO3N LIWA ZI E iB 3NVd JUNIND2 NI G30IAUSNd SINIM TONLNOD dOLS LAVLS V3NV JILYWOLNY 3NIDN3 ANY SY37 QYO1 OV YOJ SLNIOd NUIL23NND3 2 AN anis NDILJ3NNOD 2v AOZI SSNINOIAN AJLYJH HOOT ABYANYIS I 7921812313 bec SALON ec 25 Generac Power Systems Inc HOLIMS TWANVW SSO OLNV LMS dWV SZ3NIINI ASNA LH HOLV1N93H JOVLIOA HA ATdWASSV NOISSAYdNS VS SdINV SL ISNA d SOd ZdlH1S TVNINYIL ESL Quvos LINOHIO MOVd 3Hd 89d NOILOANNOO dNIDN3 93 SOd dlH1S TVNINYIJL ZSL A00 1d WHLNAN gN YINVIYE OT 280 SOd OZ dIYIS TYNINHHL LSL HALI HNOH NH Haxvaua LINOHIO 190 ONISN3S ALITILN HWHHSNHL LHL HJTIOHLNOO HONH3AOS N99 HOLIOVdVO dvo HOLIMS 3SIOH3X3 LIS ZMS 1H9I1 Linvs H YOLVIS HOLVNH3ITV SV aua9qa1 ONIHV38 OL LS3SO19 p QV31GQ3u HLIM HSNHad
27. of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed semi annually or following each 50 hours of operation of the unit and requires approximately 1 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer 4 A mid level inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed annually or following each 100 hours of operation of the unit and requires approximately 4 0 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer eo Generac Power Systems Inc 10 1 Section 4 Maintenance Centurion Liquid cooled 15 kW and 25 kW Generators MAINTENANCE Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Required Task Required Task to be done Comp to be done Comp Required 3 months Date Semi Date to be done monthly Initials Break in Initials annually Initials Annually 10 hrs 30 hrs 50 hrs 100 hrs Disable the unit from operating per the first page warning Check
28. 0 0A7568 0D8659 0D8662 0D8661 0D8658 067042 0C2454 033530 051716 022152 0912970064 023762 0912970063 022264 067035 078115 0C2634A 022473 022097 022127 0D8663 0D8665 0E0072D 0E0072B 0E0072Q 0E0072C 0E0072A 0E0072M 0E0072P 0E0072L 0E0072N 0E0072G 0E0072J 0E0072F 0E0072E 0E0072K 0E0072H 0D2023 0F3390 037337 OD8664A 0D8664B 0E0072R QTY Section 9 Exploded Views and Parts Centurion Liquid cooled 25 kW Generator Acoustic Compartment Drawing No 0E0772 G DESCRIPTION ROOF ACSTC 8 STND CMPRTMNT 1 5L DUCT CENTER 1 5L SUPPORT RADIATOR 1 5L MITSU BRACE SIDE 1 5L MITSU DOOR WELDMENT 1 5 EPS CORNER POST REAR RH SIDE 1 5L DOOR REAR COMPARTMENT 1 5L BRACE REAR 1 5L MITSU CORNER POST REAR LH SIDE 1 5L LATCH 8 CAM SCREW TH FRM M6 1 X 16 NWA Z JS SCREW PHM 10 32 X 5 8 ZINC NUT HEX M5 0 8 G8 YEL CHR WASHER LOCK 10 ASSEMBLY BASE DOOR GROUND WIRE WASHER SHAKEPROOF EXT 10 STL GRD WIRE ASS Y 99HSB WASHER LOCK 8 M4 SCREW PPHM 8 32 X 5 16 WASHER SELF LOCKING DOME ASSEMBLY COVER ACCESS WASHER FLAT 1 4 ZINC WASHER LOCK M6 1 4 NUT HEX 1 4 20 STEEL BAFFLE CNTRL PNL 1 5L ACOUSTIC BAFFLE DOOR 1 5L ACOUSTIC UNIT ACSTC INSLTN 1 5L DUCT RH PNL ACSTC INSLTN 1 5L DUCT LH PNL ACSTC INSLTN 1 5L RAD SUPPORT ACSTC INSLTN 1 5L DUCT FNT PNL ACSTC INSLTN 1 5L ROOF PANEL ACSTC INSLTN 1 5L SIDE DR PNL ACSTC INSLTN 1 5L SIDE DR PNL ACSTC INSLTN 1 5L SIDE BRC PNL ACSTC INSLTN 1 5L DR BAFFLE PL ACSTC IN
29. 1PH GJK ASSY STATOR 25KW 1PH A ASSY STATOR 25KW 1PH D ASSY STATOR 25KW 3PH D BEARING CARRIER REAR ASSY HOLDER BRUSH SCREW PPHM M4 0 7 X 16 COVER REAR BEARING CARRIER BOLT STATOR X 16 LG SCREW RHM 10 24 X 2 WASHER LOCK 10 FAN amp RING GEAR ASSEM KEY SQ 3 8 X 1 STEEL SPACER FLEX PLATE PLATE FLEX SCREW HHC M12 1 75 X 40 G8 8 WASHER LOCK M12 SCREW HHC M10 1 5 X 35 G8 8 WASHER LOCK M10 NUT HEX M10 1 5 G8 YEL CHR PLUG PLASTIC 3 8 NPT FLEX CONDUIT 1 BLACK NOT SHOWN WASHER FLAT 3 8 M10 ZINC SPACER ROTOR SHAFT SCREW HHC M12 1 25 X 25 G8 8 WASHER FLAT M12 DECAL WARN ENG START WASHER SHAKEPROOF INT 8 WASHER FLAT 34 ID X 75 OD DECAL DANGER STANBY UNITS PARTS LISTS OG Generac Power Systems Inc 45 PARTS ITEM CONDO Om NN cO 13 14 15 16 17 LISTS OG PART NO 077483 038804D 038805B 0742600131 022131 046526 052213 075763 0D8668 050331A 050331 002454 025507 027482 QTY 1 1 1 1 1 1 1 3 1 1 1 2 1 2 Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators Battery Drawing No 0E0770 A STARTER SOLENOID TO ENGINE BLOCK DESCRIPTION BATT 12VDC 75 AH 26 CABLE BATT RED 4 X 20 00 CABLE BATT BLK 4 X 23 00 ASSY WIRE 16 RED 1 6 WASHER FLAT 3 8 ZINC WASHER LOCK M10 SCREW HHC M10 1 25 X 20 G8 8 BOOT BATTERY CABLE BRACKET BATTERY HOLD DOWN 1 5 BATTERY POST COVER RED BATT
30. 3 CH Section 9 Exploded Views and Parts LISTS Centurion Liquid cooled 15 kW and 25 kW Generators 0 Alternator Drawing No 0A9348 F To Engine Crankshaft OS WA ZON Wh re Ws ANTANN AAA d Wks To Blower Pa 44 Generac Power Systems Inc ITEM PART NO QTY 1 098671 1 098681 1 098675 1 098936 1 2 0A5336A 1 3 0A1659 1 4 071912 4 5 049226 4 6 051713 4 7 022129 4 8 098672 1 098673 1 098674 1 098682 1 098683 1 098684 1 098676 1 098677 1 098678 1 097620 1 098937 1 097621 1 9 0A5382 1 10 075591 1 11 075476 4 12 0A5601 1 13 075554B 4 14 0A9375 4 15 022152 4 16 097146 1 17 042558 1 18 0A5061 1 19 0A4989 1 20 053557 1 21 051769 6 22 049541 4 23 046526 4 24 045772 4 26 087599 1 27 077043E 1 28 022131 4 29 072578 1 30 0A7043 5 31 049808 5 32 058589 1 33 023365 4 35 0A8830 4 36 072080 1 USED ON PRE PACKAGED UNITS ONLY Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators Alternator Drawing No 0A9348 F DESCRIPTION ASSY ROTOR 10KW ASSY ROTOR 15KW ASSY ROTOR 20KW ASSY ROTOR 25KW HOUSING BLOWER SCREEN AIR OUTLET SCREW PPHM M5 0 8 X 8 SS WASHER LOCK M5 WASHER FLAT M5 WASHER LOCK Me 5 16 ASSY STATOR 10KW A ASSY STATOR 10KW D ASSY STATOR 10KW GJK ASSY STATOR 15KW 1PH A ASSY STATOR 15KW 3PH D ASSY STATOR 15KW 1PH GJK ASSY STATOR 20KW 1PH A ASSY STATOR 20KW 1PH D ASSY STATOR 20KW
31. 4 7 OUT OF SERVICE PROCEDURE 4 7 1 REMOVAL FROM SERVICE If the generator cannot exercise every seven days and it is to be out of service longer than 90 days prepare 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 fault on the control panel 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 SAE 15W 40 oil having API Service Class SD SE or SF See Engine Oil Recommendations in Section 1 14 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 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 9 Clean and wipe the entire generator 4 7 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Verify that utility power is turned off to the transfer switch 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 recom mended oil i
32. CE Section 4 Maintenance Figure 4 1 Oil Dipstick and Oil Fill Cap SS N RU OIL DIPSTICK AN 4 4 2 BATTERY FLUID 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 separators DO NOT USE TAP WATER IN BATTERY 4 4 3 ENGINE COOLANT Check coolant level in coolant recovery bottle See Section 1 10 Specifications e 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 inspect gasket in radiator pressure cap Replace cap if necessary To have pressure cap tested contact an authorized Generac Service Dealer Inspect cooling system and coolant recovery system for leaks 4 5 MAINTENANCE OWNER OPERATOR CAN PERFORM 4 5 1 CHECK ENGINE OIL LEVEL Refer to Checking Fluid Levels Section 4 4 4 5 2 CHECK BATTERY Check battery fluid level each week as outlined under Checking Fluid Levels Section 4 4 Check battery cables for condition tightness corrosion or damage Clean tighten or replace as necessary 4 5 3 EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes See Section 3 5 Weekly Exercise Cycle 16
33. Correct rated frequency and voltage are supplied only at the proper governed speed Some connected electrical load devices may be damaged by incorrect frequency and or voltage Only qualified technicians should adjust the governed speed 4 5 9 CHANGING ENGINE OIL Refer to maintenance performed by authorized service facilities for engine oil and filter change frequencies Drain the oil while the engine is still warm from running This means warm up the engine shut it down and drain immediately as follows Centurion Liquid cooled 15 kW and 25 kW Generators Remove OIL DRAIN HOSE from its retaining clip 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 Turn OIL FILTER Figure 4 2 counterclockwise and remove Dispose of old filter 5 Apply light coating of new engine oil to seal of new oil filter Install FILTER and tighten by hand only DO NOT OVERTIGHTEN N 6 Remove OIL FILL CAP Add recommended oil see SPECIFICATIONS DO NOT FILL ABOVE THE DIPSTICK FULL MARK Crankcase oil capacity is 4 0 U S quarts 3 8 liters 7 Start engine and check for oil leaks Figure 4 2 Oil Filter OIL FILTER caution amp After refilling the crankcase with oil always check oil level on dipstick NEVER OPERATE ENGINE WITH OIL BELOW THE DIPSTICK ADD MARK
