Owner’s Manual and Installation Instructions · 2016. 2. 16. · RION product line by Generac Power Systems Inc. This model is designed and manufactured to supply electrical power

®

Owner’s Manual andInstallation Instructions

CENTURION 3500Air-cooled, Prepackaged

Automatic Standby Generator• Model: 04791-0

3.4kW LP

Not intended for use as Primary Power in place of utility or in life-support applications. !!

This manual shouldremain with the unit.

DEADLY EXHAUST FUMES. OUTDOOR INTALLATION ONLY!!

DANGER

Generac® Power Systems, Inc.

INTRODUCTIONThank you for purchasing this model of the CENTU-RION product line by Generac Power Systems Inc.This model is designed and manufactured to supplyelectrical power for residences.

READ THIS MANUAL THOROUGHLYIf any portion of this manual is misunderstood, con-tact the nearest Generac Authorized Service Dealerfor starting, operating and servicing procedures.

Throughout this publication, and on tags and decalsaffixed to the generator, DANGER, WARNING, CAU-TION and NOTE blocks are used to alert personnel tospecial instructions about a particular operation thatmay be hazardous if performed incorrectly or care-lessly. Observe them carefully. Their definitions areas follows:

After this heading, read instructions that, if notstrictly complied with, will result in serious person-al injury, including death, as well as property dam-age.

After this heading, read instructions that, if notstrictly complied with, may result in serious person-al injury or property damage.

After this heading, read instructions that, if notstrictly complied with, could result in damage toequipment and/or property.

NOTE:

After this heading, read explanatory statementsthat require special emphasis.

These safety warnings cannot eliminate the hazardsthat they indicate. Common sense and strict compli-ance with the special instructions while performingthe service are essential to preventing accidents.

Four commonly used safety symbols accompany theDANGER, WARNING and CAUTION blocks. The typeof information each indicates follows:

This symbol points out important safety infor-mation that, if not followed, could endangerpersonal safety and/or property of others.

This symbol points out potential explosion haz-ard.

This symbol points out potential fire hazard.

This symbol points out potential electricalshock hazard.

CONTENTSThis manual contains pertinent owner’s information,including warranty, electrical diagrams, explodedviews and lists of repair parts for generator modelnumbers 04791-0. In addition, the latter portion ofthis manual contains information necessary for theproper installation of these generators.

OPERATION AND MAINTENANCEIt is the owner's responsibility to perform all safetychecks, to make sure that all maintenance for safeoperation is performed promptly, and to have theequipment checked periodically by a GeneracAuthorized Service Dealer. Normal maintenance ser-vice and replacement of parts are the responsibility ofthe owner and, as such, are not considered defects inmaterials or workmanship within the terms of thewarranty. Individual operating habits and usage con-tribute to the need for maintenance service.

Proper maintenance and care of the generator ensurea minimum number of problems and keep operatingexpenses at a minimum.

HOW TO OBTAIN SERVICEWhen your generator requires servicing or repairs,simply contact a Generac Authorized Service Dealerfor assistance. Service technicians are factory trainedand are capable of handling all service needs.

When contacting a Generac Authorized ServiceDealer about parts and service, always supply thecomplete model number and serial number of theunit as given on its data decal, which is located on thegenerator.

Model No. ____________ Serial No. ______________

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DANGER

AUTHORIZED SERVICEDEALER LOCATION

To locate the nearest GENERAC AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322ONLY DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

Table of ContentsCENTURION 3500 Home Standby Generator

Generac® Power Systems, Inc. 1

Part I – Owner’s ManualIntroduction ........................................Inside Front Cover

Read This Manual Thoroughly ....................................IFC

Contents ......................................................................IFC

Operation and Maintenance ........................................IFC

How to Obtain Service..................................................IFC

Authorized Service Dealer Locator Number ................IFC

Safety Rules ........................................................................2

Section 1 - General Information ....................................4

1.1 Generator Identification ........................................4

1.2 Unpacking/Inspection............................................5

1.3 Safety ....................................................................6

1.4 Protection Systems................................................6

1.5 Location ................................................................6

1.6 Specifications ........................................................6

Section 2 - Operation........................................................7

2.1 Generator Control Panel........................................7

2.2 Before Starting the Engine ....................................8

2.3 Battery Connection................................................8

2.4 The Battery ..........................................................9

2.5 Before Initial Start-up............................................9

2.6 Stopping the Generator ......................................10

2.7 Applying Loads to Generator ..............................10

2.8 Do Not Overload the Generator ..........................10

2.9 Protection Systems..............................................10

2.10 Additional Information........................................12

Section 3 - Maintenance ................................................12

3.1 Checking the Engine Oil Level ............................12

3.2 Changing the Engine Oil and/or Oil Filter ..........12

3.3 Maintaining the Engine Air Cleaner ....................13

3.4 Clean Air Intake ..................................................14

3.5 Checking the Engine Spark Plug ........................14

3.6 Clean Spark Arrestor ..........................................14

3.7 Cleaning the Generator ......................................15

3.8 Battery Maintenance............................................15

3.9 Exercising the Generator ....................................16

3.10 Out of Service Procedure ....................................16

3.11 Adjusting Valve Clearance ..................................17

3.12 Generator Service Interval ..................................17

Part II – Installation InstructionsSafety Rules ......................................................................19

Section 1 - General Information ..................................21

1.1 Tools Required ....................................................21

1.2 Items That Must Be Purchased ..........................21

1.3 Plan the Location of the Generator......................21

Section 2 - Installation ..................................................22

2.1 Site Preparation and Generator Placement ........22

2.2 Power Cord Installation ......................................22

2.3 Mount Power Transfer Motor ..............................23

2.4 Install Propane Tanks ........................................23

2.5 Set System for Automatic Operation ..................25

2.6 How to Keep the Regulator Operating Efficiently & Safely ..............................................25

2.7 What is Regulator Freeze Up?..............................25

Appendix 1 - Troubleshooting ......................................26

Appendix 2 - Notes..........................................................27

Appendix 3 - Electrical Data ........................................30

Appendix 4 - Exploded Views and Parts Lists ..........34

Appendix 5 - Warranty ..................................................48

2 Generac® Power Systems, Inc.

Study these SAFETY RULES carefully beforeinstalling, operating or servicing this equipment.Become familiar with this manual and with the unit.The generator can operate safely, efficiently and reli-ably only if it is properly installed, operated andmaintained. Many accidents are caused by failing tofollow simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possibilitythat might involve a hazard. The warnings in thismanual, and on tags and decals affixed to the unit,are, therefore, not all-inclusive. If using a procedure,work method or operating technique Generac doesnot specifically recommend, satisfy yourself that it issafe for others. Also make sure the procedure, workmethod or operating technique chosen does not ren-der the generator unsafe.

Despite the safe design of this generator, oper-ating this equipment imprudently, neglectingits maintenance or being careless can causepossible injury or death. Permit only responsi-ble and capable persons to operate or maintainthis equipment.

Potentially lethal voltages are generated bythese machines. Ensure all steps are taken torender the machine safe before attempting towork on the generator.

Parts of the generator are rotating and/or hotduring operation. Exercise care near runninggenerators.

GENERAL HAZARDS• For safety reasons, Generac recommends that the

maintenance of this equipment is carried out by aGenerac Authorized Service Dealer.

• The generator engine releases DEADLY carbonmonoxide gas through its exhaust system. Thisdangerous gas, if breathed in sufficient concentra-tions, can cause unconsciousness or even death.Never operate the generator inside any garage orother enclosed area. DO NOT OPERATE THEGENERATOR IF THE EXHAUST SYSTEM ISLEAKING OR HAS BEEN DAMAGED. SYMPTOMSOF CARBON MONOXIDE POISONING ARE (a)inability to think coherently, (b) nausea, (c) vomit-ing, (d) twitching muscles, (e) throbbing temples,(f) dizziness, (g) headaches, (h) weakness, and (i)sleepiness. IF EXPERIENCING ANY OF THESESYMPTOMS, MOVE INTO FRESH AIR IMMEDI-ATELY. IF SYMPTOMS PERSIST, GET MEDICALHELP. Shut down the generator and do not operateit until it has been inspected and repaired.

• The engine exhaust fumes contain carbon monox-ide, which can be DEADLY. This dangerous gas, ifbreathed in sufficient concentrations, can causeunconsciousness or even death. This exhaust sys-tem must be installed properly, in strict compli-ance with applicable codes and standards.Following installation, do nothing that might ren-der the system unsafe or in noncompliance withsuch codes and standards. Never operate thisequipment with a leaking or defective exhaust sys-tem.

• Keep hands, feet, clothing, etc., away from drivebelts, fans, and other moving or hot parts. Neverremove any drive belt or fan guard while the unit isoperating.

• Adequate, unobstructed flow of cooling and venti-lating air is critical to correct generator operationand is required to expel toxic fumes and fuel vaporsfrom the generator. Without sufficient cooling air-flow, the engine/generator overheats, which causesserious damage to the generator. Do not alter theinstallation or permit even partial blockage of ven-tilation provisions, as this can seriously affect safeoperation of the generator.

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DANGER

Safety RulesCENTURION 3500 Home Standby Generator

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment.! !

The engine exhaust from this productcontains chemicals known to the state

of California to cause cancer, birthdefects or other reproductive harm.

WARNING:! !

This product contains or emits chemicalsknown to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:! !

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should befollowed during installation and maintenance of the generator and batteries.! !


• When working on this equipment, remain alert atall times. Never work on the equipment whenphysically or mentally fatigued.

