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Generac Power Systems 1.6L 18 kW manual

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Table of contents for the manual

  • Page 1

    ST ANDBY GENERA T OR O WNER'S MANU AL This manual should remain with the unit. A ne w standar d of reliability Serial Number 1.6L 18 kW Models   N ot i nt ended for us e i n c r i t i c al l i f e s uppor t appl i c at i ons.  ONL Y QU ALIFIED ELECTRICIANS OR CONTRA CT ORS SHOULD A TTEMPT INST ALLA TION! DEADL Y EXHA UST FUMES. OUTDOO[...]

  • Page 2

    Standby Generator Sets T able of Contents SECTION P AGE SAFETY RULES ................................................ 1-1 INTRODUCTION ..................................................... 1-3 Read this Manual Thoroughly ................................... 1-3 Operation and Maintenance ...................................... 1-3 How to Obtain Servic[...]

  • Page 3

    Study these SAFETY RULES carefully before install- ing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely , efficiently and reli- ably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental ru[...]

  • Page 4

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

  • Page 5

    1-3 I NTRODUCTION Thank you for purchasing this model of the standby generator set product line. Every effort was expended to make sure that the information and instructions in this manual were both accurate and current at the time the manual was written. However , the manufacturer reserves the right to change, alter or otherwise improve this produ[...]

  • Page 6

    I DENTI F ICA TION REC ORD D A T A LA BE L Every generator set has a DA T A LABEL that contains important information pertinent to the generator . The data label, which can be found attached to the gen- erator’s lower connection box, lists the unit ’s serial number and its rated voltage, amps, wattage capacity , phase, frequency , rpm, power fa[...]

  • Page 7

    E QUIPM ENT DE SCRI PTION This equipment is a revolving field, alternating cur - rent generator set. It is powered by a gaseous fueled engine operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for 2-pole direct drive units and 2300 - 3000 rpm for quiet drive gear units. See the Specifications section for exact numbers. The unit comes com[...]

  • Page 8

    ENGI N E P RO TECTIVE DEVICE S The standby generator may be required to operate for long periods of time without an operator on hand to monitor such engine conditions as coolant tempera- ture, oil pressure or rpm. F or that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shuttin[...]

  • Page 9

    F U E L SYST E M FUE L RE QUIRE MEN T S The standby generator may be equipped with one of the following fuel systems: • Natural gas fuel system • Propane vapor (PV) fuel system The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type of fuel system installed on the uni[...]

  • Page 10

    SP E CI F ICA TIONS GEN ERA T OR T ype ............................................................................. Synchronous Rotor Insulation .................................................................... Class F Stator Insulation ................................................................... Class F T otal Har monic Distor tion ....[...]

  • Page 11

    COLD WEA THER KIT F or cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: • Battery W armer • 4” Junction Box with hardware • 6 qt. pack 5W -30 synthetic oil (engine) R E C ON FIGU R I NG TH E FU EL SY S TEM NOTE: All models are configured to run on natural gas from the factory . T o reconfigure [...]

  • Page 12

    GEN ER A T OR AC LEAD C ONN ECTIONS See “V oltage Codes”. This generator may be rated at any one of three voltages, either single -phase or three -phase. The electrical wires in the unit ’s AC con- nection (lower) panel should be installed according to the number of leads and the voltage/phase required for the application. If there are any qu[...]

  • Page 13

    I NS T ALLA TION Refer to the separate “Installation Guide” supplied with the unit. P R EP AR A TION B EFOR E ST ART -UP The instructions in this section assume that the standby generator has been properly installed, ser - viced, tested, adjusted and otherwise prepared for use by a competent, qualified installation contractor . Be sure to read [...]

  • Page 14

    • Battery charger connection to 120 V AC. • Communication wires connected between transfer switch and generator (HTS only). • Unit secured to pad. S T ART -U P CH E CKLIS T  Before working on the generator , ensure the fol- lowing: • The AUTO/OFF/MANU AL switch is in the OFF position. • The 120V AC supply to the battery charger is swit[...]

  • Page 15

    GEN ER A T OR CONTROL AND OP ER A TION Refer to the appropriate control panel operator’s manual for this unit. OP ER A TING U N IT WITH MAN UAL TR ANSF ER SWIT CH If the generator was installed in conjunction with a transfer switch capable of manual operation only , the following procedure applies. A manually operated transfer switch is one that [...]

  • Page 16

    MAI NTENANCE P ER FOR M ED B Y SERVICE F ACI LITIES  Before working on the generator , ensure the fol- lowing: The AUTO/OFF/MANU AL switch is in the OFF position. The 15A fuse has been removed from the con- trol box. The 120V AC supply to the battery charger is switched OFF . EVER Y TH R EE MONTHS 1. Check battery condition. 2. Inspect and test [...]