34. DIG A Connecting this generator to an electrical A system normally supplied by an electric utility shall be by means of a transfer switch so as to isolate the electric system from the utility distribution system when the generator is operating Failure to isolate the electric system by these means will result in damage to the generator and may also result in injury or death to utility workers due to backfeed of electrical energy If an open bottom is used the generator is to f be installed over non combustible materials and should be located such that combustible materials are not capable of accumulating under the generator set Only qualified competent installation contractors or electricians thoroughly familiar with applicable codes standards and regulations should install this standby electric power system The installation must comply strictly with all codes standards and regulations pertaining to the installation This genset must be installed on a level surface The base frame must be level within two 2 inches all around caution amp A After the system has been installed do nothing that might render the installation in noncompliance with such codes standards and regulations Centurion Liquid cooled 15 kW and 25 kW Generators NOTE For more information about the installation of a standby system you can order Engine Generator Standby Electric Power Systems Installer s Guide and Reference M
35. ED 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 battery hydrometer 18 Generac Power Systems Inc Centurion Liquid cooled 15 kW and 25 kW Generators A pan A Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If the fluid is spilled flush the affected area immediately with clear water A Do not use any jumper cables or booster battery to crank and start the generator engine If the battery has completely discharged remove it from the generator for recharging A 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
36. ERY POSTCOVER BLACK SCREW TH FRM M6 1X16 N WA Z JS WASHER SHAKEPROOF EXT 7 16 STL WASHER SHAKEPROOF EXT 5 16 STL 46 Generac Power Systems Inc ITEM PART NO 0A4355 0E2844 036434 036449 0E0109 001318 0D8657 0E0170 0D9437 060366 039253 022145 022129 045771 0A8974 027837 o QTY po m B A D a a C G Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators PARTS Ce LISTS i We Muffler Drawing No 0E0773 A 0 DESCRIPTION MANIFOLD EXHAUST 1 5L NIPPLE TOE 1 5NPTX5 5 BLK IRON BOLT U 5 16 18 X 2 09 SADDLE 2 INCH PIPE EXHAUST 1 5L STNDRD amp ACSTC FLEX PIPE EXHAUST SUPPORT RADIATOR 1 5L MITSU BLANKET EXHAUST 1 5L MITSU MUFFLER 1 5L ACOUSTIC amp STANDARD STRAP MUFFLER 6 DIA SCREW HHC M8 1 25 X 20 G8 8 WASHER FLAT 5 16 ZINC WASHER LOCK Me 5 16 NUT HEX M8 1 25 G8 YEL CHR CAP RAIN 2 SCREW RHM 1 4 20 X 2 1 4 Generac Power Systems Inc 47 Section 10 Warranty WARRANTY Centurion Liquid cooled 15 kW and 25 kW Generators 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 equipm
37. FORMED BY AUTHORIZED SERVICE FACILITIES EVERY THREE MONTHS Check battery state of charge and condition Inspect and test fuel system Check transfer switch Inspect exhaust system Check engine ignition system Check fan belts ONCE EVERY SIX MONTHS Test Engine Safety Devices low oil pressure low coolant level high coolant temperature ONCE ANNUALLY Test engine governor adjust or repair if needed Clean inspect generator Flush cooling system FIRST 100 OPERATING HOURS Change engine oil and oil filter After initial change service engine oil and filter at 150 operating hours or six months whichever comes first 2 Retorque cylinder head See Section 1 13 Torque Specs 3 Retorque intake and exhaust manifold See Section 1 13 Torque Specs EVERY 500 OPERATING HOURS Service air cleaner Check starter Check engine DC alternator CIR aaron r gt Sr IP Se MAINTENANCE S Section 4 Maintenance F EVERY 800 OPERATING HOURS 1 Retorque cylinder head See Section 1 13 Torque Specs 2 Retorque intake and exhaust manifold See Section 1 13 Torque Specs 3 Check engine compression 4 Check valve clearance 4 2 COOLING SYSTEM Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation This includes high grass weeds brush leaves and snow Without sufficient cooling and ven
38. Generac Power Systems Inc Centurion Liquid cooled 15 kW and 25 kW Generators 4 5 4 INSPECT COOLING SYSTEM Inspect engine cooling system at least once each month Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness Check fluid levels as outlined above 4 5 5 PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fasteners Look for fuel oil or coolant leaks 4 5 6 INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condition tightness leaks security damage 4 5 7 CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defective belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 3 4 inch Adjust belt tension as required 4 5 8 INSPECT ENGINE GOVERNOR Visually inspect electronic governor A Dia A Do not attempt to adjust the governor Only qualified service persons should adjust the governor Excessively high operating speeds are dangerous and increase the risk of personal injury Low speeds impose a heavy load on the engine when adequate engine power is not available and may shorten engine life
39. ION Section 3 Operation Centurion Liquid cooled 15 kW and 25 kW Generators 1 gt 3 1 USING A STANDARD GTS TRANSFER SWITCH 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 Solid state circuits in the transfer switch monitor utility power source voltage When utility source voltage drops below a pre set level transfer switch action closes the circuit The engine then cranks and starts as controlled by the pre packaged generator s Control Module circuit board After the engine starts and when the generator AC output voltage and frequency have reached a pre set value transfer switch circuits signal the transfer switch main contacts to actuate to the Standby power source side Generator AC output then powers load circuits When the utility power source voltage is restored above a pre set level transfer switch solid state circuits signal the switch main contacts to move back to their utility power source side Following re transfer back to the utility power source side transfer switch circuit board action opens the circuit Engine then shuts down NOTE If the generator is installed in conjunction with an engineered GTS type engineered transfer switch refer to the applicable transfer switch
40. OVIa e nao J4 IYVIS 682 pp ang NMOHd rg 84 SCH 3 c MOTI3A e ezz GEZ z s JONVHO 9 A 918 An 8LI HOLVNLOV vGze 56 U GLS OSL YL v6L 98 rv 9 anid YONHSAOD OL cL qaq v 9LS SCH A NIEZLE Se 0 ez Pat gg sis SI EN vszz anid 8L ZL 9L SL bi EL CL ILOLO 8 2 9 Greece 9 6 bee L ama 92413 9 EMS ama 6cc G HA v god 1 SIS GLS z ELECTRICAL DATA lt ee Generac Power Systems Inc Section 8 Electrical Data Centurion Liquid cooled 15 kW and 25 kW Generators a A a ELECTRICAL Wiring Diagram 1 5L Engine Drawing No 0EO343 A DATA lt 4 LOS DIS WLS WTS FS 48 0 49 13 14 T 15 14 13 an lt ABC M 16 S 85 13 ch 56 BE ZEK 3 85 mn e LI III IT CONTROL pen nn PANEL LI L m CONNECTION 9 Q 7 7 8 9 10 11 12 O O O O O DEUTSCH 10 14 OOOO 11 14 5 E a 1 o a O k N LEGEND CC CONTROL CONTACTOR DIS DISTRIBUTOR d2 V DCA DC ALTERNATOR li BATTE RY EH ENGINE HEATER GRD FS FUEL SOLENOID EH GRD GROUND LOS LOW OIL PRESSURE SWITCH TO 120V 15A sock SM STARTER MOTOR WTS WATER TEMPERATURE SWITCH UTILITY FED WHITE WLS WATER LEVEL SENSOR CIRCUIT GREEN TO ELECTRONIC GOVERNOR GOVERNOR SE CONTROLLER ACTUATOR CONNECTOR Generac Power Systems Inc 27 Centurion Liquid cooled 15 kW and 25 kW Gen
