Generac Power Systems 005396-0, Owner'S Manual

Page 1: ...nance Troubleshooting Electrical Data Parts Warranty FOR THE NEAREST AUTHORIZED SERVICE CENTER 1 800 333 1322 Owner s Manual MODELS 004987 2 15 000 Watt 005396 0 17 500 Watt www centuriongenerators com COMMERCIAL INDUSTRIAL RESIDENTIAL ...

Page 2: ...2 6 2 Adding Gasoline 10 2 7 To Start The Engine 11 2 8 Stopping The Engine 11 2 9 Automatic Idle Control 12 2 10 Cold Weather Operation De Icer 12 2 11 Low Oil Pressure Shutdown System 12 2 11 1 Initial Start up 12 2 11 2 Sensing Low Oil Pressure 12 2 11 3 Restarting 12 2 12 Charging a Battery 12 Section 3 Maintenance 13 3 1 Maintenance Schedule 13 3 2 Product Specifications 13 3 2 1 Generator Sp...

Page 3: ...y Always disconnect spark plug wires and place the wires where they cannot contact the spark plugs to prevent accidental starting when setting up transporting adjusting or making repairs to the generator The generator produces dangerously high voltage that can cause extremely hazardous electrical shock Avoid contact with bare wires terminals etc Never permit any unqualified person to operate or se...

Page 4: ...he generator Parts of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS Never operate in an enclosed area or indoors For safety reasons the manufacturer recommends that the maintenance of this equipment is carried out by an Authorized Dealer The engine exhaust fumes contain carbon monoxide which can be DEADLY This dangerous gas if breathed...

Page 5: ...ions 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 operated in accordance with the manufacturer s instructions and recommendations Do not alter the construction of the generator or change controls which might create an unsafe operating conditi...

Page 6: ...heel kit is not intended for over the road use Refer to Figure 2 and install the wheel kit as follows Place the generator on a hard flat surface Stand at the engine end of the unit and gently tilt the generator forward high enough to place wooden blocks beneath the cradle This will allow space to install the wheel assemblies Attach an axle bracket assembly with attached sleeve to either side of th...

Page 7: ...tery cables to the stator Connect the RED battery cable to the battery Positive terminal After making sure that the connection is tight slip the rubber boot over the terminal connection Connect the BLACK battery cable to the battery Negative terminal Make sure the connection is tight Double check all connections to ensure they are in the correct location and secure See Figure 3 Figure 3 Battery Co...

Page 8: ...30 Amp single phase 60 Hz electrical lighting appliance tool and motor loads 6 120 240 Volt AC 50 Amp Receptacle Located on underside of control panel Supplies electrical power for the operation of 120 240 Volt AC 50 Amp single phase 60 Hz welder or motor loads 7 Air Cleaner Filters intake air as it is drawn into the engine 8 Choke Knob Used when starting a cold engine 9 Winter Summer Valve See Co...

Page 9: ...efective appliance can cause a ground fault A GFCI receptacle does NOT protect against circuit overloads short circuits or shocks For example electric shock can still occur if a person touches charged electrical wires while standing on a non conducting surface such as a wood floor Figure 8 120 VAC 20 Amp GFCI Receptacle Testing the GFCI Test the GFCI outlet every month as follows Plug a test lamp ...

Page 10: ...ore attempting to recharge a battery Figure 11 12 Volt DC 10 Amp Receptacle 2 2 6 120 240 VAC 50 AMP RECEPTACLE Use a NEMA 14 50 plug with this receptacle Connect a 4 wire cord set rated for 250 Volts AC at 50 Amps to the plug Figure 12 Figure 12 120 240 VAC 50 Amp Receptacle 50 A Use this receptacle to operate 120 240 Volt AC 60 Hz electrical loads requiring up to 12 000 watts 12 0 kW of power Th...

Page 11: ...han for running This surge of power lasts only a few seconds when starting such motors Make sure to allow for high starting wattage when selecting electrical devices to connect to the generator 1 Figure the watts needed to start the largest motor 2 Add to that figure the running watts of all other connected loads The Wattage Reference Guide is provided to assist in determining how many items the g...

