Generac Power Systems Centurion 005223-0 Owner's Manual
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Generac Power Systems Centurion 005223-0 Owner's Manual

Generac Power Systems Centurion 005223-0 Owner's Manual

Standby generator
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Serial Number
STANDBY GENERATOR
OWNER'S MANUAL
®
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
0F7936
No.
Part
CENTURION
CENTURION
CENTURION
Not intended for use in critical life support applications.
—CAUTION—
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
Model: 005223-0
A new standard of reliability
QT
3.9L
40kW
This manual should remain with the unit.
09/05
0
Rev.
Cover028

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Summary of Contents for Generac Power Systems Centurion 005223-0

  • Page 1  Not intended for use in critical life support applications. ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! 0F7936 Part Model: 005223-0 A new standard of reliability —CAUTION— 3.9L 40kW  This manual should remain with the unit.

  • Page 2: Table Of Contents

    SECTION SAFETY RULES ... 1-1 INTRODUCTION ...1-3 Read this Manual Thoroughly ...1-3 Operation and Maintenance ...1-3 How to Obtain Service ...1-3 IDENTIFICATION RECORD ...2-1 Data Label ...2-1 EQUIPMENT DESCRIPTION ...3-1 Equipment Description ...3-1 Engine Oil Requirements ...3-1 Coolant Recommendations...3-1 ENGINE PROTECTIVE DEVICES ...4-1 High Coolant Temperature Switch ...4-1 Low Coolant Level Sensor ...4-1 Low Oil Pressure Switch ...4-1...

  • Page 3: Safety Rules

     SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe 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.  WARNING: The engine exhaust from this product contains chemicals known to the state...

  • Page 4: Fire Hazards

    • Before performing any maintenance on the gen- erator, disconnect its battery cables to prevent accidental start-up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last. • Never use the generator or any of its parts as a step.

  • Page 5: Introduction

    INTRODUCTION Thank you for purchasing this model of the standby generator set product line. Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written.

  • Page 6: Identification Record

    ENGINE RPM ALTERNATOR SUBTRANSIENT REACTANCE ALTERNATOR TRANSIENT REACTANCE CLASS ROTOR GENERAC POWER SYSTEMS, INC. Standby Generator Sets General Information For actual information related to this particular model, please refer to the Manual Drawing Listing located at the end of this manual, or to the data label affixed to the unit.

  • Page 7: Equipment Description

    EQUIPMENT DESCRIPTION This equipment is a revolving field, alternating cur- rent generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers.

  • Page 8: Engine Protective Devices

    ENGINE PROTECTIVE DEVICES The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant tempera- ture, oil pressure or rpm. For that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutting down the unit when the oil pressure is too low, the coolant temperature is too high, the coolant...

  • Page 9: Fuel Systems

    FUEL SYSTEM FUEL REQUIREMENTS The standby generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (PV) fuel system The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the unit.

  • Page 10: Specifications

    SPECIFICATIONS GENERATOR Type ... Synchronous Rotor Insulation ... Class H Stator Insulation ... Class H Total Harmonic Distortion ...< 3.5% Telephone Interference Factor (TIF) ...< 50 Alternator Output Leads 3-phase ... 4-wire Bearings ...Sealed Ball Coupling ...Flexible Disc Load Capacity (Standby Rating) ...40kW* NOTE: Generator rating and perfomance in accordance with ISO8528-5, BS5514, SAE J1349, ISO3046 and DIN 6271 Standards.

  • Page 11: Cold Weather Kit

    COLD WEATHER KIT For cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: • Battery Warmer • 4” Junction Box with hardware • 6 qt. pack 5W-30 synthetic oil (engine) RECONFIGURING THE FUEL SYSTEM NOTE: All models are configured for natural gas or LP vapor from the factory.

  • Page 12: General Information

    GENERATOR AC LEAD CONNECTIONS See “Voltage Codes”. This generator may be rated at any one of three voltages, either single-phase or three-phase. The electrical wires in the unit’s AC con- nection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application.

  • Page 13: Installation

    INSTALLATION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. PREPARATION BEFORE START-UP The instructions in this section assume that the standby generator has been properly installed, ser- viced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor. Be sure to read the “Safety Rules”, as well as all other safety information in this manual, before attempting to operate this (and related) equipment.