• Inspect the generator regularly, and contact thenearest Generac Authorized Service Dealer immedi-ately for parts needing repair or replacement.

• Before performing any maintenance on the genera-tor, disconnect its battery cables to prevent acci-dental start up. Disconnect the cable from the bat-tery post indicated by a NEGATIVE, NEG or (–)first. Reconnect that cable last.

• Never use the generator or any of its parts as astep. Stepping on the unit can stress and breakparts, and may result in dangerous operating con-ditions from leaking exhaust gases, fuel leakage,oil leakage, etc.

ELECTRICAL HAZARDS• The generator covered by this manual produces

dangerous electrical voltages and can cause fatalelectrical shock. Avoid contact with bare wires, ter-minals, connections, etc., while the unit is running.Ensure all appropriate covers, guards and barriersare in place before operating the generator. If workmust be done around an operating unit, stand onan insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device whilestanding in water, while barefoot, or while handsor feet are wet. DANGEROUS ELECTRICALSHOCK MAY RESULT.

• During installation, have the generator properlygrounded (bonded) by means of an approvedbonding conductor. DO NOT disconnect the bond-ing conductor. DO NOT reconnect the bondingconductor to any generator part that might beremoved or disassembled during routine mainte-nance. If the grounding conductor must bereplaced, use only a flexible conductor that is ofNo. 12 American Wire Gauge (AWG) copper wireminimum.

• In case of accident caused by electric shock, imme-diately shut down the source of electrical power. Ifthis is not possible, attempt to free the victim fromthe live conductor. AVOID DIRECT CONTACTWITH THE VICTIM. Use a nonconducting imple-ment, such as a dry rope or board, to free the vic-tim from the live conductor. If the victim is uncon-scious, apply first aid and get immediate medicalhelp.

• Never wear jewelry when working on this equip-ment. Jewelry can conduct electricity resulting inelectric shock, or may get caught in moving com-ponents causing injury.

FIRE HAZARDS

• For fire safety, the generator must be installed andmaintained properly. Installation always mustcomply with applicable codes, standards, laws andregulations. Adhere strictly to local, state andnational electrical and building codes. Complywith regulations the Occupational Safety andHealth Administration (OSHA) has established.Also, ensure that the generator is installed inaccordance with the manufacturer’s instructionsand recommendations. Following proper installa-tion, do nothing that might alter a safe installationand render the unit in noncompliance with theaforementioned codes, standards, laws and regu-lations.

EXPLOSION HAZARDS• Do not smoke around the generator. Wipe up any oil

spills immediately. Ensure that no combustiblematerials are left in the generator compartment, oron or near the generator, as FIRE or EXPLOSIONmay result. Keep the area surrounding the genera-tor clean and free from debris.

Safety RulesCENTURION 3500 Home Standby Generator


1. Generator Air Intake2. Engine AUTO/OFF/MANUAL Switch3. Fuse4. LED Indicator5. Demand Regulator (Inside Compartment)6. Change-over Regulator7. Circuit Breakers8. Starter Contactor9. Fuel Inlet

10. Tank Hook-ups.11. Battery (In Compartment)

12. Oil Filter13. Oil Drain (From Underside)14. Oil Dipstick15. Air Filter (Behind Access Panel)16. Oil Fill17. Spark Plug18. Tank Hold Down Brace19. Exhaust Hood

(Tailpipe and Spark Arrestor Inside)20. Ground Lug21. Data Decal (Located inside compartment)

Section 1 – General InformationCENTURION 3500 Home Standby Generator

Please record the following information from the generator DATA DECAL or information decal.

1. Model Number ____________________ 2. Serial Number __________________

3. kW Rating__________________________ 4. Rated Voltage __________________

0723470.8L/0.84QT

RATOR POWER

PUSH TO RESET

GENERATORPOWERFUSE

7.5A

1.1 GENERATOR IDENTIFICATION

Model: 004700-0 — QUIETPACT 40G

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13 14, 16 12 8 17 4 3 7

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1.1.1 POWER TRANSFER MONITORThe Power Transfer Monitor controls the automaticfunction of the Centurion 3500 generator set. It’s sixfoot utility sensing cord monitors the utility line whenit is plugged into a standard household 120 volt out-let.

NOTE:

Automatic start-up upon utility power outage willnot occur if six foot sensing cord is not pluggedinto a utility powered 120 volt outlet.

Figure 1.2 — Power Transfer Monitor

1. Generator Power Conduit (15 foot)2. Circuit Breaker Reset (2)3. Generator Power Indicator Lamp4. Utility Power Indicator Lamp5. Generator Exercise Switch6. Switched GFCI Outlet7. Standby GFCI Outlet8. Utility Sensing Cord (6 foot)

1.1.1.1 Generator Power ConduitThis conduit connects the Power Transfer Monitor,which is located inside the home, to the generatoroutside.

1.1.1.2 Circuit Breaker ResetIf the generator should experience an overload forany reason, the circuit breaker(s) will trip. The cir-cuit breaker reset(s) should be pushed to reset afteroverload condition has been corrected.

1.1.1.3 Generator Power Indicator LampThis lamp will illuminate when the generator hasstarted and is supplying power to the Power TransferMonitor’s GFCI outlets.

1.1.1.4 Utility Power Indicator LampThis lamp will be illuminated when normal utilitypower is available.

1.1.1.5 Generator Exercise SwitchThis switch activates the exercise cycle of the genera-tor. Make sure the combined loads do not exceed gen-erator capacity.

1.1.1.6 Switched GFCI OutletThis outlet is powered by the utility and by the gen-erator. When utility power is present is acts as anoth-er normal household outlet. When the generator issupplying power this outlet is then being suppliedwith power from the generator.

NOTE:

There will be a momentary “No Power” periodbetween the time of utility failure and the genera-tor start up.

1.1.1.7 Standby GFCI OutletThis outlet is ONLY powered by the generator. Use itfor additional items during a utility power outagewhen the generator is providing backup electricity forthe home.

1.1.1.8 Utility Sensing CordWhen plugged into a standard grounded 120 volt out-let this cord allows the Power Transfer Monitor tosense the utility line condition and react to a poweroutage.

1.2 UNPACKING/INSPECTIONAfter unpacking, carefully inspect the contents fordamage.

• This standby generator set has been factory sup-plied with a weather protective enclosure that isintended for outdoor installation only.

• This standby generator set is prepackaged with anautomatic power transfer monitor. The powertransfer monitor is prewired with 15 foot conduitand six foot utility sensing cord with plug. ThePower Transfer Monitor is for indoor installationonly.

If any loss or damage is noted at time of delivery, havethe person(s) making the delivery note all damage onthe freight bill or affix his or her signature under theconsignor’s memo of loss or damage.

If loss or damage is found after delivery, separate thedamaged materials and contact the carrier for claimprocedures if applicable.

Use this generator to supply electrical power foroperating 120-volt, single-phase, 60 Hertz, AC elec-trical loads. These loads can require up to 3,400watts (3.4 kW) of power, but cannot exceed 28.3 ACamperes of current at 120 volts.

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Do not overload the generator. Some installa-tions may require that electrical loads be alter-nated to avoid overloading. Applying exces-sively high electrical loads may damage thegenerator and may shorten its life. Add up therated watts of all electrical lighting, appliance,tool and motor loads the generator will powerat one time. This total should not be greaterthan the wattage capacity of the generator. Ifan electrical device nameplate gives only voltsand amps, multiply volts times amps to obtainwatts (volts x amps = watts). Some electricmotors require more watts of power (or ampsof current) for starting than for continuousoperation.

1.3 SAFETYBefore attempting to use the generator set, carefullyread the “Safety Rules” section of this manual.Comply strictly with these rules to prevent accidentsand damage to equipment and/or property. We sug-gest copying and posting the “Safety Rules” in poten-tial hazard near the generator. Stress safety to alloperators and potential operators of this equipment.

1.4 PROTECTION SYSTEMSUnlike an automobile engine, the generator may haveto run for long periods of time with no operator pre-sent to monitor engine conditions. For that reason,the engine is equipped with the following systemsthat protect it against potentially damaging condi-tions:

1. Overcrank2. Overspeed3. Low Oil Pressure Sensor4. High Temperature Sensor5. UnderspeedThere is an LED readout on the control panel to noti-fy personnel that one of these faults has occurred.Detail of of the protection systems can be found inSection 2.9.

1.5 LOCATIONInstall the generator set, in its protective enclosure,outdoors, where adequate cooling and ventilating airis always available. Consider these factors:

• Install the unit where air inlet and outlet openingswill not become obstructed by leaves, grass, snow,etc. If prevailing winds will cause blowing or drift-ing, consider using a windbreak to protect the unit.

• Install the generator on high ground where waterlevels will not rise and endanger it.

• Allow sufficient room on all sides of the generatorfor maintenance and servicing. A good rule is toallow three feet of space on all sides.

• Where strong prevailing winds blow from onedirection, face the generator air inlet openings tothe prevailing winds.

1.6 SPECIFICATIONS

1.6.1 FUEL REQUIREMENTS AND RECOM-MENDATIONS

With LP gas, use only the LP vapor withdrawal sys-tem. This type of system uses the vapors formedabove the liquid fuel in the storage tank.

Recommended fuel should have a BTU content of atleast 2,520 BTU's per cubic foot. Ask the LP fuel sup-plier for the BTU content of the fuel.

This generator has been designed for a specific typeof tank. Acceptable tank types are DOT-4BA240 andDOT-4BW240. Any deviation in tank type may notallow the tank to fit in the LP enclosure.