41. S LED 1 is RED The LED will be on when utility sensing is NOT available to the circuit board This LED will function only when the AUTO OFF MANUAL switch is set in the Auto position LED 2 is YELLOW This LED will be on when the circuit board battery charger is on This LED will cycle on and off with the battery charger 4 85 hours on the 4 85 hours off LED 3 is GREEN This LED will flash when the circuit board has load voltage available to it This LED will function when voltage is available across T1 and T2 1 76 OVERCRANK SHUTDOWN After 90 seconds of crank rest cycles this function ends cranking if the engine fails to start in that 90 second span 1 76 DC FUSE This clearly labeled fuse is located on the front panel of the control system It protects the panel wiring and components from damaging overload Always remove this fuse before commencing work on the generator The unit will not start or crank if the fuse is blown Replace the fuse with one of the same size type and rating Generac normally uses an AGC fuse rated at 15 amps part number 022676 1 8 UNPACKING 1 8 1 UNPACKING PRECAUTIONS Handle shipping cartons and crates with care Use care to avoid damage from dropping bumping collision etc Store and unpack cartons with the proper side up as noted on the shipping carton 1 8 2 INSPECTION After unpacking carefully inspect the generator for any damage that may have occurred durin
42. SLTN 1 5L RR CRNR TOP ACSTC INSLTN 1 5L RR CRNR BOTT ACSTC INSLTN 1 5L REAR DR PNL ACSTC INSLTN 1 5L REAR BRC PNL ACSTC INSLTN 1 5L BAFFLE PANEL ACSTC INSLTN 1 5L CNTRL SUPPT GASKET CLIP ON SELF GRIPPING LATCH AND CAM NUT HEX JAM 3 8 24 SS DUCT LH SIDE 1 5L DUCT RH SIDE 1 5L INSUL ACO 1 5L DUCT FRNT PNL Generac Power Systems Inc age LISTS 35 dg Lem Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators 0 Control Panel Drawing No 0E0778 G 36 Generac Power Systems Inc ITEM PART NO QTY 0D9322 0D9332 0D9325A 0D9330 0C1457 064009 032300 022676 0E4494 082573 083048 083264 076009A 0E0331 056739 049350 047822 048766 057335 098647 0E1454 0E1459 072566 080882 0A8955 022097 022473 002212 023762 sch sesch sesch sesch sesch sch sch sesch sesch m N QG po A HS HS HS HS p Lo DESCRIPTION PANEL BACK 8 BOTTOM GUARDIAN PANEL LH SIDE GUARDIAN 8 SPRN PANEL FRONT CONTROL GUARDIAN W SILKSC PANEL RH SIDE C PANEL SML BRK HOURMETER LIGHT 12VDC 02A LED RED PILOT HOLDER FUSE FUSE 15A X AGC15 SWITCH ROC DPDT ON OFF ON SWITCH ROCKER DPST 125V SPD ASSEMBLY REGULATOR POTTED TFMR ASM CMA 240 12V PP LOGIC ASM 50 60HZ HARNESS CONTROL PANEL PP GUARDIAN RELAY SOLENOID 12VDC PNL MNT CIRCT BRK 4 X 1 ETA 46 500 P BLOCK TERM 20A 7 X 6 X 1100V BLOCK
43. TERM 20A 2 X 6 X 1100V BLOCK TERM 20A 20 X 6 X 1100V ASSY L C ELECT GOV DECAL CUST CONNT PRE PACK1 5L DECAL TERMINAL STRIP PRE PACK NUT SPACER 250 PCB SCREW PPH TAPPING 6 X 5 8 SS SCREW PHM M6 1 0 X 20MM WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC SCREW PHTT M4 0 7 X 16 ZYC WASHER SHAKEPROOF EXT 10 STL Section 9 Exploded Views and Parts Centurion Liquid cooled 15 kW and 25 kW Generators PARTS Ce LISTS Control Panel Drawing No 0E0778 G 0 ITEM PART NO QTY DESCRIPTION 30 002267 14 SCREW HHTT M5 0 8 X 12 BP 31 023897 15 WASHER FLAT 10 ZINC 32 002454 4 SCREW TH FRM M6 1X16 N WA Z JS 33 054199 1 DECAL HIGH VOLTAGE 34 081988 1 DECAL EXERCISE INFO 35 0E2514 1 STRAIGHT WIRE CONNECTOR 1 1 2 36 0A1354A 1 REGULATOR DC ALT 37 074908 4 SCREW HHTT M5 0 8 X 10 BP 38 020911 4 SCREW PPHM M5 0 8 X 30 ZINC 39 051713 5 WASHER FLAT M5 40 049226 5 WASHER LOCK M5 41 051716 5 NUT HEX M5 0 8 G8 YEL CHR 42 036261 4 RIVET POP 125 X 129 133 30 43 0D9334 1 PANEL TOP 44 061979 1 BUS BAR 45 022237 1 WASHER LOCK 3 8 46 022241 1 NUT HEX 3 8 16 STEEL 47 057073 1 JUNCTION BLOCK 3 8 16 48 055440 1 SCREW HHC M5 0 8 X 25 G8 8 49 0D8671 1 HINGE CONTINUOUS 1 5L CNTL PNL 50 0912970080 1 WIRE ASSEMBLY 51 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 52 033121 1 SCREW HHC 10 32 X 1 2 53 026850 1 WASHER SHAKEPROOF EXT 1 4 STL 54 022158 1 NUT HEX 10 32 STEEL 55 022152 1 WASHER LOCK 10 56 0A3968 1 CAPACITOR FILTER ASY 57 0C2323 2 SCREW PHTT 6 32 X
44. W HHC M6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 NUT HEX M6 X 1 0 G8 YEL CHR WASHER FLAT 1 4 ZINC BRACKET HEATER TUBING 5 8 ID X 18 LG SCREW CRMPTIT 1 4 20 X 5 8 SCREW CRIMPTITE 10 24 X 3 8 HOSE LOWER RADIATR HOSE UPPER RADIATR HOSE 9 32 ID 36 LG BOLT CARR 1 4 20 X 1 3 4 JS500 SPACER 41 X 75 X 87 ST ZNC NUT HEX 1 4 20 STEEL CAP RADIATOR CLAMP HOSE 38 87 SCREW TH FRM M6 1 X 16 N WA Z JS TANK COOLANT RECOVERY BRACKET WATER BOTTLE 1 5L MIT BARBED STR 1 4 NPT X 3 8 FOAM 1 5 X 1 ADH BAK SCREW SWAGE 10 32 X 5 16 Z YC SPRING CLIP HOLDER 37 62 ASSY RAD DRAIN HOSE FAN GUARD KIT 0E3596 NOT USED WITH LEVEL ONE GUARDING PARTS LISTS OG Generac Power Systems Inc 41 CH Section 9 Exploded Views and Parts gt Centurion Liquid cooled 15 kW and 25 kW Generators Fuel System Drawing No 0E0774 D L P VAPOR 42 Generac Power Systems Inc a a S Ap 39 4 S 35 a6 S SCH 39 40 41 42 43 44 gt PART NO 075580 0E1006 039253 022145 022129 045771 0A7040 032552 029032 0E1056 029032 0A5547 048031C 0D1509 0E0591 059402 037561 0E1028 059401 091526 049226 026307 062522 022127 022259 050279 0A6125 0D8492Q 0D8492R 0E1104 0E0668 0E0590 0C5133 0E0665 0E1108 033138 022152 0E0645 063463A 0E1558 057823 0E1111 042907 002454 SHOWN IN OTHER VIEW INCLUDED IN ITEM 19 CARBURETOR ASY QTY PO po N HS HS HS HS c
45. a pair of stationary windings with two leads brought out of each winding Each single winding can supply 120VAC 60 Hertz When the two windings are connected in series a 240VAC 60 Hertz output results Typically the two hot leads in the circuit are Wires No 11 and 44 The Neutral leads are the junction of Wires 22 and 33 Figure 1 1 Generator AC Connection System 240 VOLTS CIRCUIT BREAKER NOTE Rated power of generator is subject to and limited by such factors as ambient temperature altitude engine condition and other factors Engine power will decrease about 3 for each 1000 feet above 3000 feet and will decrease an additional 1 5 for each 10 F above 77 F Maximum output power of the generator is limited by maximum engine power Section 1 General Information Centurion Liquid cooled 15 kW and 25 kW Generators GENERAL INFORMATION Figure 1 2 Main Circuit Breaker Phase 1 1 Actual Current 62 5 104 2 C B Rating 70 125 Circuit Breaker 70A BQ2 125A BQ2 Amp Rating of CB structured under model 1 5 MAIN CIRCUIT BREAKER The generator s main circuit breaker is included with the unit The breaker for each unit is described in Figure 1 2 1 6 GENERATOR FUEL SYSTEM The generator has been factory tested and adjusted using a natural gas fuel system If propane LP requirements gas is preferred contact an authorized service dealer Refer to Secion 1 12 Recommended
46. a separate Emergency Distribution Panel Load circuits powered by that panel are within the wattage amperage capacity of the generator set When this method is used it is difficult to overload the generator The transfer switch must meet the following requirements It must have an ampere rating equal to or greater than the total amperage rating of the emergency distribution panel circuit Have it installed between the buildings main distribution panel and the emergency distribution panel 10 Generac Power Systems Inc Centurion Liquid cooled 15 kW and 25 kW Generators 2 6 TOTAL CIRCUIT ISOLATION METHOD When a generator capable of powering all electrical loads in the circuit is to be installed use the Total Circuit Isolation Method It is possible for the generator to be overloaded when this isolation method is employed The following apply to the transfer switch in this type of system Ampere rating of the transfer switch must be equal to or greater than the ampere rating of the normal incoming utility service The transfer switch is installed between the utility service entrance and the building distribution panel 2 7 GROUNDING THE GENERATOR The National Electrical Code requires the frame and external electrically conductive parts of this equipment to be properly connected to an approved earth ground and or grounding rods For that purpose a GROUND LUG Figure 2 2 is provided on the gene
47. adway New York N Y 10018 INSTALLATION Hh Section 2 Installation 2 2 GENERATOR LOCATION Install the generator set in its protective enclosure outdoors where adequate cooling and ventilating air is always is available Consider these factors 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 drifting consider a windbreak to protect the unit 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 Allow three feet of space on all sides NOTE LOCAL LAWS OR CODES MAY REQUIRE DIFFERENT OFFSET DISTANCES Where strong prevailing winds blow from one direction face the generator air inlet openings into the prevailing winds Install the generator as close as possible to the transfer switch This reduces the length of wiring and conduit Install the generator as close as possible to the fuel supply to reduce the length of piping HOWEVER REMEMBER THAT LAWS OR CODES MAY REGULATE THE DISTANCE 2 5 GENERATOR MOUNTING AND SUPPORT Retain the generator compartment to a steel mesh or rebar reinforced concrete slab with 1 4 inch masonry type anchor bolts Be sure the bolts are long enough to retain the compartment The slab should be at least five inches thick and should extend beyond the enclosu