  • Page 14: Start-Up Inspection

    START-UP CHECKLIST  Before working on the generator, ensure the fol- lowing: • The AUTO/OFF/MANUAL switch is in the OFF position. • The 120VAC supply to the battery charger is switched OFF . PREPARATION FOR START-UP • Ensure that the 120VAC circuit breaker to the bat- tery charger is open.

  • Page 15: Operation

    GENERATOR CONTROL AND OPERATION Refer to the appropriate control panel operator’s manual for this unit. OPERATING UNIT WITH MANUAL TRANSFER SWITCH If the generator was installed in conjunction with a transfer switch capable of manual operation only, the following procedure applies. A manually operated transfer switch is one that will not provide automatic start-up and does not include an intelligence circuit.

  • Page 16: Maintenance

    MAINTENANCE PERFORMED BY AUTHORIZED SERVICE FACILITIES  Before working on the generator, ensure the fol- lowing: • The AUTO/OFF/MANUAL switch is in the OFF position. • The 15A fuse has been removed from the con- trol box. • The 120VAC supply to the battery charger is switched OFF .

  • Page 17: Engine Coolant

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

  • Page 18: Changing The Engine Air Cleaner

    7. Start engine and check for oil leaks. Figure 10.2 - Oil Filter Oil Filter CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner, (part number 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover.

  • Page 19: Battery Maintenance

    BATTERY MAINTENANCE The battery should be inspected per the “Service Schedule” section. The following procedure should be followed for inspection: 1. Inspect the battery posts and cables for tightness and corrosion. Tighten and clean as necessary. 2. Check the battery fluid level of unsealed batteries and, if necessary, fill with DISTILLED WATER ONLY.

  • Page 20: Service Schedule

    SERVICE SCHEDULE 30 KW - 150 KW STANDBY GAS ENGINE DRIVEN GENERATOR SETS The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application.
  • Page 21 Maintenance Level 1 Tasks Recom- mended Comp. to be done Comp. to be done to be done (Date- monthly/ Initials) 10 hrs. 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary.
  • Page 22 Maintenance Level 1 Tasks Recom- mended Comp. to be done Comp. to be done to be done (Date- monthly/ Initials) 10 hrs. 10. Check the engine accessory drive belts and fan coupling device if equipped for correct tension, wear, weather cracking, and damage.
  • Page 23 Maintenance Level 1 Tasks Recom- mended Comp. to be done Comp. to be done to be done (Date- monthly/ Initials) 10 hrs. 18. Start and exercise the unit at full rated load (use a load bank if the site load is not enough) for at least 2 hours looking for leaks,...