Gaseous fuels such as liquid propane (LP) gasare highly explosive. Even the slightest sparkcan ignite such fuels and cause an explosion.No leakage of fuel is permitted. LP gas, whichis heavier than air tends to settle in low areas.

1.6.2 FUEL CONSUMPTION

Fuel consumption is in gal/hr.

1.6.3 ENGINE OIL REQUIREMENTSUse only high quality detergent oil rated withAmerican Petroleum Institute (API) ServiceClassification SF, SG or SH. The recommended oilweights include the following:

• During summer months: SAE 30. An acceptablesubstitute is SAE 10W-30.

• During winter months: SAE 5W-30. DO NOT USESAE 10-W40.

Crankcase and oil filter capacity is approximately800 mL or .84 U.S. quarts. Do NOT use special addi-tives. See Sections 3.1 and 3.2 for oil level check andfill procedures.

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Model 1/2 Load Full LoadCenturion 3500 0.55 0.73(04791-0)


Section 2 – OperationCENTURION 3500 Home Standby Generator

1.6.4 ENGINEType of Engine ............................GN-220, Single-cylinderCooling Method..................................................Air-cooledRated Horsepower ..................................7.8 @ 4,200 rpmDisplacement............................................................220ccCylinder Block ....................Aluminum w/Cast Iron SleeveType of Governor ........................Mechanical, Fixed SpeedAir Cleaner ..................Paper Element w/Foam PrecleanerStarter ................................................12-volt DC ElectricIgnition System ................Solid-state w/Flywheel MagnetoRecommended Spark Plug

Champion ..........................................................RC12YCAC ..........................................................................R45SFram Autolite ..............................................................65

Spark Plug Gap ..................................0.03. inch (76 mm)Recommended Minimum

Battery ......................................235cc Amperes @ 32°F/195cc Amperes @ 0° F

1.6.5 GENERATORRated Maximum Continuous

AC Output (LP) ................................3,400 Watts (3.4kW)Rated Voltage ................................................120 Volts ACRated Maximum Continuous

AC Current (LP) ........................................28.3 AmperesPhase ......................................................................SingleRotor RPM................................................................3,600Number of Rotor Poles ....................................................2Engine RPM..............................................................3,600Rated AC Frequency ................................................60 HzBattery Charge Voltage ....................................14 Volts DCBattery Charge Current ..........................2 Amperes (max)Length ..................................................843 mm (33.2 in.)Width ....................................................504 mm (19.8 in.)Height ......................................................966 mm (38 in.)Weight ......................................................90 kg (275 lbs.)

2.1 GENERATOR CONTROL PANELThe following features are mounted on the generatorcontrol panel (Figure 2.1):

Figure 2.1 — Generator Control Panel

2.1.1 SHUT DOWN INDICATORThis LED will flash a specific number of times to indi-cate a specific failure. Shutdowns and their failurecodes follow in Section 2.9, Protection Systems. Thesecodes can also be referenced on the decal located onthe air filter cover, located below the control panel.

2.1.2 AUTO/OFF/MANUAL SWITCH

2.1.2.1 Auto PositionSelecting this switch position activates fully automat-ic system operation. It also allows the user the abili-ty to start and exercise the generator from the remotePower Transfer Monitor.

2.1.2.2 Off PositionThis switch position shuts down the engine. Thisposition also prevents the engine from starting.

2.1.2.3 Manual PositionSelecting this switch position will crank and start theengine. Transfer to standby power will not occurunless there is a utility failure.

With the switch set to AUTO, the engine maycrank and start at any time without warning.Such automatic starting normally occurs whenutility power source voltage drops below a pre-set level or during the normal exercise cycle. Toprevent possible injury that might be caused bysuch sudden starts, always set the switch toOFF and remove the fuse before working on oraround the generator or transfer switch. Then,place a “Do Not Operate” tag on the generatorpanel and on the transfer switch.

2.1.3 FUSEThe generator panel's 7.5 amp fuse protects the DCcontrol circuit against overload. The fuse is wired inseries with the battery output lead to the panel. If thefuse element has melted open, the engine cannotcrank or start. The same fuse also protects the bat-tery charge circuit against overload. If the fuse ele-ment has melted open, battery charging will not bepossible. Replace the fuse using only an identical 7.5amp fuse.

2.1.4 MAIN BREAKERSThe main breakers protect the generator’s AC outputcircuit against overload and provide a method ofturning OFF the generator’s 120-volt AC output to thePower Transfer Monitor’s outlets. The CENTURION3500 has two (2) 15-amp breakers.

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PULL TO DISCONNECTGENERATOR POWER

CONTROL CENTER

AUTODETAILS OFFSEE CHARTBELOW FOR

DOWN

INDICATOR

SHUT

MAN.

GREEN BAR INDICATES TRIPPUSH TO RESET

GENERATORPOWERFUSE

7.5A



2.2 BEFORE STARTING THE ENGINENOTE:

Instructions and information in this manualassume the generator has been properly installedand connected.

2.2.1 ENGINE LUBRICATIONHave the engine crankcase properly serviced with therecommended oil before starting. Refer to Section1.6.2 and Sections 3.1 and 3.2, for oil servicing pro-cedures and recommendations.

Any attempt to crank or start the engine beforeit has been properly serviced with the recom-mended oil may result in an engine failure.

2.2.2 FUEL SUPPLYThe engine must have an adequate supply of properfuel to operate. Before starting it, check that sufficientfuel is available.

2.2.3 COOLING AND VENTILATING AIRAir inlet and outlet openings in the generator com-partment must be open and unobstructed for contin-ued proper operation. Without sufficient cooling andventilating airflow, the engine/generator overheats,which causes it to shut down and may damage thegenerator.

2.2.4 ENGINE EXHAUST GASBefore starting the generator engine, be sure there isno way for exhaust gases to endanger people or ani-mals. Close windows, doors near the generator that,if open, might permit exhaust gases to do so.

The generator engine releases DEADLY carbonmonoxide gas through its exhaust system. Thisdangerous gas, if breathed in sufficient concen-trations, can cause unconsciousness or evendeath. Never operate the generator set insideany enclosed area. make sure THE EXHAUSTSYSTEM IS not LEAKING AND HAS NOT BEENDAMAGED. SYMPTOMS OF CARBON MONOX-IDE POISONING ARE (a) inability to think coher-ently, (b) nausea, (c) vomiting, (d) twitchingmuscles, (e) throbbing temples, (f) dizziness, (g)headaches, (h) weakness, and (i) sleepiness. IFEXPERIENCING ANY OF THESE SYMPTOMS,MOVE INTO FRESH AIR IMMEDIATELY. IF SYMP-TOMS PERSIST, GET MEDICAL HELP. Shut downthe generator and do not operate it until it hasbeen inspected and repaired.

2.3 BATTERY CONNECTIONBefore connecting the battery, complete the followingsteps:

1. Set the generator's AUTO/OFF/MANUAL switch toOFF.

2. Make sure the Power Transfer Monitor’s sensingcord (6 foot) is not plugged into an electrical out-let.

If the AUTO/OFF/MANUAL switch is not set toits OFF position, the generator can crank andstart as soon as the battery cables are connect-ed. If the utility power supply is not disabledby unplugging the 6 foot sensing cord fromelectrical outlet, sparking can occur at the bat-tery posts and cause an explosion.

Battery cables were factory connected at the genera-tor (Figure 2.2). Connect the cables to the batteryposts using the hardware supplied in the manual bagas follows:

3. Slide the red battery terminal boot over the bat-tery cable, then connect the cable (from thestarter contactor) to the battery post indicated bya positive, POS or (+).

4. Connect the black battery cable (from frameground) and the two green grounding wires (fromthe control panel) to the battery post indicated bya negative, NEG or (-).

NOTE:

Damage will result if battery connections are madein reverse.

Figure 2.2 — Battery Cable Connections

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2.4 THE BATTERYServicing of the battery is to be performed or super-vised by personnel knowledgeable of batteries andthe required precautions. Keep unauthorized person-nel away from batteries.

When replacing the battery, use the following type ofbattery, Group U1 12-volt battery with a rating of 235cold-cranking amps at 0° C (32° F); 195 cold-crank-ing amps at -17.8º C (0º F) minimum. When using amaintenance-free battery, it is not necessary to checkthe specific gravity or electrolyte level. Have theseprocedures performed at the intervals specified inthe “Service Schedule.” A negative ground system isused. Battery connections are shown on the wiringdiagrams. Make sure the battery is correctly connect-ed and terminals are tight. Observe battery polaritywhen connecting the battery to the generator set.

Do not dispose of the battery in a fire. The bat-tery is capable of exploding.

A battery presents a risk of electrical shock andhigh short circuit current. The following precau-tions are to be observed when working on bat-teries:

• Remove watches, rings or other metal objects;• Use tools with insulated handles;• Wear rubber gloves and boots;• Do not lay tools or metal parts on top of the bat-

tery; and• Disconnect charging source prior to connecting or

disconnecting battery terminals.

Do not open or mutilate the battery. Releasedelectrolyte has been known to be harmful tothe skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that isharmful to the skin and eyes. It is electricallyconductive and corrosive. The following proce-dures 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 thor-

oughly and immediately with water and seek med-ical attention; and

• Spilled electrolyte is to be washed down with anacid neutralizing agent. A common practice is touse a solution of one pound (500 grams) bicarbon-ate of soda to one gallon (4 liters) or water. Thebicarbonate of soda solution is to be added untilthe evidence of reaction (foaming) as ceased. Theresulting liquid is to be flushed with water andthe area dried.