Page 12: ... fuel tank Always leave room for fuel expansion To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator engine Leaded REGULAR grade gasoline is an acceptable substitute Do not use premium gasoline Do not mix oil with gasoline Clean area around fuel fill cap remove cap Slowly add unleaded regular gasoline to fuel tank Be careful not to overfill Allow about 1 2 of ta...

Page 13: ...hen fully in to the Run position If engine falters move choke knob back out to 1 2 Choke position until the engine runs smoothly and then to Run position NOTE If engine fires but does not continue to run move choke lever to Full Choke and repeat starting instructions IMPORTANT Do not overload the generator Also do not overload individual panel receptacles These outlets are protected against overlo...

Page 14: ...s while recharging An explosive mixture will remain around the battery for a long time after it has been charged The slightest spark can ignite the hydrogen and cause an explosion Such an explosion can shatter the battery and cause blindness or other serious injury DANGER Do not permit smoking open flame sparks or any other source of heat around a battery Wear protective goggles rubber apron and r...

Page 15: ... inch or 1 01 mm Gasoline Capacity 16 U S gallons Oil Type Summer SAE 30 Winter 5W 30 Synthetic or 10W 30 Oil Capacity w Filter Change 1 7 Qts w o Filter Change 1 4 Qts Run Time Fuel Consumption 1 2 Load 10 Hours 1 6 gallons per hour 3 3 GENERAL RECOMMENDATIONS The warranty of the generator does not cover items that have been subjected to operator abuse or negligence To receive full value from the...

Page 16: ...ore often NOTE Whenever possible run engine for approximately 5 minutes to get the engine oil hot This will aid in draining the oil Use the following instructions to change the oil while the engine is still warm Clean area around oil drain hose and plug Remove oil drain plug from end of hose and oil fill plug to drain oil completely into a suitable container When oil has completely drained install...

Page 17: ...igure 20 Spark Arrestor 3 6 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation check the valve clearance in the engine and adjust if necessary Important If feeling uncomfortable about doing this procedure or the proper tools are not available please take the generator to the nearest service center to have the valve clearance adjusted This is a very important step to insure longest lif...

Page 18: ... of an engine while in storage To avoid engine problems the fuel system should be emptied before storage of 30 days or longer as follows Remove all gasoline from the fuel tank DANGER Drain fuel into approved container outdoors away from open flame Be sure engine is cool Do not smoke Start and run engine until engine stops from lack of fuel While engine is still warm drain oil from crankcase Refill...

Page 19: ...Overchoking 8 Low oil level 9 Excessive rich fuel mixture 10 Intake valve stuck open or closed 11 Engine has lost compression 1 Clean or replace air cleaner 2 Fill fuel tank 3 Drain fuel tank and fill with fresh fuel 4 Connect wire to spark plug 5 Replace spark plug 6 Drain fuel tank fill with fresh fuel 7 Put choke knob to No Choke position 8 Fill crankcase to proper level 9 Contact Authorized Se...

Page 20: ...18 Section 5 Notes ...

Page 21: ...19 Section 6 Electrical Data Schematic Drawing No 0G2894 A ...

Page 22: ...20 20 Section 6 Electrical Data Wiring Diagram Drawing No 0G2892 A ...

Page 23: ...21 21 Section 6 Electrical Data Wiring Diagram Drawing No 0G2892 A ...

Page 24: ...22 Section 7 Exploded Views and Parts Lists GT 990 Engine Drawing No 0G2963 G Part 1 ...

Page 25: ...L RELIEF 27 0C3010 2 BALL 1 2D OIL RELIEF 28 093873 2 WASHER LOCK RIB M6 29 0F5458 1 SCREW PLASTITE HI LOW 10 30 0C5998 1 CLAMP OIL TUBE 32 0F2664E 1 ASSEMBLY DIPSTICK GTH 990 PORTABLE ITEM PART NO QTY DESCRIPTION 33 0D3745 1 TUBE DIPSTICK 34 0C3027 1 O RING 3 8 X 35 0E9842A 1 SEAL 42 I D CRANKSHAFT GREEN 36 0F8054 1 GEARCOVER ADAPTOR GTH990 760 37 0C3006 10 SCREW HHFC M10 1 5 X 55 38 080318 8 SCR...