48. aler about parts and service always supply the complete model number of the unit as given on the front cover of this manual or on the DATA CARD affixed to the unit Model No Serial No AUTHORIZED SERVICE DEALER LOCATION To locate the nearest GENERAC AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 OR Locate us on the web at WWW generac com Centurion Liquid cooled 15 kW and 25 kW Generators Introduction Inside Front Cover Read This Manual Thoroughly IFC Operation and Maintenance IFC How to Obtain Service IFC Authorized Dealer Locator Number IFC Sale by Rules eitis decidua ii Redes 2 Section 1 General Information 4 LI GCOCE uuu M 4 12 Transfer Switch 4 1 8 Automatic System Operation 4 1 4 Generator AC Connection Systems 4 1 5 Main Circuit Breaker scsssssteazcsccascnsisisccsstatasazesdes 5 1 6 Generator Fuel SYSISIN ege geseet apakuq 5 1 7 Engine Protective DEVICES eee EE SP 5 1 7 1 Low Oil Pressure Switch 5 1 7 2 High Coolant Temperature Switch 5 1 7 3 Low Coolant Level Switch 6 1 7 4 Overspeed Shutdown 6 1 7 5 PCB Operatio
49. ame or spark in battery area Discharge static electricity from body before touching batteries by first touching a grounded metal surface Servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries Recommended batter is Group 26 12VDC 550 CCA 75 AH minimum All batteries must be at 100 percent state of charge before they are installed on the generator Generac Power Systems Inc 11 INSTALLATION LED Section 2 Installation 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 are correctly connected and terminals are tight Observe battery polarity when connecting batteries to the generator set NOTE Damage will result if the battery connections are made in reverse 2 11 PREPARATION BEFORE START UP The instructions in this section assume that the standby generator has been properly installed serviced tested adjusted and otherwise prepared for use by a competent qualified installation contractor Be sure to read the Safety Rules on Pages 2 and 3 as well as all other safety information in this manual before attempting to operate t
50. and testing by Generac or a Generac Authorized Warranty Service Dealer is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be examined by the nearest Generac Authorized Warranty Service Dealer All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac Centurion 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 e Engine All Components e Alternator All Components e Transfer System All Components Steel enclosures are warranted against rusting for the first year of ownership only Damage caused after receipt of generator is the responsibility of the owner and is not covered by this warranty Nicks srapes dents or scratches to the painted enclosure should be repaired promptly by the owner 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 Centurion generators that utilize non Generac replacement parts Generac Centurion generators utilizing non Generac transfer switche
51. anual part 046622 from a Generac Authorized Service Dealer 2 1 1 NFPA STANDARDS The following published standards booklets pertaining to standby electric systems are available form the National Fire Protection Association NFPA Batterymarch Park Quincy MA 02269 NFPA No 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINES NFPA No 76A ESSENTIAL ELECTRICAL SYSTEMS FOR HEALTH CARE FACILITIES e NFPA No 220 STANDARD TYPES OF BUILDING CONSTRUCTION NFPA No 68 GUIDE FOR EXPLOSION VENTING NFPA No 70 NATIONAL ELECTRICAL CODE e NFPA No 30 FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE NFPA No 10 INSTALLATION MAINTENANCE AND USE OF PORTABLE FIRE EXTINGUISHERS 2 1 2 OTHER PUBLISHED STANDARDS In addition to NFPA standards the following information pertaining to the installation and use of standby electric systems is available Article X NATIONAL BUILDING CODE available from the American Insurance Association 85 John Street New York N Y 10038 AGRICULTURAL WIRING HANDBOOK obtainable from the Food and Energy Council 909 University Avenue Columbia MO 65201 ASAE EP 364 2 INSTALLATION AND MAINTENANCE OF FARM STANDBY ELECTRIC POWER available from the American Society of Agricultural Engineers 2950 Niles Road St Joseph MI 49085 A52 1 AMERICAN NATIONAL STANDARD FOR CHIMNEYS FIREPLACES AND VENTING SYSTEMS available from the American National Standard Institute 1430 Bro
52. ation provisions as this can seriously affect safe operation of the generator Keep the area around the generator clean and uncluttered Remove any materials that could become hazardous When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and promptly repair or replace all worn damaged or defective parts using only factory approved parts Important Safety Instructions SAFETY RULES Centurion Liquid cooled 15 kW and 25 kW Generators 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 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 conditions from leaking exhaust gases fuel leakage oil leakage etc ZA ELECTRICAL HAZARDS A 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 well as the standby generator Avoid contact with bare wires terminals connections etc on the generator as well as the transfer switch if applicable Ensure all appropriate covers guards and barriers are in place before operating t
53. cal electrical loads during utility power failure The unit has been factory installed in a weather resistant all metal enclosure and is intended for outdoor installation only Use this generator as a source of electrical power for the operation of 120 and or 240VAC single phase loads These models are available They are rated as follows Model 004912 Provides 15 000 watts 15 kW of single phase power Model 004913 Provides 25 000 watts 25 kW of single phase power WARNING amp If this generator is used to power electrical A load circuits normally powered by a utility power source it is required by code to install a transfer switch The transfer switch must effectively isolate the electric system from the utility distribution system when the generator is operating NEC 701 Failure to isolate an electrical system by such means results in damage to the generator and may also result in injury or even death to utility power workers due to backfeed of electrical energy 1 2 TRANSFER SWITCH This generator system includes a matched automatic transfer switch which is intended to be used in conjunction with the Centurion generator It is supplied in a NEMA 3R enclosure The NEMA 3R enclosure is weather resistant and can be used indoors or outdoors Follow these rules Install the transfer switch on a firm sturdy supporting structure To prevent switch distortion level the switch if necessary This can be d
54. d by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning To prevent injury perform the following steps in the order indicated before starting any maintenance Disable the generator set from starting and or connecting to the load by setting the control panel AUTO OFF MANUAL switch to the OFF position Remove the control panel fuse Turn off utility supply to engine water heater Turn off the battery charger by turning off utility supply to the transfer switch Remove the negative battery cable The battery charger must be turned off BEFORE removing the battery cable to prevent an over current condition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the first three months or the first 80 hours of operation after purchase of the unit and requires approximatelu 2 5 man hours per unit to complete This inspection contains some maintenance tasks which require special tools equipment and or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer 3 An operational inspection