  • Page 17

    Figure 10.1 - Oil Dipstick and Oil Fill Cap OIL FILL CAP OIL DIPSTICK B A TTE R Y FL UID Check battery electrolyte fluid based on the Maintenance Schedule. Fluid should cover separa- tors in all battery cells. If fluid level is low , add dis - tilled water to cover tops of separators. DO NOT USE T AP W A TER IN BA TTERY . ENGI NE COOLANT Check cool[...]

  • Page 18

    CHANGI NG ENGIN E OI L Refer to maintenance performed by service facilities for engine oil and filter change frequencies. Drain the oil while the engine is still warm from run- ning . This means warm up the engine, shut it down and drain immediately as follows: 1. Remove OIL DRAIN HOSE from its retaining clip. 2. Loosen and remove OIL DRAIN HOSE CA[...]

  • Page 19

    M IS CELL AN E OUS MAI NTENANCE CLEAN ING TH E GEN ER A T OR Keep the generator as clean and as dry as possible. Dirt and moisture that accumulates on internal gen- erator windings have an adverse effect on insulation resistance. P eriodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system o[...]

  • Page 20

    SERVICE S CH EDU LE The following is a recommended maintenance schedule for small standby and residential generator sets. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe applica- t[...]

  • Page 21

    Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly Initials) Break-in Initials) annually Initials) Annually Initials) 10 Hrs. 30 Hrs. 50 Hrs. 100 Hrs. 1. Disable[...]

  • Page 22

    Maintenance Level 1 Level 2 Level 3 Level 4 T asks Recom- T ask Required T ask Required T ask T ask mended Comp . to be done Comp . to be done Comp . Required Comp . to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- monthly In itials) Break-in Initials) annually Initials) Annually Initials) 10 Hrs. 30 Hrs. 50 Hrs. 100 Hrs. 13. Initi[...]

  • Page 23

    TROU B LE SHOO TI NG GU I DE P ROB LEM CAUSE C OR R E CTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defectiv e 2. Tighten, clean or replace battery cables. batter y cables as necessary . 3. Defectiv e star ter contactor . 3. Replace contactor.* 4. Defectiv e star ter motor . 4. Replace star ter motor.* 5[...]

  • Page 24

    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

  • Page 28

    [...]

  • Page 29

    1 0G4827 1 ASSY RTR 104 KD1 HI EF F (18KW) 0 G2927 1 R TR-102-20.0AD1 CPL (2006) (20KW) 0 G2827 1 A SSY RTR 25KW 2P (2006) (25KW) 0G34 51C 1 RTR 1 02 30KD2 (20 06) CPL CHI ( 30KW) 2 0G0820A 1 HOUSING BLOWER LG PILOT 3 0G4452 1 BLOWE R HOUSING SCREE N 4 020746 4 S CREW PPHM M5-0. 8 X 8 ZINC 5 049226 4 WASHE R LOCK M5 6 051713 4 WASHE R FLAT M5 7 022[...]

  • Page 30

    [...]

  • Page 31

    1 N/A N/A UL BREAKER BQ2 A 0D5543 1 CB 0090A 2P 240V S BQ2 LL 0D5544 1 CB 0100A 2P 240V S BQ2 LL 0A2077 1 CB 0125A 2P 240V S BQ2 LL B 0G 44 99 1 CB COVER 20-25K 1P (BQ2) C 0C2265 2 SCREW PHTT M4- 0.7 X 12 ZYC D 0C2264 2 WASHER LOCK # 8-M4 E 0E7890 1 BR KT CB MTG BA CK F 0G4497 1 CIRCUIT BREAKE R SUPPORT (BQ) G 05 2619 2 SCREW HH C M5-0.8 X 20 G8. 8[...]

  • Page 32

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  • Page 33

    C O M PO N EN T S IN CL UD ED IN 0 G 4 5 7 8 E 1 0 F 1 8 2 3A 1 EN C L H SB C O N TR O L P AN EL 2 0F 307 8 1 C OV ER C ON T R O L PA N E L 3 0F 260 6 1 H IN G E C O N T I NU O U S H -P A N E L 4 03 62 6 1 6 R IV E T P O P .1 2 5 X .2 7 5 S S 5 0 E 7 3 5 8 4 SC RE W P PP H H I- L O #4 -24 X 3 /8 6 05 27 7 7 3 W A S H E R F L A T M3 7 0 G 395 8C 1 A[...]

  • Page 34

    [...]

  • Page 35

    1 0G3418 1 RA DIATOR SUPPORT LH SIDE 1.6L 2 0G3421 1 V ENTURI 1.6L 3 0G3419 1 RA DIATOR SUPPORT RH SIDE 1.6L 4 0E9837B 1 RADIATOR 1.6L C HY 5 0G3553 1 FAN COO L 450MM DIA 7 B LADE 6 0E 3257 2 S CREW HWHTF M 6-1.0 X 16 7 0G4080 1 HOSE LOWE R RADIATO R 1.6L 8 099502 6 CLAMP H OSE #24 B1.0 6-2.00 9 0G4070 1 HOSE RE AR COOLANT 1. 6L 10 0G4072 1 TUBE EN[...]

  • Page 36

    [...]