Page 26: ...24 Section 7 Exploded Views and Parts Lists GT 990 Engine Drawing No 0G2963 G Part 2 ...

Page 27: ... 1 WRAPPER LOWER CYLINDER 2 111 0D1143 1 WRAPPER UPPER CYLINDER 2 112 0F1177 1 ASSEMBLY GROUND WIRE 113 ITEM PART NO QTY DESCRIPTION 114 0G3110 4 SCREW TAPTITE M6 1 0 X 20 ZINC 115 0G3224B 1 ASSY IGN COIL W DIODE NO ADV 116 0F6263 1 PUMP IMPULSE 117 0G0290 1 HOSE 3 8 ID x 6 1 2 SAE J30R9 118 0G0926 2 SCREW HHFCS M6 1 0 X 16 G8 8 119 0G0832 1 ELBOW RUBBER 90 DEG GASOLINE 120 0E7585A 2 SPARKPLUG CHA...

Page 28: ...26 Section 7 Exploded Views and Parts Lists Generator Drawing No 0G2964 ...

Page 29: ...1 BATTERY CABLE BLACK 19 0C2417A 1 EARTH STRAP 3 8X 3 8 20 082121C 1 CLIP J VINYL COAT 625 ID 21 066386 1 ASSEMBLY BRUSH HOLDER 22 0C2824 1 SCREW TAP R 10 32 X 9 16 23 0A2038 1 WASHER FLAT 3 8 ZINC 24 022237 1 WASHER LOCK 3 8 25 0D6214 1 SHIELD RUBBER MOUNT 26 045764 1 SCREW HHTT M4 0 7 X 8 27 051731 4 SCREW HHC M8 1 25 X 50 G8 8 28 022145 21 WASHER FLAT 5 16 ZINC 29 049820 4 NUT LOCK HEX M8 1 25 ...

Page 30: ...28 Section 7 Exploded Views and Parts Lists Control Panel Drawing No 0G2965 B ...

Page 31: ...METAL 17 5 KW 26 075207A 4 CIRCUIT BREAKER 30A 27 075207 2 CIRCUIT BREAKER 20A 28 068868 2 OUTLET 30A 120V RECEPT 29 0D4969 1 OUTLET 50A 125 250V ITEM PART NO QTY DESCRIPTION 30 043437 1 OUTLET 30A 125 250V 31 0D4968 1 OUTLET 20A 120V DPLX 32 0D4966 1 OUTLET 20A 120V GFCI 33 051715 14 NUT HEX M4 0 7 15 KW 005396 10 NUT HEX M4 0 7 17 5 KW 34 038150 14 WASHER FLAT 8 15 KW 005396 35 022264 14 WASHER ...

Page 32: ...30 Section 7 Exploded Views and Parts Lists Frame Handle Wheel Kit Drawing No 0E0695 B ...

Page 33: ... 1 0 X 12 26 064101 6 NUT LOCK FL 3 8 16 27 039214 6 BOLT CARR 3 8 16 X 1 28 0D9165 1 AXLE 3 4 DIA X 30 15 kW 0D2496 1 AXLE 3 4 DIA X 27 25 12 5 kW 29 045900 2 WASHER FLAT 3 4 15 kW 045900 4 WASHER FLAT 3 4 12 5 kW 30 0D7668 2 12 3 PNEUM WHEEL 3 4 AXLE 15 kW 0D2495 2 10 PNEUM WHEEL 3 4 AXLE 12 5 kW 31 0D4999 2 PIN COTTER 1 8 X 1 1 4 32 0D4044 2 BRACKET WHEEL SPACER 33 0D3700 4 NUT FLANGE M6 1 0 NY...

Page 34: ...owever be aware that 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 contacting a Generac Authorized Warranty Dealer as soon as a problem oc...

Page 35: ... by Generac according to Subsection 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...

Page 36: ...ck of proper oil levels Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper use 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 Failures caused by any external cause or act of God such as colli...