Lead-acid batteries present a risk of firebecause they generate hydrogen gas. The fol-lowing procedures are to be followed:

• DO NOT SMOKE when near the battery;• DO NOT cause flame or spark in battery area; and• Discharge static electricity from body before touch-

ing the battery by first touching a grounded metalsurface.

Be sure the AUTO/OFF/MANUAL switch is set tothe OFF position before connecting the batterycables. If the switch is set to AUTO or MANUAL,the generator can crank and start as soon asthe battery cables are connected.

2.5 BEFORE INITIAL START-UPBefore starting the generator, complete the fol-lowing:1. Set the generator's main circuit breakers (located

in generator’s control panel) to their OFF orOPEN positions by pulling the reset buttons out-ward. A visible GREEN stripe should appear.

2. Set the generator's AUTO/OFF/MANUAL Switch tothe OFF position.

3. Turn OFF all loads connected to the PowerTransfer Monitor through the GFCI outlets.

4. Check the engine crankcase oil level and, if nec-essary, fill to the dipstick full mark with the rec-ommended oil. Do not fill above the oil FULLmark.

5. Check the fuel supply. Both tanks should be full.6. The changeover valve tank indicator should be

GREEN.

2.5.1 INITIAL START UP - PURGING THEFUEL SYSTEM

To purge the air that is in the lines of the fuelsystem, perform the following:1. Connect the LP tanks and open both tank valves.

Make sure that the selector lever on thechangeover regulator is pointing at one of the twotanks. Also verify that the Full/Empty indicator ontop of the changeover regulator is GREEN.

2. Set the generator's main circuit breakers to theirOFF or OPEN positions by pulling the reset but-tons outward. A visible Green stripe shouldappear.

3. Move the AUTO/OFF/MANUAL switch to the MAN-UAL position.

!

!

!

DANGER



4. The engine will crank and attempt to start forapproximately 15 seconds. Due to the air that willbe in the fuel lines, the engine may not start dur-ing the first 15 second cranking cycle. If theengine does not start during the first crank cycle,it will rest for approximately 15 seconds and thenattempt to start again. The complete startingcycle is as follows:

• 15 seconds ON• 15 seconds OFF• 7 seconds ON• 7 seconds OFF• Repeat for 45 seconds, Approximately 90 sec-

onds total. The engine should start during thefirst or second attempt.

5. If the unit does not start during this crank cycle,verify that all fuel connections are tight and thatthe tank valves are open. Turn theAUTO/OFF/MANUAL switch to the OFF position,wait 3-5 seconds, then repeat steps 3-4.

6. If the engine does not start after repeating steps3-4, contact the nearest Generac AuthorizedService Dealer for assistance.

2.5.2 CHECKING AUTOMATIC OPERATIONTo check the system for proper automatic operation,proceed as follows:

1. Set the generator's main circuit breakers to theirOFF or OPEN positions by pulling the reset but-tons outward. A visible GREEN stripe shouldappear.

2. Check that the AUTO/OFF/MANUAL switch is setto OFF.

3. Turn ON the utility power supply to the PowerTransfer Monitor by plugging the 6-foot sensingcord into a standard household outlet.

4. Set the generator's main circuit breakers to theirON or CLOSED position by pressing in the resetbuttons.

5. Set the AUTO/OFF/MANUAL switch to AUTO, thesystem is now ready for automatic operation.

6. Turn off the utility power supply to the PowerTransfer Monitor by unplugging it’s 6-foot powercord from the household outlet.

Once the Power Transfer Monitor senses the utilitysource power is turned OFF, and after an approxi-mate five second delay, the engine should crank andstart. After starting, the Power Transfer Monitorshould connect load circuits to the standby or gener-ator side. Both sets of GFCI outlets on the PowerTransfer Monitor should have power. Confirm trans-fer of power by depressing the test buttons on bothGFCI outlets. Each one should trip and the indicatorwill illuminate.

With the generator running and power is available tothe GFCI outlets, turn the utility power supply ONonce again by plugging the six foot power cord into astandard household outlet. The following shouldoccur.

• The Power Transfer Monitor should sense thereturn of utility power and transfer the loadsplugged into the SWITCHED GFCI back to the util-ity source. Any loads connected to the STANDBYGFCI will remain powered by the generator until itshuts down. In the event of a real outage, theseloads would be reconnected to the utility.

• About two minutes after re-transfer, the engineshould shut down. However, if the engine was notrun for it's minimum run time based on startingtime, it may run for a longer period of time beforeshutting down. (20 minutes max.)

• The minimum run time is pre-programmed intothe generator micro processor and is provided toensure that the starting battery is fully chargedbefore the engine shuts down. The minimum runtime is based on the time it takes for the engine tocrank and start. For every one second of cranking,the generator will run for 1.5 minutes.

2.6 STOPPING THE GENERATOR1. Turn OFF all electrical loads using the means

provided (such as the generator fs main circuitbreakers).

2. Let generator run at no-load for a few minutes, tostabilize internal engine generator temperatures.

3. Place the AUTO/OFF/MANUAL switch in its OFFposition.

2.7 APPLYING LOADS TO GENERATORWhen applying electrical loads to the generator,observe these guidelines:

Before applying electrical loads, let the generatorstabilize and warm up for a minute or two.DO NOT overload the generator.

2.8 DO NOT OVERLOAD THE GENERATOR

Read the rated wattage/amperage capacity of the gen-erator in GENERATOR data, (see Section 1.6.5).Applying electrical loads in excess of the unit’s ratedcapacity will cause the engine/generator to automati-cally shut down.

To avoid overloading, add up the wattage of all con-nected electrical lighting, appliance, tool and motorloads. This total should not be greater than the gen-erator’s rated wattage capacity.


Section 3 – MaintenanceCENTURION 3500 Home Standby Generator

• Most lighting, appliance, tool and motor loads indi-cate their required watts on their nameplate ordata plate. For light bulbs, simply note the wattagerating of the bulb.

• If a load does not show its rated wattage, multiplythat load’s rated VOLTS times AMPS to obtainWATTS.

• Induction type motors (such as those that run afurnace fan, refrigerator, window air conditioner,etc.) need about 2-1/2 time more watts of power forstarting than for running (for a few seconds duringmotor starting). Be sure to allow for this when con-necting electrical loads to the generator. First, fig-ure the watts needed to start electric motors in thesystem. To that figure, add the running wattages ofother items that will be operated by the generator.

• Do not apply heavy electrical loads for the first twoor three hours of operation.

2.9 PROTECTION SYSTEMS

2.9.1 OVERCRANK — 2 FLASHES OF LEDThis feature prevents the generator from damagingitself when it continually attempts to start and anoth-er problem, such as no fuel supply, prevents it fromstarting. The unit will crank and rest for a preset timelimit. Then, it will stop cranking, and the LED willlight indicating an overcrank failure. The AUTO/OFF/MANUAL switch will need to be set to OFF and thenback to AUTO to reset the generator control board.

NOTE:

If the fault is not repaired, the overcrank featurewill continue to activate.

2.9.1.1 Approximate Crank Cycle Times• 15 seconds ON• 15 seconds OFF• 7 seconds ON• 7 seconds OFF• Repeat for 45 seconds

Approximately 90 seconds total

2.9.2 OVERSPEED — 3 FLASHES OF LEDThis feature protects the generator from damage byshutting it down if it happens to run faster than thepreset limit. This protection also prevents the gener-ator from supplying an output that could potentiallydamage appliances connected to the generator cir-cuit. Please reference Appendix 1, Troubleshooting, ifthis fault occurs.

2.3.3 LOW OIL PRESSURE SWITCH —4 FLASHES OF LED

This switch (Figure 2.2) has normally closed (N.C.)contacts that are held open by engine oil pressureduring cranking and operating. Should oil pressuredrop below a preset level, switch contacts close, andthe engine automatically shuts down. The unit shouldnot be restarted until oil is added. Please referenceAppendix 1, Troubleshooting, if this fault occurs.

2.9.4 HIGH TEMPERATURE SWITCH —5 FLASHES OF LED

This switch (Figure 2.2), which has normally open(N.O.) contacts, is mounted near the oil filter. Thecontacts close if the temperature should exceedapproximately 284° F (140° C), initiating an engineshutdown. Please reference Appendix 1,Troubleshooting, if this fault occurs.

Figure 2.3 — Low Oil Pressure and HighTemperature Switches

2.9.5 UNDERSPEED — 6 FLASHES OF LEDThis feature protects the generator from damage byshutting down if it happens to run slower than thepreset limit. Please reference Appendix 1,Troubleshooting, if this fault occurs.

2.9.6 FIELD BOOSTThe Controller Circuit Board houses a field boostdiode and resistor. These two components are part ofa “field boost” circuit (Figure 2.4). During enginecranking only, a positive DC (battery) voltage is deliv-ered through the diode, resistor, brushes and sliprings, to the generator rotor. Application of this volt-age to the rotor “flashes the field” whenever it is start-ed. Flashing of the field each time the generator startsmakes sure that a sufficiently strong magnetic field isavailable to produce “pickup” voltage in the statorwindings.

High Temperature Switch

Low Oil PressureSwitch

✧



Figure 2.4 — Field Boost Circuit

2.9.7 OVERVOLTAGE PROTECTIONA solid-state voltage regulator (Figure 2.5) controlsthe generator’s AC output voltage. This regulator sup-plies an excitation current to the rotor. By regulatingthe rotor’s excitation current, the strength of its mag-netic field is regulated and, in turn, the voltage deliv-ered to connected electrical loads is controlled. Whenthe AC frequency is 60 Hertz, voltage is regulated at120 volts (voltage-to-frequency ratio is 2-to-1).