55. e Refer to specific instructions and warnings that accompany the battery If such information is not available observe the following precautions when handling a battery DO NOT use jumper cables and a booster battery to crank or start the generator engine DO NOT recharge a weak battery while it is installed in the generator Remove battery from generator and recharge in a well ventilated area away from fuel vapors sparks heat or flames Battery electrolyte fluid is an extremely caustic sulfuric solution that can cause severe burns DO NOT permit fluid to contact eyes skin clothing painted surfaces wiring insulation etc If any battery fluid is spilled flush the affected area with clear water immediately Always wear safety glasses rubber apron and gloves when handling a battery Batteries give off explosive hydrogen gas while charging The gas can form an explosive mixture around the battery for several hours after charging Any spark heat or flames can ignite the gas and cause an explosion which can shatter the battery causing blindness or other serious injury 4 6 5 BATTERY MAINTENANCE The battery should be inspected per the Service ochedule Section 6 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 DISTILL
56. e needed to assure proper gas pressure to the generator Improper gas pressure can cause hard starting and could affect engine durability 1 12 RECONFIGURING THE FUEL SYSTEM NOTE All models are configured for natural gas from the factory To reconfigure the fuel system from NG to LP follow these steps 1 Turn the main gas supply off 2 Remove the carburetor fuel hose from the outlet port Port 1 of the demand regulator Figure 1 8 Remove the brass hose fitting from the outlet port Port 1 of the demand regulator Remove pipe plug from Port 2 Install brass hose fitting into Port 2 Install pipe plug into Port 1 Connect carburetor gas hose to brass fitting Tighten all clamps and plugs Make sure fuel supply is of the proper pressure and type for configuration 10 Reverse the procedure to convert back to natural gas Figure 1 8 Reconfigure the Fuel System gt R LR Port 1 Port 2 FUEL HOSE FUEL HOSE a BRASS HOSE BRASS HOSE SE lis Ko FITTING io BEBE d EE OUT OUT PORT1 PORT 2 ZA HOUSING HOUSING PORTS PORTS NG FUEL SYSTEM LP FUEL SYSTEM NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for simultaneous fuels has been made Generac Power Systems Inc 7 INSTALLATION Im Section 2 Installation
57. ective Battery Out of fuel Fuel solenoid FS is defective Open Wire 14 from Engine Control circuit board Spark plugs defective Flame arrestor air cleaner plugged or damaged Plugged fuel line Defective spark plugs Engine oil level is low Engine is overheated Defective Low Oil Pressure Switch Defective Coolant Temperature Switch Defective Control Module circuit board Coolant Level is Low Defective Low Coolant Level Switch Defective Auto Off Manual switch Open disconnected wire 15A between Auto Off Manual switch and Control Module circuit board Defective Control Module circuit board Check main line circuit breaker Check circuit breaker A fuses Transfer switch set to NORMAL position Generator internal failure Thermal circuit breaker open CORRECTION 1 2 W JO OT WP R OO MN Replace fuse Tighten clean or replace battery cables as necessary Replace contactor Replace starter motor Remove change or replace battery Replenish fuel Replace solenoid Reconnect wire Clean regap or replace plugs Clean or replace as needed Unclog fuel line Clean regap or replace plugs Check oil and add oil as needed Check cooling system for leaks Replace switch Replace switch Replace board Repair leak Add coolant Replace Switch Replace switch Reconnect clo
58. ent 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 modification 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 during 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 Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware tha
59. equipment Generac also strongly recommends instructing other users to properly start and operate the unit This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensure a minimum number of problems and keep operating expenses at a minimum See a Generac Authorized Service Dealer for service aids and accessories Operating instructions presented in this manual assume that the standby electric system has been installed by a Generac Authorized Service Dealer or other competent qualified contractor Installation of this equipment is not a do it yourself project HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact a Generac Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all of servicing needs When contacting a Generac Authorized Service De
60. erators Wiring Diagram 1 5L Guardian Drawing No 0E1525 Section 8 Electrical Data ELECTRICAL gt DATA Deel O ov1a ESL NOILOANNOO HOLIMS HHHSNVHL ADVMOVdsYd YOLVINOJIY ADVLIOA YA SAYVO9 TVNINYIL z LSL ONISN3S ALITLLO H3INHOJSNVHI LHL HOLIMS JFSIDYIXI LAS MS HOLIMS IWANVW sSO0 OLNV LMS AT9WIFSSV NOISSSAYdNS VS Hd TIOHLNOO AYVOIH LINDYID ddd H113WANOH WH HOLVOIGNI LINVA LHOM Td FANM NI SdINV SZ dSfd LI SdINV SL dSnd d NOLLO3NNOO 3NION3 Od ONIGNIM NOILVLIOXS Jda Su3xv3us LINOHIO Z LO HOLIOVdVO dvo YOLVLS YOLVNYILIV SV FASVHd L A013 0cG1 NOILOANNOO YANWOLSNO ci 00 L3 ZN Fa N LIN TOHLNOO HONHHAOD NOD HOLOH YOLVNYIJILIV HV TEN Y6L Z ZN IN ZL LL Lgo e ad QN3931 je E KS MOV ld ee vec ovig LHL Movid anna 03H YOLVNLOV NMOHS nao
61. g shipment If loss or damage is noted at the time of delivery have the person s making delivery note all damage on the freight bill or affix their signature under the consignor s memo of loss or damage 1 9 LIFTING THE GENERATOR warninc A When lifting or hoisting equipment is used be careful not to touch overhead power lines The generators weight of more than 900 pounds requires proper tools equipment and qualified personnel to be used in all phases of handling and unpacking 1 10 SPECIFICATIONS 1 10 1 GENERATOR Single Phase Model 004913 oo4912 Rated Max Cont ki MN 15 AC Power Output kW Rated voltage volts N120 240 2 No of Rotor Poles 2 4 Driven Speed of Rotor 3600 1800 Rotor Excitation System Direct excited brush type Type of Stator 4 Wire Rotor Stator Insulation Class F H 1 10 2 ENGINE E Mitsubishi Displacement 92 inches 1 5 liters Cylinder Arrangement 4 in line Valve Ee E Overhead Cam lli Gero olm 1 3 4 2 Number of Main Bearings eee 5 Compression RADO ees 9 tol No of Teeth on Flywheel 104 Ignition Timing at TOUDT DM l u d chata 35 degrees BTDC ACOBOOTDO EE 43 degrees BTDC Spark Eeer 0 020 0 025 inch Recommended Spark Plugs C MAM PONT EE RN11YC4 ODER S ii i o orn So paf ta ik e a ta k ia a jo pe a af
62. gations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty service evidence must be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the following address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 48 Generac Power Systems Inc Section 10 Warranty Centurion Liquid cooled 15 kW and 25 kW Generators WARRANTY 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 continue 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
63. he control panel Match wires 178 and 183 in the transfer switch to 178 and 183 on the terminal strip in the control panel The conductors for the two wire start circuit must be in their own conduit 2 10 BATTERY INSTALLATION A DIG A Standby generators installed with automatic transfer switches will crank and start automatically when normal UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel do not connect battery cables until the normal source voltage at the transfer switch is correct and the system is ready to be put into operation Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery A Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protective goggles protective clothing and gloves when handling a battery If the fluid is spilled flush the affected area immediately with clear water INSTALLATION Hh
64. he electric utility distribution system when the generator is operating Failure to isolate the two electric system power sources from each other by such means will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when normal UTILITY source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to personnel disable the generator s automatic start circuit battery cables etc before working on or around the unit Then place a Do Not Operate tag on the generator control panel and on the transfer switch In case of accident caused by electric shock immediately 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 dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS Keep a fire extinguisher near the generator at all times Do NOT use any carbon tetra chloride type extinguisher Its fumes are t