  • Page 37

    1 0G33 43 1 MOUNT ING BASE 1.6 L 2007 C1 2 02748 2 2 WASHER S HAKEPROO F EXT 5/1 6 STL 3 07093 6 2 DAMPENE R VIBRATIO N 4 07093 6C 2 VIB. IS O. 70-75 DU RO 5 03925 3 8 SCREW HH C M8-1.2 5 X 20 G8.8 6 02214 5 1 2 WASHE R FLAT 5/16 ZINC 7 02212 9 1 2 WASHE R LOCK M8-5/16 8 04577 1 4 NUT HEX M 8-1.25 G 8 YEL CHR 9 07195 6 4 WASHER FL AT M8 10 0517 30 [...]

  • Page 38

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  • Page 39

    1 0F3 408C 1 BATTERY TRAY , C1 & C2 2 0F3411 1 STRAP BATTE RY RETAI NMENT 3 025507 1 WASHE R SHAKEPROOF EXT 7/16 STL 4 059980 1 S CREW HHC M10-1.5 X 25 G10.9 5 046526 1 WASHE R LOCK M10 6 077483 REF BATTERY 12VDC 75-A H 26 7 050331A REF BATTERY P OST COVER RED + 8 050331 REF BATTERY POST COVE R BLK - 9 0 38805J 1 CA BLE BATTERY BLA CK #1 X 30.0[...]

  • Page 40

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  • Page 41

    1 0G0207 REF ENGINE GEN ERAC 1. 6L NG 2 0G0834 1 E NGINE PLATE 1.6L 3 0G0820 REF HOUSING BLOWER MAC HINED 1.6L 4 0E 9747 1 S TARTER 12 VO LT 5 0G0839 2 E NGINE MOUNTING F OOT STAMPIN G 6 0G0781 1 E XHAUST MANIFOLD 1.6L MACHINE D 7 0G0722 1 INT AKE MANIFOLD M ACHINED 1. 6L 8 0G4059 1 S HIELD 1.6L EXHAUS T HEAT 9 0G4604 1 DC AL TERNATOR A DAPTER MAC [...]

  • Page 42

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  • Page 43

    1 098290 1 ASM MO TOR STEPPE R 2 098941A 1 HOUSING GOVE RNOR CONNECT OR 3 098958A REF CONNEC TOR INTERFA CE ASSEMBLY 4 098942A 1 COVER CONNE CTOR HOUSI NG 5 098225 2 S CREW FHM #2 X 5/8 SELF TAP 6 043146 3 S CREW HHC M6-1.0 X 10 G8.8 7 022097 5 WASHE R LOCK M6-1 /4 8 084543A 1 SCREW PHM M3- 0.5 X 12MM 9 098783 1 LEV ER STEPPER MOT OR 10 037 398 2 N[...]

  • Page 44

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  • Page 45

    1 026812 2 ELBOW 90D 3/4 NPT 2 07558 0 1 FLANGE FUE L INLET 3 0G1397A 1 FUEL REG. REWO RK 1.6L 3600 '07 ( 3600RPM) 0G1397B 1 FUEL REG. REWO RK 1.6L 1800 '07 (1800RPM) 4 03925 3 2 SCREW HHC M 8-1.25 X 20 G 8.8 5 02214 5 2 WASHER FL AT 5/16 ZINC 6 02212 9 4 WASHER LOCK M8-5/16 7 04577 1 2 NUT HEX M8- 1.25 G8 YEL CHR (1) 8 0F1570 1 BODY C AR[...]

  • Page 46

    [...]

  • Page 47

    (1) 1 0G3337 1 ROOF 1.6L C1 (1) 2 0G3336 1 REAR INTAKE WRAP 1.6L C1 (2) 3 077992 16 NUT HEX L OCK M6-1.0 SS NY INS (1) 4 0G3341 2 RIGHT SIDE DOOR 1.6 L C1 (1) 5 0G3335 1 FRONT DISCHARGE W RAP 1.6L C1 6 0F4 487A 1 ASSY A CCESS COVER 7 022127 1 NUT HEX 1/4-20 STEEL 8 022097 1 WASHE R LOCK M6-1/ 4 9 022473 1 WASHE R FLAT 1/4-M6 ZI NC 10 0C2454 16 SCRE[...]

  • Page 48

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  • Page 49

    1 0F7366 1 MUFFLE R C1 2 0F7647 1 MUFFLE R SADDLE 3 0F8095 1 PIPE EXHAUST O UTLET 4 0G3576 1 EX HAUST PIPE L OWER 1.6L 5 0E3257 4 SCREW HWHTF M 6-1.0 X 16 6 0F7644 2 MUFFLE R STRAP 7 0C6119 1 BO LT U 5/16-1 8 X 2-1/4 8 036434 3 BOLT U 5/16-1 8 X 2.09 9 036449 3 SADDLE 2 INC H 10 0221 29 6 WASHER LOCK M8-5/16 11 0222 59 6 NUT HEX 5/16- 18 STEEL 12 0[...]

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