Figure 2.5 — Solid State Voltage Regulator

The voltage regulator also incorporates a “voltagesurge protection circuit”. This circuit prevents trou-blesome surges in the generator AC output voltage.Voltage surge is a common cause of damage to elec-tronic equipment.

2.10 ADDITIONAL INFORMATION

2.10.1 BREAK-IN PERIODThe first few hours of operation is the break-in peri-od for the generator. Properly breaking in the genera-tor is essential to minimize fuel consumption andprovide maximum engine performance. During thisbreak-in period, follow this procedure:

• Run the unit at different electrical loads by plug-ging items into the Power Transfer Monitor’s out-lets. This will help seat the engine piston ringsproperly.

• Check the engine oil level frequently. Add oil ifneeded. It is normal for the generator engine toconsume more oil than is normal until the pistonrings have properly seated.

• After operating the unit for the break-in period,complete the tasks recommended under Section2.10.2.

2.10.2 POST BREAK-IN CHECK-UPAfter the break-in period, the owner should performthe following maintenance items:

• Change the engine crankcase oil and oil filter.• Check the oil level.• Inspect the cooling and ventilation openings.• Check the engine ignition system.• Inspect the entire electrical system.• Inspect the engine exhaust system.

2.10.3 ATTENTION REQUIRED AFTER SUBMERSION

If the generator has been submerged in water, itMUST NOT be started and operated. Following anysubmersion in water, have a Generac/CenturionAuthorized Service Dealer thoroughly clean and drythe generator.

2.10.4 OPERATION IN HIGH GRASS ORBRUSH

Never operate the generator while it is in contact withhigh grass, weeds, brush, leaves or any other com-bustible substance. Such materials can ignite andburn from the heat of the exhaust system. The gener-ator exhaust system becomes extremely hot duringoperation and remains hot for a long time after it hasshut down.

2.10.5 EFFECTS OF MOISTURE AND DIRTKeep the generator set as clean and dry as possible.Protect the unit against excessive dust, dirt, corrosivevapors, etc. Permitting dirt and moisture to accumu-late on generator windings will have an adverse effecton the insulation resistance of those windings.

When moisture is allowed to remain in contact withwindings, some of the moisture will be retained invoids and cracks in the insulation. This causes areduced insulation resistance and will eventuallycause problems. Dirt will make the problem worse,since dirt tends to hold moisture in contact withwindings. Salt (as from sea air) also will worsen theproblem since it tends to absorb moisture from theair. Salt and moisture, when combined, form an elec-trical conductor which is detrimental to the genera-tor.

CONTROLLERCIRCUITBOARD

CLOSEST TOBEARING

FIELD

4

O FGRND


3.1 CHECKING THE ENGINE OILLEVEL

For oil capacities and requirements, see “Engine OilRequirements,” Section 1.6.3. Check the enginecrankcase oil level weekly. To check the engine oillevel, proceed as follows (see Figure 3.1):

1. Remove the oil fill/dipstick cap and wipe the dip-stick dry with a clean, lint-free cloth.

2. Install and tighten the oil fill/dipstick cap; then,remove it again. The oil level should be at the dip-stick “Full” mark.

3. If necessary, slowly add oil until it reaches thedipstick “FULL” mark. DO NOT FILL ABOVETHE “FULL” MARK.

Never operate the engine with the oil levelbelow the “Add” mark on the dipstick. Doingthis could damage the engine.

4. Install and tighten the oil fill/dipstick cap beforeoperating the engine.

3.2 CHANGING THE ENGINE OILAND/OR OIL FILTER

• Change the engine oil after the break-in period,(see Section 2.10.1). Thereafter, change oil everytwelve months. Change the oil more frequently ifunit operates during extended power outages ofseveral days at a time, in dusty conditions or athigh ambient temperatures.

• Change the engine oil filter after the break-in peri-od, and every twelve months thereafter.

To change the oil and/or oil filter, proceed as follows(see Figure 3.1):

1. Run the engine until it is thoroughly warmed up(at least five minutes) then shut OFF the engine.

2. Immediately after the engine shuts OFF, removethe plug from the tube with a 5/16” allen wrenchand drain the oil into a suitable container.Loosening the oil fill/dipstick cap will allow thecrankcase to drain faster.

3. After the oil has drained, replace the plug ontothe end of the oil drain tube.

4. With the oil drained, remove the old oil filter byturning it counterclockwise. Place a towel under-neath to catch excess oil.

5. Apply a light coating of clean engine oil to the gas-ket of the new filter. Fill the filter until saturatedwith clean oil.

6. Screw the new filter on by hand until its gasketlightly contacts the oil filter adapter. Then, tight-en the filter an additional 3/4 to one turn.

7. Remove the oil fill/dipstick cap and wipe the dip-stick dry with a clean, lint-free cloth. This will beused later to check the oil level.

8. Slowly add the proper type and amount of rec-ommended oil (see Section 1.6.3). Periodicallyuse the dipstick to check the oil level and contin-ue to fill the crankcase until the oil reaches thedipstick “Full” mark. DO NOT FILL ABOVE THE“FULL” MARK.

9. Install and tighten the oil fill/dipstick cap beforeoperating the engine.

10. Start the engine and check for leaks.NOTE:

Check the oil level and fill to the “FULL” markafter checking for leaks. The filter will retain someoil.

!


LO

OSEN * PERFORM MORE OFTEN IN DUSTY CONDITIONSINSPECT & CLEANPLUGS EVERY 5000D45110D9723070185072347

IF NECESSARY

5W-30 OR 5W-20

SAE VISCOSITYSAE 30 OR 10W-30

0.8L/0.84QT

HOURS. REPLACE PLUGS

REPLACEMENT INFORMATION

API SERVICE CLASSIFICATION SF, SG OR SHWHEN SERVICE OR PARTS ARE NEEDED IN

THE USA OR CANADA, CONTACT THE GENERACSERVICE LOCATOR AT 1-800-333-1322.

TEMPERATURE40˚F AND HIGHER

-20˚F TO 40˚F

SPARK PLUGS:

OIL FILTER P/N:

PREFILTER P/N:AIR FILTER P/N:

SPARK PLUG P/N:OIL CAPACITY WITH FILTER:

S E R V IC E A C C E S S P A N E L

GENERATOR SHUTDOWNINFORMATION SYSTEM

CHECK DAILY

CHANGE EVERY 100

EVERY 100 HOURS.REPLACE ELEMENTEVERY 250 HOURS.

HOURS. (OR ANNUALLY)

CLEAN PREFILTER

MAINTENANCE SCHEDULE

LOW OIL PRESSURE

6 FLASHES = UNDERSPEED

OIL & OIL FILTER:

LOCATED BEHIND PANEL

OIL LEVEL:

*AIR FILTER:

FAULTSIGNAL2 FLASHES =3 FLASHES =

5 FLASHES =4 FLASHES =

OVERCRANKOVERSPEED

HIGH OIL TEMP }

*

*

*

MANUALSEE OWNERS

FOR FURTHEREXPLANATION

PULL TO DISCONNECTGENERATOR POWER

CONTROL CENTER

AUTODETAILS OFFSEE CHARTBELOW FOR

DOWN

INDICATOR

SHUT

MAN.

GREEN BAR INDICATES TRIPPUSH TO RESET

GENERATORPOWERFUSE

7.5A

Figure 3.1 – Oil Maintenance Features

Dipstick & Oil Fill

Oil Drain(Underneath)

Oil Filter


3.3 MAINTAINING THE ENGINE AIRCLEANER

3.3.1 CLEANING THE FOAM PRECLEANERClean and re-oil the foam precleaner every sixmonths. Service the foam precleaner more frequent-ly if operating the generator in extremely dusty ordirty conditions. Use the following procedure (Figure3.2):

Figure 3.2 — Engine Air Cleaner

1. Turn the two screws counterclockwise to loosen.2. Remove the cover, foam precleaner and paper fil-

ter.3. Remove the foam precleaner from the cover.4. Wash the foam precleaner in liquid detergent and

water.5. Wrap the foam precleaner in a clean cloth and

gently squeeze it dry.6. Saturate the foam precleaner in clean engine oil.

Gently squeeze it in a clean cloth to removeexcess oil and to distribute oil (DO NOT TWIST).

7. Install the foam precleaner into the cover, fol-lowed by the paper filter.

8. Install the cover, foam precleaner and paper filter.9. Tighten the two screws to retain the filter in place.

3.3.2 CLEANING OR REPLACING THE PAPERFILTER

Once each year or more frequently if operating indirty or dusty conditions, clean or replace the paperfilter. The new replacement filter must be flame retar-dant. Service the paper filter more frequently if oper-ating the generator in extremely dusty or dirty condi-tions. Use the following procedure (Figure 3.2):

1. Follow steps 1-3 in Section 3.3.1; service thefoam precleaner if necessary.

2. Remove the paper filter.3. Clean the air filter by tapping it gently on a solid

surface. If the filter is too dirty, replace it with anew one. Dispose of the old filter properly.

4. Clean the air cleaner cover then reassemble fol-lowing steps 7-9 in Section 3.3.1.

3.4 CLEAN AIR INTAKEClean all foreign material from the air intake (Figure3.3) at least once every six months. Clean more oftenif necessary.

Inspect the area around the generator periodicallyand remove all grass, leaves, etc., from area.

Figure 3.3 — Cleaning Air Intake

3.5 CHECKING THE ENGINE SPARKPLUG

Clean the spark plug and reset the spark plug gapannually. Replace spark plug when the electrodeshave worn to the point where the proper gap cannotaccurately be set, or if the insulation is cracked.