  • Page 24: Troubleshooting

    TROUBLESHOOTING GUIDE PROBLEM CAUSE 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. *Contact the nearest Authorized Dealer for assistance. Standby Generator Sets Troubleshooting 1.
  • Page 25 Standby Generator Sets Notes...
  • Page 26 Standby Generator Sets Notes...
  • Page 27 Standby Generator Sets Notes...
  • Page 29 0F3137 PAN CB CONN BOX 0F3188 STAND RH CONTROL 0F3189 STAND LH CONTROL 023484N BUSHING SNAP SB-2.5-31 5 *** 0F6366B 1 / 2 XFMR DUAL 120V/16V (FOR 120/240V & 277/480V UNITS) 0F6366A XFMR DUAL 104V/16V (FOR 120/208V UNITS) 6 *** 043180 2 / 4 WASHER FLAT M4...
  • Page 31 0F3438 RTR 390 30AD1 CPL 0F3440 RTR 390 40AD2 CPL HI-EF 0F6188 ASSY RTR 390 30KD1 CPL 0F6190 ASSY RTR 390 40KD2 CPL 0F3439 STR 390 30AD1 CPL 0F3441 STR 390 40AD2 CPL 0F6189 STR 390 30GD1 CPL 0F6199 STR 390 40GD2 CPL 0F6655 ASSY STR 390 30KD1 CPL 0F6656...
  • Page 33 0F3270 MTG BASE 3.9L 40KW C2 052860 NUT FLANGED HEX M12-1.75 052251 DAMPENER VIBRATION 40 BLUE 052257 SPACER .49 X .62 X 1.87 PWDR/ZNC 052252 DAMPENER VIBRATION 052259 WASHER FLAT M12 052891 SCREW HHC M12-1.75 X 80 G8.8 0536210410 ASSY WIRE 14.00" 042909 SCREW HHC M8-1.25 X 30 G8.8 047411...
  • Page 35 0F3408 TRAY BATTERY 0F3411 STRAP BATTERY RETAINMENT 058208 BATT 12VDC 24F 625 036833 SCREW HHC 3/8-16 X 1 G8 022237 WASHER LOCK 3/8 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATT POST COVER RED + 050331 BATT POST COVER BLK - 038805H CABLE BATT BLK #1 X 23.00 038804Y...
  • Page 37 0E5048A FLEXPLATE HSB 3.9L CHRYSLER (1800RPM) 0F3903A FLEX PLATE 2 POLE 3.9L CHRY (3600RPM) 0F2982 ENG ADAPTER MACH 3.9L HSB NSPS 0E6703 COVER FLYWHEEL ACCESS 0F3795 ENGINE INSERTED VALVE 3.9L (3600 RPM) 0E8336 MAKE 3.9L CHRYSLER ENGINE (1800 RPM) 0E7841 GASKET THERMOSTAT ADAPTOR 0E7254 MACH THERM ADAPTOR 3.9L CHRY...
  • Page 39 0F1823A ENCL HSB CONTROL PANEL 0F3078 COVER CONTROL PANEL 0F2606 HINGE CONTINUOUS H-PNL 036261 RIVET POP .125 X .275 SS 0F2627A COVER CONTROL PANEL SIDE 043181 SCREW PHM M3-0.5 X 10MM 052777 WASHER FLAT M3 0F4245A AASY PCB COMM CTRLR 1800 RPM 0F1262 HOLDER FUSE WICKMANN 178.6150 10 *...
  • Page 41 0F3203 WELDMENT RAD SUPPORT 3.9L C2 035685 CLAMP HOSE #28 1.32-2.25 0F2608 RADIATOR 598 X 568 X 49 CPL RH 0F4413 HOSE UPPER RAD CPL C2 3.9L 0F4414 HOSE LOWER RAD CPL C2 3.9L 0E7854 CLUTCH COOLING FAN 0F2820 FAN 22" DIA 10 BLADE 051756 SCREW HHC M10-1.5 X 20 G8.8 046526...
  • Page 43 0F6504 PIPE R/H SIDE MUFFLER 0F3127 PIPE L/H SIDE 3.9L CPL 0F2808B PIPE EXHAUST MUFFLER OUT 0F0738 MUFFLER 7" X 9"-(2) 2" IN/2.5" OUT 0F2962 MUFFLER STRAP 0F2830 MUFFLER BRACKET STIFFENER 047411 SCREW HHC M6-1.0 X 16 G8.8 022097 WASHER LOCK M6-1/4 022473 WASHER FLAT 1/4-M6 ZINC 080762...
  • Page 45 0F6322 BOTTOM PLATE, AIR CLEANER 3.9L 0F5418 ELEMENT AIR FILTER 0E6406 HOLDER VENTURI 0E7702 HOLD DOWN AIR CLEANER 0F6323 PLATE, AIR CLEANER TOP 3.9L 037561 NUT WING 1/4-20 NYLK 049815 SCREW HHC M5-0.8 X 16 G8.8 049226 WASHER LOCK M5 051713 WASHER FLAT M5 0E6586...
  • Page 47 033212 SCREW HHC 5/16-18 X 1-1/4 G5 075580 FLANGE FUEL INLET 0F6390 REGULATOR ASSEMBLY DUAL FUEL 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16-M8 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 CLEAR ZINC 0E8286 STREET EL 45 DEG 1/2"...
  • Page 49 0F5853 (XX) REAR WRAP C2 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 0F5849 (XX) DOOR C2 087233 RIVET POP .1875 X .450 SS 0E3257 SCREW TH-FRM M6 W/CAP SHKPRF W 0F5852 (XX) DISCHARGE DUCT,LH & RH SIDE C2 0F5850 (XX) FRONT CORNERS C2 0F5851 (XX)
  • Page 56 • A Generac Power Systems, Inc. Transfer Switch is highly recommended to be used in conjunction with the genset. If a Non - Generac Power Systems, Inc. Transfer Switch is substituted for use and directly causes damage to the genset, no warranty coverage shall apply.

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