65. he generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard 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 If people must stand on metal or concrete while installing operating servicing adjusting or repairing this equipment place insulative mats over a dry wooden platform Work on the equipment only while standing on such insulative mats The National Electrical Code NEC Article 250 requires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground and or grounding rods This grounding will help prevent dangerous electrical shock that might be caused by a ground fault condition in the generator set or by static electricity Never disconnect the ground wire Wire gauge sizes of electrical wiring cables and cord sets must be adequate to handle the maximum electrical current ampacity to which they will be subjected Before installing or servicing this and related equipment make sure that all power voltage supplies are positively turned off at their source Failure to do so will result in hazardous and possibly fatal electrical shock Connecting this unit to an electrical system normally supplied by an electric utility shall be by means ofa transfer switch so as to isolate the generator electric system from t
66. hen it opens This means the exercise timer will not be reset If this fuse does open carefully check the wiring to the start fuel field boost and transfer outputs before replacing the fuse 3 2 6 SET EXERCISE TIME SWITCH This switch allows for programming the generator to start and exercise automatically See Section 3 5 Weekly Exercise Cycle 3 5 MANUAL TRANSFER AND START UP To transfer electrical loads to the STANDBY GENERATOR power source side and start the engine manually refer to the Owner s Manual of the particular transfer switch 3 4 AUTOMATIC OPERATION To set the system for fully automatic operation proceed as follows Check that load circuits are connected to the utility power supply Set the AUTO OFF MANUAL switch to its AUTO position Set the generator main circuit breaker to its ON or CLOSED position 3 5 WEEKLY EXERCISE CYCLE The generator will start and exercise once every seven days During this weekly exercise the unit runs for about 20 minutes and shuts down Transfer of loads to generator output does not occur during the exercise period To select day and time for exercising proceed as follows e Set the AUTO OFF MANUAL switch to OFF e Set generator main circuit breaker to OFF or OPEN 14 Generac Power Systems Inc Locate the rocker switch on the control panel identified with the words Set Exercise Time Figure 3 2 Push Set Exercise Time
67. his and related equipment 2 11 1 PRIOR TO INITIAL START UP A caution amp A Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended types and quantities of engine fluids oil coolant fuel etc may result in an engine failure Before starting the generator for the first time the installer must complete the following procedures For follow up maintenance information and or service intervals please refer to Section 4 Maintenance 2 11 2 TRANSFER SWITCH If this generator is used to supply power to any electrical system normally powered by an electric utility the National Electrical Code requires that a transfer switch be installed The transfer switch prevents electrical backfeed between two different electrical systems For additional information see the applicable transfer switch manual for this unit The transfer switch as well as the generator and other standby components must be properly located and mounted in strict compliance with applicable codes standards and regulations 12 Generac Power Systems Inc Centurion Liquid cooled 15 kW and 25 kW Generators 2 11 3 FUEL SYSTEM Make sure the fuel supply system to the generator a delivers the correct fuel at the correct pressure and b is properly purged and leak tested according to code No fuel leakage is
68. hts You also have other rights from state to state GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Revision 10 01 04 Part No OE5129 Revision G 12 20 04 Printed in U S A
69. im 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 1 2 LPG Natural Gas carburetion assembly and its internal a Spark plug components b Ignition module a Fuel controller if so equipped 4 Catalytic Muffler Assembly if so equipped including b Mixer and its gaskets if so equipped a Muffler gasket c Carburetor and its gaskets if so equipped b Exhaust manifold d Primary gas regulator if so equipped 5 Crankcase Breather Assembly including e LP liquid vaporizer if so equipped 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 Part 2 Generac Power Systems Inc 49 Section 10 Warranty WARRANTY Centurion Liquid cooled 15 kW and 25 kW Generators GENERAC POWER SYSTEMS TWO YEAR LIMITED WARRANTY FOR CENTURION PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS For a period of two years from the date of original sale Generac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspection
70. kmanship 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 e Expenses related to customer instruction or troubleshooting where no manufacturing defect is found e Rental equipment used while warranty repairs are being performed Costs incurred for equipment used for removal and or reinstallation of generator i e cranes hoists lifts etc e Overnight freight costs for replacement part s e Overtime labor e 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 consequential damages so the above limitation may not apply to you This warranty gives you specific legal rig
71. manual for exact operating parameters and timing sequences 3 2 CONTROL CONSOLE COMPONENTS The components of a liquid cooled generator control console Figure 3 1 are as follows Figure 3 1 Liquid Cooled Generator Panel BS FAULT HOUR METER 15 A INDICATOR SP AGC AUTO SET EXERCISE OEF i TME ON MANUAL 3 2 1 HOURMETER Indicates time the generator has operated in hours and tenths of hours Use the hourmeter along with the periodic maintenance schedule for the generator set 3 2 2 AUTO OFF MANUAL SWITCH Use this three position switch as follows Set the switch to AUTO for fully automatic operation See Section 3 4 Automatic Operation Set switch to MANUAL position to crank and start the generator engine Set switch to OFF position to shut down an operating engine With OFF selected operation will not be possible A an A With switch set to AUTO engine can crank A and start suddenly without warning Such automatic start up normally occurs when utility source voltage drops below a pre set level To prevent possible injury that might be caused by such sudden starts set the AUTO OFF MANUAL switch to OFF before working on or around the unit Then place a DO NOT OPERATE tag on control console 3 2 3 FAULT INDICATOR LAMP The lamp goes ON when one or more of the following engine faults occurs and when engine shuts down Ove
72. n LED S 6 1 7 6 Overcrank Shutdown 6 LS Sn PACKING tT 6 1 8 1 Unpacking Precautions 6 152 IBSDECNOR owe ddr oss 6 LO Liine the Generator aston TREE CEE hri 6 1 10 ZEIEN 7 mmt cii O 1 KE ENOG aaa suu eg 7 1 11 Fuel Consumption 7 1 12 Reconfiguring the Fuel System 7 1 13 Torque Specifications 8 1 14 Engine Oil Recommendations 8 1 15 Coolant Recommendations 8 1 16 Before Installation 8 Section 2 INSTALLATION 8 2 1 Generator Installation 8 2 1 1 NFPA Standards tenetis 9 2 1 2 Other Published Standards 9 2 24 Generator LOCANOD aw EE WAGA 9 2 3 Generator Mounting and Support 9 2 4 Basic Standby Electric System 9 2 5 Emergency Circuit Isolation Method 10 2 6 Total Circuit Isolation Method 10 2 7 Grounding the Generator 10 2 8 Generator AC Neutral Connections 11 2 9 Transfer Switch Start Signal Connections 11 2 10 Battery Installation erret ooi 11 2 10 1 Vented Batteries