1. Clean the area around the base of the spark plugto keep dirt and debris out of the engine. Removethe spark plug and check the condition. Replacethe spark plug if worn or if reuse is questionable.

2. Clean spark plug by scraping or washing using awire brush and commercial solvent. Do not blastthe spark plug to clean.

3. Check the spark plug gap using a wire feelergauge. Adjust the gap to 0.030 inch (0.76 mm) bycarefully bending the ground electrode (Figure3.4).

Figure 3.4 — Setting the Spark Plug Gap

USTCUSTC



Sparking can occur if the wire terminal doesnot fit firmly on the spark plug terminal end. Ifnecessary, re-form the wire terminal to obtain atight fit.

3.6 CLEAN SPARK ARRESTORThe engine exhaust muffler has a spark arrestorscreen. Inspect and clean the screen at least onceeach year.

NOTE:

If using the generator on any brush-covered orgrass-covered unimproved land, it must equippedwith a spark arrestor. The spark arrestor must bemaintained in good condition by the owner.

Clean and inspect the spark arrestor as follows:

• Remove the screen retaining bracket by removingthe screw (Figure 3.5).

• Slide the spark arrestor screen out from theexhaust pipe.

• Inspect screen and replace if torn, perforated orotherwise damaged. DO NOT USE a defectivescreen. If screen is not damaged, clean it with com-mercial solvent.

• Replace the screen and the retaining bracket.Reinstall screw.

Figure 3.5 — Spark Arrestor

3.7 CLEANING THE GENERATORKeep the generator set as clean and dry as possible.Protect the unit against excessive dust, dirt, corrosivevapors, etc. Permitting dirt and moisture to accumu-late on generator enclosure reduces the effectivity ofthe power-coat paint to maintain color and appear-ance.

Do NOT use a forceful spray of water to cleanthe generator. Water will enter the generatorinterior and cause problems, and may alsocause corrosion of brackets and linkage on thegenerator.

3.7.1 CORROSION PROTECTIONPeriodically wash and wax the generator enclosureusing automotive type products. Frequent washing isrecommended in salt water/coastal areas. Sprayengine linkage, steel brackets and fasteners with alight oil such as WD-40®.

3.8 BATTERY MAINTENANCEAll lead-acid batteries will discharge when not in use.The generator battery should be inspected as follows:

3.8.1 EVERY SIX MONTHS• Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.• Check the battery fluid level of unsealed batteries

and, if necessary, fill with Distilled Water Only. Donot use tap water in batteries.

• Have the state of charge and condition checked.This should be done with an automotive-type bat-tery hydrometer if battery is not a maintenancefree type.

NOTE:

Servicing of the battery is to be performed orsupervised by personnel knowledgeable of batter-ies and the required precautions. Keep unautho-rized personnel away from batteries. Damage willresult if the battery connections are made inreverse.

Do not dispose of the battery in a fire. The bat-tery is capable of exploding. Storage batteriesgive off explosive hydrogen gas. This gas canform an explosive mixture around the batteryfor several hours after charging. The slightestspark can ignite the gas and cause an explo-sion. Such an explosion can shatter the batteryand cause blindness or other injury. Any areathat houses a storage battery must be properlyventilated. Do not allow smoking, open flame,sparks, or any spark producing tools or equip-ment near the battery. Discharge static electrici-ty from body before touching the battery byfirst touching a grounded metal surface.

A battery presents a risk of electrical shock andhigh short circuit current. The following precau-tions are to be observed when working on bat-teries:

• Remove watches, rings or other metal objects;• Use tools with insulated handles;• Wear rubber gloves and boots;• Do not lay tools or metal parts on top of the bat-

tery;

DANGER

!

RETAINING SCREW P/N 056892

SPARK ARRRESTORSCREEN P/N 089680

EXHAUST PIPEP/N 0E2138

!



• Disconnect any charging source prior to connectingor disconnecting battery terminals; and

• Do not use any jumper cables or booster battery tocrank and start the generator engine. If any bat-tery has discharged, remove it for recharging.

Do not open or mutilate the battery. Releasedelectrolyte has been known to be harmful tothe skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that isharmful to the skin and eyes. It is electricallyconductive and corrosive. The following proce-dures 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 thor-

oughly and immediately with water and seek med-ical attention; and

• Spilled electrolyte is to be washed down with anacid neutralizing agent. A common practice is touse a solution of 1 pound (500 grams) bicarbonateof soda to one gallon (4 liters) or water. The bicar-bonate of soda solution is to be added until theevidence of reaction (foaming) has ceased. Theresulting liquid is to be flushed with water and thearea dried.

3.9 EXERCISING THE GENERATORGenerac recommends that this unit be exercised atleast once every seven days. This generator systemdoes not have an automatic exerciser or a utility fedbattery charger. The unit must be manually startedand run in order to charge the starting battery andfully lubricate the engine. It is imperative that the bat-tery be fully charged in the event of a power outage toensure that the generator starts automatically.Couple the exercising of the generator along withanother task or activity that is done once a week.

3.9.1 TO EXERCISE THE GENERATOR:• Make sure the AUTO/OFF/MANUAL switch located

on the generator control panel is set in the AUTOposition, and then depress and hold the EXER-CISE switch located on the Power TransferMonitor for about ten seconds.

• The engine will start to crank and the unit will thenstart.

• The unit will exercise for an amount of time that ispredetermined by the time that it takes for the gen-erator to crank and start. The unit will exerciseapproximately 1.5 minutes for every second thatthe starter motor cranks during engine start-up.The unit will run for a minimum of two minutesand a maximum of 20 minutes based on the cranktime.

IMPORTANT: The generator power outlet located onthe Power Transfer Monitor will be "LIVE" during thisexercise cycle.

• After the generator completes its predeterminedexercise cycle, the unit will enter a cool down cyclethat will last approximately two minutes.

• The generator will then shut down, and the unitwill return to automatic operation.

3.10 OUT OF SERVICE PROCEDURE

3.10.1 REMOVAL FROM SERVICEIf unable exercise the generator every seven days, ordo not require the generator's services for an extend-ed period of time, please prepare the generator as fol-lows:

1. Start the engine and let it warm up.2. Close the fuel shutoff valves on both propane

tanks and allow the unit to shut down.3. While the engine is still warm from running,

drain the oil completely. Refill the crankcase withSAE 10W-30 oil having API classification “ForService SF.”

4. Attach a tag to the engine indicating the viscosityand classification of the oil in the crankcase.

5. Remove the spark plug and pour two or threetablespoons of clean, fresh engine oil into thespark plug threaded openings. Reinstall andtighten the spark plug.

6. Disconnect battery cables (negative NEG or (—)first). Remove the battery and store it in a cool,dry room on a wooden board. Never store the bat-tery on any concrete or earthen floor.

7. Clean and wipe the entire generator.

3.10.2 RETURN TO SERVICETo return the unit to service after storage, proceed asfollows:

1. Check the tag on the engine for oil viscosity andclassification. Verify that the correct recommend-ed oil is used in the engine (see Section 1.6.3). Ifnecessary, drain and refill with the proper oil.

2. Check the state of the battery. Fill all cells ofunsealed batteries to the proper level with dis-tilled water. DO NOT USE TAP WATER IN THEBATTERY. Recharge the battery to 100 percentstate of charge, or, if defective, replace the battery.

3. Clean and wipe the entire generator.4. Reconnect the battery (positive POS or (+) first).

Observe battery polarity. Damage may occur if thebattery is connected incorrectly.

5. Unplug any items plugged into the PowerTransfer Monitor’s GFCI outlets.

!

!



6. Start the unit by depressing and holding theEXERCISE switch on the Power Transfer Monitorfor about ten seconds. Allow the unit to run forexercise cycle.

7. Re-plug items needing protection back into thePower Transfer Monitor’s switched GFCI outlet.

8. The generator is now ready for service.

3.11 ADJUSTING VALVE CLEARANCEAfter the first six months, adjust the valve clearancein the engine.

When adjusting valve clearance, the engine should beat outdoor ambient temperature and the pistonshould be at Top Dead Center (TDC) of its compres-sion stroke (both valves closed). Correct clearance is0.001-0.003 inch (0.03-0.07mm). Adjust valve clear-ance as follows:

1. Loosen the rocker arm jam nut. Use an allenwrench to turn the pivot ball stud while checkingclearance between the rocker arm and the valvestem with a feeler gauge (Figure 3.6).

Figure 3.6 — Adjusting Valve Clearance

2. When valve clearance is correct, hold the pivotball stud with the allen wrench and tighten therocker arm jam nut with a crows foot. Tighten thejam nut to 65-85 inch-pounds torque. After tight-ening the jam nut, recheck valve clearance tomake sure it did not change (Figure 3.7).

Figure 3.7 — Tightening Jam Nut

3.12 GENERATOR SERVICE INTERVALCENTURION 3500

Annually ................................Clean Spark Arrestor

Annually..............................Change Engine Oil/filter

Every Six Months........................Clean Air Pre-filter

Annually....................................Inspect Spark Plugs

Annually................Replace Paper Air Filter Element

As Needed ................................Replace Spark Plugs1st Six Months

Annually ..............................Adjust Valve Clearance



PART II –INSTALLATIONINSTRUCTIONS

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!