73. ng the Spark Plug Gap SET PLUG GAP AT 0 5 0 6 mm 0 020 0 L inch GRI 4 5 12 COOLANT CHANGE Every year have Authorized Service Facility drain flush and refill the cooling system See Section 1 10 SPECIFICATIONS for cooling system recommen dations 4 6 MISCELLANEOUS MAINTENANCE 4 6 1 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulates on internal generator windings have an adverse effect on insulation resistance QL Periodically clean generator exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is housed inside an all weather enclosure clean the enclosure with a soft damp cloth or sponge and water Apply a coat of automotive type wax once a year to help prevent corrosion Generac Power Systems Inc 17 MAINTENANCE Section 4 Maintenance 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 Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying 4 6 2 BATTERY All lead acid storage batteries discharge when not in us
74. nstallation operation servicing and repair of this and related equipment must always 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 operated and serviced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon monoxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate ventilation must be provided Exhaust gases must be piped safely away from any building near the generator to an area where people animals etc will not be harmed This exhaust system is designed to comply with applicable 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 ventilating air is critical to prevent buildup of explosive gases and to ensure correct generator operation Do not alter the installation or permit even partial blockage of ventil
75. on 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 responsible 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 cla
76. one by placing washers between the switch enclosure and the mounting surface Never install the switch where water or any corrosive substance might drip onto the enclosure Protect the switch at all times against excessive moisture dust dirt lint construction grit and corrosive vapors It is highly recommended to utilize a Generac Centurion transfer switch with this generator or it may void the warranty a Generac Power Systems Inc Section 1 General Information Centurion Liquid cooled 15 kW and 25 kW Generators 1 3 AUTOMATIC SYSTEM OPERATION When this generator along with its transfer switch has been installed and interconnected a circuit board in the generator panel constantly monitors utility power source voltage Should that voltage drop below a preset value and remain at such a low state for a preset amount of time the generator cranks and starts After the generator starts the transfer switch transfers load circuits so the generator can power them When utility source voltage has been restored the switch re transfers back to the utility source voltage and the generator then shuts down Please reference the transfer switch manual for specific information 1 4 GENERATOR AC CONNECTION SYSTEMS The generator was shipped from the factory with its stator AC output leads connected in a single phase three wire generator AC connection system Figure 1 1 The stator assembly in this system consists of
77. oxic and the liquid can deteriorate wiring insulation Keep the extinguisher properly charged and be familiar with its use Consult the local fire department for any questions pertaining to fire extinguishers A EXPLOSION HAZARDS A Provide adequate ventilation around the generator to prevent build up of explosive gas Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Generac generator sets may operate using one of several types of fuels All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the units fuel system frequently and correct any leaks immediately Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service Gases such as natural gas and liquid propane LP gas are extremely EXPLOSIVE Natural gas is lighter than air and LP gas is heavier than air install leak detectors accordingly Generac Power Systems Inc 3 GENERAL INFORMATION 1 1 GENERATOR This equipment is a liquid cooled engine driven generator set The generator is designed to supply electrical power that operates criti
78. permitted See Section 1 10 Specifications for more information 2 11 4 GENERATOR SET LUBRICATION Check the engine crankcase oil level before operating and if necessary add oil to the proper level the dipstick FULL mark Never operate the engine with the oil level below the dipstick ADD mark See Section 1 10 Specifications and Section 1 14 Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with 15W 40 oil This oil should be changed after 30 hours of operation 2 11 5 ENGINE COOLANT Have the engine cooling system properly filled with the recommended coolant mixture Check the system for leaks and other problems See Section 1 10 Specifications and Recommended Coolant 2 11 6 BELT TENSION Check the engine fan belt tension and condition prior to placing the unit into service and at recommended intervals Belt tension is correct when a force of approximately 22 pounds 10 kg applied midway between pulleys deflects the belt about 3 8 to 5 8 inch 10 to 16 mm 2 11 7 ELECTRICAL SYSTEM Make sure the generator is properly connected to an approved earth ground and or ground rod Make sure the generator battery is fully charged properly installed and interconnected and ready for use Check to ensure that there are no loose electrical connections Restrain any loose wires to keep them clear of any moving generator set components OPERAT
79. ranted emissions related part to fail to be identical in all material respects to the part as described in the engine manufacturer 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 Owner s Manual 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 Owner s Manual 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 Owner s Manual 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 Subsecti
80. rator mounting base Consult a qualified electrician for grounding requirements in the area Grounding procedures must meet local regulations A pan A Do not connect the ground wire to any pipe that carries a flammable or explosive substance FIRE or an EXPLOSION may result Proper grounding helps protect personnel against electrical shock in the event of a ground fault condition in the generator or in connected electrical devices In addition grounding helps dissipate static electricity that often builds up in ungrounded devices Figure 2 2 Generator Grounding Lug typical BASE GROUNDING LUG Centurion Liquid cooled 15 kW and 25 kW Generators 2 8 GENERATOR AC NEUTRAL CONNECTIONS 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 The actual result depends on the electrical characteristics of the particular installed generator 2 9 TRANSFER SWITCH START SIGNAL CONNECTIONS If the generator is to be installed with an automatic transfer switch such as a Generac GTS type switch it will be necessary to connect the two wire start control system Connect the two wire start signal from the automatic transfer switch to the automatic start connection which is located in the right hand corner inside t
81. rcrank Overspeed Low oil pressure High coolant temperature Low coolant level 3 2 4 15 AMP FUSE The fuse protects the control console s DC control circuit against electrical overload If the fuse has melted open due to an overload or is removed engine cranking and startup may still occur when the AUTO OFF MANUAL switch is placed in the AUTO or MANUAL positions NOTE To disable the control board and thus prevent potential crank and run the 15 amp fuse AND the 7 5 amp in line fuse must both be removed or the battery cables should be disconnected Should you need to replace the fuse use only an identical AGC 15 amp replacement fuse Generac Power Systems Inc 13 OPERATION Section 3 Operation J gt Centurion Liquid cooled 15 kW and 25 kW Generators 3 2 5 7 5 AMP IN LINE FUSE This in line fuse is connected in wire 15A which runs between the AUTO 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 outputs If this fuse has melted open or is removed the control board will be disabled and the unit will not be able to crank and run when the AUTO OFF MANUAL switch is placed in the AUTO or MANUAL positions Replace the fuse with an identical AGC 7 5 amp fuse NOTE This fuse will not remove the positive battery input power from the PCB w