DANGER


IMPORTANT SAFETY INSTRUCTIONSCENTURION 3500 Home Standby Generator

Study these SAFETY RULES carefully beforeinstalling, operating or servicing this equipment.Become familiar with this manual and with the unit.The generator can operate safely, efficiently and reli-ably only if it is properly installed, operated andmaintained. Many accidents are caused by failing tofollow simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possiblecircumstance that might involve a hazard. The warn-ings in th is manual, and on tags and decals affixedto the unit, are, therefore, not all-inclusive. If using aprocedure, work method or operating techniqueGenerac does not specifically recommend, satisfyyourself that it is safe for others. Also make sure theprocedure, work method or operating technique thatchosen does not render the generator unsafe.

Despite the safe design of this generator, oper-ating this equipment imprudently, neglectingits maintenance or being careless can causepossible injury or death. Permit only responsi-ble and capable persons to operate or maintainthis equipment.

Potentially lethal voltages are generated bythese machines. Ensure all steps are taken torender the machine safe before attempting towork on the generator.

Parts of the generator are rotating and/or hotduring operation. Exercise care near runninggenerators.

GENERAL HAZARDS• For safety reasons, Generac recommends that the

maintenance of this equipment is carried out by aGenerac Authorized Service Dealer.

• The generator engine releases DEADLY carbonmonoxide gas through its exhaust system. Thisdangerous gas, if breathed in sufficient concentra-tions, can cause unconsciousness or even death.Never operate the generator inside any garage orother enclosed area. DO NOT OPERATE THEGENERATOR IF THE EXHAUST SYSTEM ISLEAKING OR HAS BEEN DAMAGED. SYMPTOMSOF CARBON MONOXIDE POISONING ARE (a)inability to think coherently, (b) nausea, (c) vomit-ing, (d) twitching muscles, (e) throbbing temples,(f) dizziness, (g) headaches, (h) weakness, and (i)sleepiness. IF EXPERIENCING ANY OF THESESYMPTOMS, MOVE INTO FRESH AIR IMMEDI-ATELY. IF SYMPTOMS PERSIST, GET MEDICALHELP. Shut down the generator and do not operateit until it has been inspected and repaired.

• The engine exhaust fumes contain carbon monox-ide, which can be DEADLY. This dangerous gas, ifbreathed in sufficient concentrations, can causeunconsciousness or even death. This exhaust sys-tem must be installed properly, in strict compliancewith applicable codes and standards. Followinginstallation, do nothing that might render the sys-tem unsafe or in noncompliance with such codesand standards. Never operate this equipment witha leaking or defective exhaust system.

• Keep hands, feet, clothing, etc., away from drivebelts, fans, and other moving or hot parts. Neverremove any drive belt or fan guard while the unit isoperating.

• Adequate, unobstructed flow of cooling and venti-lating air is critical to correct generator operationand is required to expel toxic fumes and fuelvapors from the generator. Without sufficient cool-ing airflow, the engine/generator overheats, whichcauses serious damage to the generator. Do notalter the installation or permit even partial block-age of ventilation provisions, as this can seriouslyaffect safe operation of the generator.

• When working on this equipment, remain alert atall times. Never work on the equipment whenphysically or mentally fatigued.

• Inspect the generator regularly, and contact thenearest Generac Authorized Service Dealer imme-diately for parts needing repair or replacement.

• Before performing any maintenance on the genera-tor, disconnect its battery cables to prevent acci-dental start up. Disconnect the cable from the bat-tery post indicated by a NEGATIVE, NEG or (–)first. Reconnect that cable last.

!!

!

!

DANGER

SAVE THESE INSTRUCTIONS – This manual contains important instructions that should be fol-lowed during installation and maintenance of the generator and batteries.

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operationbe copied and posted in potential hazard areas near the generator set. Safety should be stressedto all operators and potential operators of this equipment.

!

! !

!

The engine exhaust from this productcontains chemicals known to the state

of California to cause cancer, birthdefects or other reproductive harm.

WARNING:! !

This product contains or emits chemicalsknown to the state of California to cause

cancer, birth defects or other reproductive harm.

WARNING:! !


IMPORTANT SAFETY INSTRUCTIONSCENTURION 3500 Home Standby Generator

• Inspect the generator regularly, and promptlyrepair or replace all worn, damaged or defectiveparts using only factory-approved parts.

• Before performing any maintenance on the genera-tor, disconnect its battery cables to prevent acci-dental start-up. Disconnect the cable from the bat-tery post indicated by a NEGATIVE, NEG or (–)first. Reconnect that cable last.

• Never use the generator or any of its parts as astep. Stepping on the unit can stress and breakparts, and may result in dangerous operating con-ditions from leaking exhaust gases, fuel leakage,oil leakage, etc.

ELECTRICAL HAZARDS• All generators covered by this manual produce dan-

gerous electrical voltages and can cause fatal elec-trical shock. Utility power delivers extremely highand dangerous voltages to the transfer switch aswell as the standby generator. Avoid contact withbare wires, terminals, connections, etc., on the gen-erator as well as the transfer switch, if applicable.Ensure all appropriate covers, guards and barriersare in place before operating the generator. If workmust be done around an operating unit, stand onan insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device whilestanding in water, while barefoot, or while handsor feet are wet. DANGEROUS ELECTRICALSHOCK MAY RESULT.

• If people must stand on metal or concrete whileinstalling, operating, servicing, adjusting or repair-ing this equipment, place insulative mats over adry wooden platform. Work on the equipment onlywhile standing on such insulative mats.

• The National Electrical Code (NEC), Article 250requires the frame and external electrically con-ductive parts of the generator to be connected to anapproved earth ground and/or grounding rods.This grounding will help prevent dangerous elec-trical shock that might be caused by a ground faultcondition in the generator set or by static electric-ity. Never disconnect the ground wire.

• Wire gauge sizes of electrical wiring, cables andcord sets must be adequate to handle the maxi-mum electrical current (ampacity) to which theywill be subjected.

• Before installing or servicing this (and related)equipment, make sure that all power voltage sup-plies are positively turned off at their source.Failure to do so will result in hazardous and pos-sibly fatal electrical shock.

• Connecting this unit to an electrical system nor-mally supplied by an electric utility shall be bymeans of a transfer switch so as to isolate the gen-erator electric system from the electric utility dis-tribution system when the generator is operating.Failure to isolate the two electric system powersources from each other by such means will resultin damage to the generator and may also result in

injury or death to utility power workers due tobackfeed of electrical energy.

• Generators installed with an automatic transferswitch will crank and start automatically whenNORMAL (UTILITY) source voltage is removed oris below an acceptable preset level. To preventsuch automatic start-up and possible injury to per-sonnel, disable the generator’s automatic start cir-cuit (battery cables, etc.) before working on oraround the unit. Then, place a “Do Not Operate”tag on the generator control panel and on thetransfer switch.

• In case of accident caused by electric shock,immediately shut down the source of electricalpower. If this is not possible, attempt to free thevictim from the live conductor. AVOID DIRECTCONTACT WITH THE VICTIM. Use a noncon-ducting implement, such as a dry rope or board, tofree the victim from the live conductor. If the victimis unconscious, apply first aid and get immediatemedical help.

• Never wear jewelry when working on this equip-ment. Jewelry can conduct electricity resulting inelectric shock, or may get caught in moving com-ponents causing injury.

FIRE HAZARDS• Keep a fire extinguisher near the generator at all

times. Do NOT use any carbon tetra-chloride typeextinguisher. Its fumes are toxic, and the liquid candeteriorate wiring insulation. Keep the extinguish-er properly charged and be familiar with its use.Consult the local fire department for any questionspertaining to fire extinguishers.

EXPLOSION HAZARDS• 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 com-bustible materials are left in the generator com-partment, or on or near the generator, as FIRE orEXPLOSION may result. Keep the area surround-ing the generator clean and free from debris.

• Generac generator sets may operate using one ofseveral types of fuels. All fuel types are potentiallyFLAMMABLE and/or EXPLOSIVE and should behandled with care. Comply with all laws regulatingthe storage and handling of fuels. Inspect the unit’sfuel system frequently and correct any leaks imme-diately. Fuel supply lines must be properlyinstalled, purged and leak tested according toapplicable fuel-gas codes before placing this equip-ment into service.

• Gaseous fluids such as liquid propane (LP) gas areextremely EXPLOSIVE. LP gas is heavier than airand settles in low areas; install leak detectorsaccordingly.



NOTE:

THE INSTALLATION SECTION OF THIS MANUALSHOULD NOT BE USED EXCLUSIVELY FOR ALLASPECTS OF INSTALLATION AND OPERATIONOF THE CENTURION UNIT. FAMILIARIZE YOUR-SELF WITH ALL FEATURES AND OPERATION OFTHE UNIT TO ENSURE SAFE USE. PLEASE READALL INFORMATION PRIOR TO INSTALLATIONAND OPERATION OF THE CENTURION EMER-GENCY AUTOMATIC SYSTEM.

1.1 TOOLS REQUIREDDrill, Drill Bits, Hole Saw (type and length will bedetermined by the materials that need drilling andcutting), Open-End Wrenches or AdjustableWrenches, Socket Wrenches or Nut Drivers, Standardand Phillips Screwdrivers, Level, Sledge Hammer,Channel-lock Pliers, Spade Shovel, and SafetyGoggles.

1.2 ITEMS THAT MUST BE PURCHASED

• (2) 20 pound propane tanks. Acceptable tank typesare DOT-4BA240 and DOT-4BW240.

• Grounding rod with grounding strap.• Crushed stone or pea gravel (approximately 8-10

cubic feet).• Black polyfilm or other vegetation blocking fabric

(5-1/2 feet x 3-1/2 feet).• Silicone caulk.• Fasteners (To mount Power Transfer Monitor).

1.3 PLAN THE LOCATION OF THEGENERATOR

Select an area outside of the home near the room thatthe Power Transfer Monitor will be located. It mustbe within two cords combined length (21”) of aninside outlet.

NOTE:

Do not place the generator directly under or nextto a window.

4a

3 ft.

1

2

3


Section 2 – InstallationCENTURION 3500 Home Standby Generator

2.1 SITE PREPARATION AND GENERATOR PLACEMENT

2.1.1 SITE PREPARATION1. Clear an area 5-1/2 feet by 3-1/2 feet of grass and

vegetation to a depth of five inches. This includesthe distance the generator should be set awayfrom a structure (three feet) and six inchesbeyond the width and length of the generatormounting pad (30" L x 24" W).

2. Lay black poly-film to cover the area.3. Fill the area to ground level with pea gravel or

crushed stone.

2.1.2 ATTACH GENERATOR TO MOUNTINGPAD

Place the mounting pad in the exact desired location.Bring the generator, still attached to the shipping pal-let, to the prepared area and place it along side of themounting pad. Remove and discard the two (2) lagscrews that hold the generator to the shipping pallet.Using a minimum of two adults, hold the mountingpad in place, gently slide the generator off of the ship-ping pallet and onto the mounting pad. Align theholes in the generator base with the holes in themounting pad. Use the supplied fasteners to attachgenerator to base (Figure 2.1).

Four Each: 1” long hex head cap screw, lock washerand flat washer.

Figure 2.1 — Attach Generator To Pad

4. Drive an 8-foot grounding rod into the ground tograde.

A. Attach one end of the grounding strap (No. 12AWG stranded copper wire) to grounding rodand the other end to the grounding lug (locatedat rear of unit). Make sure grounding rod andstrap are not exposed above ground level. (NECcode applies to grounding method.)

Figure 2.2 — Grounding Lug

2.2 POWER CORD INSTALLATION

2.2.1 DRILL PASS THROUGH HOLEThe power transfer monitor needs to be located in aposition that is appealing to the homeowner.Recommended locations are underneath or inside akitchen or utility room cabinet, or in a basementwhere access is convenient. The homeowner shouldtest multiple positions to find the most appealingone. It is not recommended that the power transfermonitor be located where water may be present, suchas under a sink.

Determine where the flexible watertight conduit(power cord) will pass through the house from insideto outside (Figure 2.3). When certain there is clear-ance on each side of the wall and within the wall,mark the location. Drill a small pilot hole to aid loca-tion of hole saw. Drill 1-1/4 inch diameter holethrough the wall with hole saw.

Figure 2.3 — Pass Through Hole

2.2.2 FEED POWER CORD OUT TO GENERATOR

From the room inside the home where the PowerTransfer Monitor will be located, feed the end of thepower cord through to outside of exterior wall (Figure2.4). DO NOT connect power cord to generator atthis time.

030795 SCREW HHV 5/16"-18 X 1"

022129 WASHER LOCK 5/16"

022145 WASHER FLAT 3/8"

Grounding Lug



Figure 2.4 — Feed Power Cord

2.2.3 GENERATOR CONNECTIONThe power cord contains five wires with spade termi-nals. These wires are color coded and and labeled foraccurate connection to the generator’s terminal strip.

NOTE:

Generator mode switch should be placed in theOFF position. Generator main circuit breakersshould be placed in the OFF or OPEN position bypulling the reset buttons outward. A visibleGREEN stripe should appear.

1. Remove the four screws that hold the cover platein place at rear of generator. Remove cover plate.

2. Remove lock ring from the coupler on end ofpower cord. Feed wires through cover plate, Sliplock ring over wires and reattach lock ring to cou-pler. Tighten lock ring securely to assure that thecoupler will not loosen during generator opera-tion.

3. Match the wires by color or by label to the match-ing terminal positions on the generator. Place theappropriate spade connectors under the match-ing terminal screws. (See Figure 2.5). Tighten thethe terminal screws securely to prevent arcing.

4. Align cover plate over threaded holes. Reinstalland tighten the four screws that hold the coverplate to back of generator compartment.

Figure 2.5 — Generator Terminal StripConnection

2.3 MOUNT POWER TRANSFER MONITOR

Hold the Power Transfer Monitor in desired locationand mark the mounting holes. The mounting holesare 1/4 inch in diameter. Drill pilot holes. Use twofasteners which are appropriate for the area formounting the Power Transfer Monitor (Figure 2.6).

NOTE:

If mounting on drywall, it is suggested to use a fas-tener that spreads behind the hole for added rigid-ity. This is necessary because of the force that willbe applied when plugging in and unplugging itemsfrom the GFCI outlets.

Figure 2.6 — Mount Power Transfer Monitor

NOTE:

DO NOT plug the six foot sensing cord into stan-dard household outlet at this time.

2.4 INSTALL PROPANE TANKSThis generator has been designed for a specific typeof tank. Acceptable tank types are DOT-4BA240 andDOT-4BW240. Any deviation in tank type may notallow the tank to fit in the LP enclosure.

Slide the latches on the top of the mesh panel down-ward. Tilt the panel toward you and lift out The tankhold down brace is held in place by a large wingnut.Loosen the wingnut to allow the brace to face per-pendicular to the opening of the tank enclosure.

Tilt the top of the first tank toward you so the bottomof the tank enters the compartment first. Set the ringon the bottom of the tank into the recessed area ofthe tank tray. Place tank in upright position in thetank compartment. Repeat this process for secondtank.

Position tanks so that the tank hold down brace canbe brought down on top of tank flanges and flangesslip into grooved areas of brace.

170

NL2

L1 RED

WHITEBLACK

BLUE

GREEN



The changeover regulator needs to be placed at aheight such that the inlet hoses are located even withor above the cylinder valves on the LP tanks. This willprevent LP vapor from condensing in the LPchangeover regulator and possibly damaging the fuelsystem.

Tighten the wingnut securely to prevent vibrationwhen the generator is running.

Connect the fuel lines by carefully threading the OPD(Overflow Protection Device) valves onto the tanks.Make sure the valve is not cross-threaded which willcause leaking. Open the valves on both tanks andswab connections with soapy water to detect anyleaks. Be careful not to crimp the power cord whenthe power transfer monitor is in it’s final position.

If a leak is detected in the system near the green swiv-el connector, there is a possibility that the flare fittinginside the tank valve has been damaged during thetank filling process. To inspect the fitting, turn off thetank valve and visually inspect the flare fitting tomake sure that there are no scratches, dents or marson the surface of the flare. If there are visible defectsin the flare fitting of the tank, a new tank must beused.

To assure that the hose does not kink, rub against thetanks or the enclosure, it is important to note the ori-entation of the valve on the tank. It should always bepointing towards the front of the cabinet. Do notallow the hose to kink or rub on the tank (Figure 2.7).

Figure 2.7 — Overhead View of LP Tank

On the propane tank changeover valve, move theblack selector lever to the left or to the right to desig-nate which tank will be the primary or service cylin-der (tank). That tank will supply fuel to the generatorfirst. When the lever is moved to a position an indi-cator will show green. When that tank empties duringgenerator operation the indicator will show red sig-nalling the need to refill the tank. The generator willstart drawing from the reserve cylinder. Thechangeover feature allows gives the benefit of unin-terrupted fuel flow to the generator.

Prior to disconnecting the service cylinder, rotate theblack lever all the way over towards the reserve cylin-der. (Figure 2.8). DO NOT ATTEMPT TO CHANGETHE LP TANK WITHOUT ROTATING THISLEVER. The full-empty indicator will turn green andthe reserve cylinder becomes the service cylinder.Refill and reinstall the empty cylinder to maintaininterruption free back up power.

For model 254-00, two-stage changeover regu-lator, failure to rotate the black lever all theway over towards the reserve cylinder willallow propane to leak from the disconnect pig-tail. Leaking propane, if ignited, will result in afire that may cause property damage, bodilyinjury or death. REMEMBER: NEVER disconnecta pigtail if the indicator is RED.

IMPORTANT: Only qualified persons should install,adjust or service LP ga regulators. If service is need-ed, contact a qualified LP dealer. Always make surecylinders are properly filled and never accept cylin-ders that are over filled. When replacing newly filledcylinders to the regulator, check all connections forleaks with an approved leak detector solution or amixture of non-ammonia soap and water. Never usematches or an open flame.

NOTE:

Low pressure regulators are designed to regulateLP vapor only.

Figure 2.8 – LP Tank Changeover Valve

DANGER

Selector Lever

Full/EmptyIndicator Window

Green - FullRed - Empty


2.5 SET SYSTEM FOR AUTOMATICOPERATION

Make sure the valves on both of the filled propanecylinders are open.

At this time, plug the six foot sensing cord into a stan-dard 120V household outlet. This will allow thePower Transfer Monitor to sense the utility powerfeed. Plug desired items into the SWITCHED GFCIoutlet on the Power Transfer Monitor. This outlet ispowered when utility power is available and when thegenerator is operating during a utility power outage.

Place the generator main circuit breakers to their ONor CLOSED position by pressing in the reset buttons.The GREEN indicator stripe should no longer be evi-dent.

Place the generator mode switch, which is located onthe generator control panel, in the AUTO position.

The system is now set for automatic operation.

2.6 HOW TO KEEP THE REGULATOROPERATING EFFICIENTLY & SAFELY

The regulator is equipped with a vent which a

Documents

Owner’s Manual and Installation Instructions · 2016. 2. 16. · RION product line by Generac Power Systems Inc. This model is designed and manufactured to supply electrical power