82. rd action will automatically shutdown the engine Figure 1 7 Figure 1 7 Control Module Assembly Circuit Board s 828358 n ua PRE PACKAGED STANDBY E ws TM T vis U li SA e a 12 R56 H C X O i Ut wi w CFG zi EM a ca R R60 Ut amp R Li LI s ig at Ti E Ri2 l SA u2 m D II rj l L a f gt z w r2 A h T W BAZSZSITZZE vis LIE l 2 z g Ati RIO CR ZN 2 W g saz us l z EE 2 a u19 EIS 9 an e uH 2292959 LI cre ka S 888 22 gugESzzsdH w 828 88 BE 8 2272259 Bara NNN NNN AV NNN Ed AV VN NNV AAA SAN ked A A ann ANN N al e ek B H Te C14 I s Ba Ki eee I s Se e TT 06 SR Boul D lt gt B sage RE EE 13 55 c CUT Ri a K 2002 GENERACPOWERSYSTEMS ASSY407600 Gre HZ L r 5 S mu T mm SEHO l I T0800 A A 6 Generac Power Systems Inc Section 1 General Information Centurion Liquid cooled 15 kW and 25 kW Generators 1 75 PCB OPERATION LED
83. re to a distance of at least three inches on all sides See page 25 for generator major dimensions 2 4 BASIC STANDBY ELECTRIC SYSTEM Figure 2 1 shows a schematic diagram of a basic standby electric system Both the UTILITY power supply and the STANDBY GENERATOR output are connected to an approved transfer switch The transfer switch is required by electrical code and serves the following functions Permits the LOAD circuits to be connected to only one power supply at a time Prevents electrical backfeed between the generator and the UTILITY power circuits Notice that both the STANDBY and the UTILITY power supplies to the transfer switch are protected against overload by a main line circuit breaker Generac Power Systems Inc s INSTALLATION LT Section 2 Installation Figure 2 1 Basic Standby Electric System MAIN LINE TO LOAD CIRCUITS STANDBY GENERATOR OUTPUT MAIN LINE CIRCUIT BREAKER NOTE Generac recommends the use of a Generac Power Systems transfer switch in conjunction with this generator 2 5 EMERGENCY CIRCUIT ISOLATION METHOD This prevents overloading the generator by keeping electrical loads below the wattage amperage capacity of the generator If the generator is powering only critical loads within the wattage amperage capacity during utility power outages consider using the emergency circuit isolation method Critical electrical loads are grouped together and wired into
84. rve them carefully Their definitions are as follows A Dita A After this heading read instructions that if not strictly complied with will result in personal injury or property damage WARNING amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage A caution A After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows A This symbol points out important safety information that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator is responsible for proper and safe use of the equipment Generac strongly recommends that the operator read this Owner s Manual and thoroughly understand all instructions before using this
85. s Repairs performed by individuals other than Centurion Generac authorized dealers Any Generac Centurion generators used as rental or trailer mounted applications Air cooled 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 Steel enclosures that are rusting due to the improper installation location in a harsh or saltwater environment or scratched where integrity of paint applied is compromised 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 e 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 and or insect 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 wor
86. s used in engine See Section 1 14 If necessary drain and refill with the proper oil MAINTENANCE 2 Section 4 Maintenance 3 Check the battery Fill all cells to the proper level with deionized water DO NOT USE TAP WATER IN THE BATTERY Remove the battery before charging Recharge the battery to 100 percent state of charge or if defective replace the battery with a 12 volt DC Group 26 26R battery rated for 75 amp hours 525 CCA minimum O F 4 Clean and wipe the entire generator 5 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 6 Open the fuel shutoff valve 7 Start the unit by moving the Auto Off Manual switch to MANUAL Allow the unit to warm up thoroughly 8 Stop the unit and set the Auto Off Manual switch to AUTO 9 Turn on the utility power to the transfer switch 10 The generator is now ready for service 4 8 FUEL PIPE SIZING Refer to chart for proper sizing of fuel supply piping Insufficient fuel pipe size can cause hard starting poor engine performance and inability to carry load NG and LP Vapor Pipe Sizing Chart Length of Pipe lron Pipe Size IPS Inches KA 70 55 ES ES 1 220 85 70 GER ETENN E Eo NEN 65 131 109 _ co O1 I O1 G C OO GD O1 O OT OIN cO O NO J W NnI LIN NO Oo O M Oo O1 101 7N O1
87. se wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Contact an Authorized Generac facility Auto reset Wait 5 min and attempt restart Generac Power Systems Inc 23 NOTES Section 6 Notes Centurion Liquid cooled 15 kW and 25 kW Generators 24 Generac Power Systems Inc INSTALLATION iagram D ion Section 7 Installat Centurion Liquid cooled 15 kW and 25 kW Generators Drawing No 0E1533 A SINAWLAYVdWUJ JILSNOJY 8 d led s3HlIVdM 90 6 ldN v NDILIJNNDD Di Cee ADdVA d 1 ab SVD WaANLYN soos COE TU E 3 LESXIC Hh gv SSAJIV AO LYIGYA v ALON L 08 29 SELI M3IA dOl dAl wwa zE 976 E dal Leet 702 ELV ALON 33S T 31DN AJJLLVH Ac FTA dAl Liebe Ss INIddlO04 aS VH Lab Sc vS9 dAl SZ O 61 INIJdLOD4 3Svq S ES O9ET CTJADUW3d SOOT HLIM NMOHS gt MIIA eve S Sc vS9 Kee 9N ONIONNDAD 219 SPA S 3LUN 88 62 667 S314 9 igno 4314340W ao 2 LATINO LSNYHXA 6c 021 DNITdN0J LAN bat NIV3G ID 90 C19 dE DMIIdDDD LAN ab E SVD TYANLYN LATNI Cep DNI 1dN0J LAN ab E sUdVA d 131N1 SNOILOSNNOI 39IAN3S 3NIDN3 SIHONI ww SLINN sq 0981 6H O6 LINN VIVI IHADIJM 0 81 SLY AJAYJAd LINONIQ INIT NIYW S INOHLIM TWNOILdO SLINN IN3WIAYdWOJ HLIM GNSVINVIS ISAVAXI X314 G I O 2 99 8 X 8 91 O22 x 291 SNUISNAWIQ 30ISNI AVAL AGILIVE
88. t 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 unapproved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem occurs 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 1 800 555 1522 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 only 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 important rights and obli
89. the engine oil level Adjust as necessary Check the engine coolant level Adjust as necessary Check the engine coolant RE Correct as necessary Check the fuel delivery system on gas engine driven units Tighten Tighten connections as necessary Check the air inlets and f necessary Check the battery electrolyte level if accessible Adjust as necessary Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary Check the unit wiring for loose connections corrosion and damage Correct as necessary Check the engine accessory drive belts for wear weather cracking and damage Replace as necessary Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 12 Test the engine and transfer switch safety devices Correct and or adjust as necessary Task Comp Date Initials Generac Power Systems Inc 21 gt Section 4 Maintenance MAINTENANCE Centurion Liquid cooled 15 kW and 25 kW Generators o 13 14 15 16 17 18 19 20 Maintenance Level 1 Level 2 Level 3 Level 4 Tasks Recom Task Required Task Required Task mended Comp to be done Comp to be done Comp Required to be done Date 3months Date Semi Date to be done monthly Initials Break in Initials annually Initials Annually
90. tilating air flow the engine generator quickly overheats which causes it to shut down See Section 7 for installation diagram and vent locations WARNING amp The exhaust system parts from this product get its 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 4 3 OVERLOAD PROTECTION FOR ENGINE DC ELECTRICAL SYSTEM Engine cranking start up and running are controlled by a solid state Engine Controller circuit board Battery voltage is delivered to that circuit board via a 15 amp fuse These overcurrent protection devices will open if the circuit is overloaded caution A If a circuit breaker opens or a fuse element melts find the cause of the overload before resetting the circuit breaker or replacing the fuse 4 4 CHECKING FLUID LEVELS 4 4 1 CHECK ENGINE OIL Check engine crankcase oil level Figure 4 1 at least every 20 hours of operation or prior to use Remove oil dipstick and wipe dry with a clean lint free cloth Install oil dipstick then remove again Oil should be between FULL and ADD marks If oil level is below the dipstick ADD mark remove oil fill cap Add the recommended oil to bring oil level up to the FULL mark DO NOT FILL ABOVE THE FULL MARK See Section 1 14 for recommended oils Generac Power Systems Inc 15 MAINTENAN

Generac 004702-0, 004703-0, 004704-0, 004705-0, 004706-0, 004707

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