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Generac Power Systems 1.6L 18 kW Owner's Manual

1.6l 18 kw models standby generator sets
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1.6L

Serial Number

18 kW
Models
STANDBY GENERATOR
OWNER'S MANUAL
A new standard of reliability
Not intended for use in critical life support applications.
—CAUTION—
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!
This manual should remain with the unit.
Catalog Number OMASPEA018-1
0G5244A
No.
Part
09/07
B
Rev.
Cover114

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Summary of Contents for Generac Power Systems 1.6L 18 kW

  • Page 1: Serial Number

    1.6L Serial Number 18 kW Models STANDBY GENERATOR OWNER'S MANUAL A new standard of reliability   Not intended for use in critical life support applications. —CAUTION— ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION! DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY! This manual should remain with the unit.

  • Page 2: Table Of Contents

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

  • Page 3: Safety Rules

     SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment.  WARNING: The engine exhaust from this product contains chemicals known to the state...

  • Page 4: Fire Hazards

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

  • Page 5: Introduction

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

  • Page 6: Identification Record

    IDENTIFICATION RECORD DATA LABEL Every generator set has a DATA 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 factor, etc.

  • Page 7: Equipment Description

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

  • Page 8: Engine Protective Devices

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

  • Page 9: Fuel Systems

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

  • Page 10: Specifications

    SPECIFICATIONS GENERATOR Type ... Synchronous Rotor Insulation ...Class F Stator Insulation ...Class F Total Harmonic Distortion ...< 5% Alternator Output Leads 3-phase ... 4-wire Bearings ...Sealed Ball Coupling ...Flexible Disc Load Capacity (Standby Rating) ... 18 kW* * NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349, ISO3046 and DIN 6271 Standards.

  • Page 11: Cold Weather Kit

    CONTROL PANEL GENERATOR CONNECTION CIRCUIT BREAKER Battery Charger Input 120 Volt + Neutral Ground Level STUB-UP AREA Concrete Slab See Install Dwg for Dimensions COLD WEATHER KIT For cold climates, optional cold weather kit (part number 0F6148) is recommended. The kit includes: •...

  • Page 12: General Information

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

  • Page 13: Installation

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

  • Page 14: Start-Up Checklist

    • Battery charger connection to 120 VAC. • Communication wires connected between transfer switch and generator (HTS only). • Unit secured to pad. START-UP CHECKLIST  Before working on the generator, ensure the fol- lowing: • The AUTO/OFF/MANUAL switch is in the OFF position.

  • Page 15: Operation

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

  • Page 16: Maintenance

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

  • Page 17: Battery Fluid

    Figure 10.1 - Oil Dipstick and Oil Fill Cap OIL FILL CAP DIPSTICK BATTERY FLUID 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.

  • Page 18: Changing Engine Oil

    CHANGING ENGINE OIL 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.

  • Page 19: Miscellaneous Maintenance

    MISCELLANEOUS MAINTENANCE CLEANING THE GENERATOR 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. Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. Use a vacuum system or dry, low pressure air to remove any accumulations of dirt.

  • Page 20: Service Schedule

    SERVICE SCHEDULE 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- tion.
  • Page 21 Maintenance Level 1 Tasks Recom- mended to be done monthly 10 Hrs. 1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessary. 3. Check the engine coolant level. Adjust as necessary. 4.
  • Page 22 Maintenance Level 1 Tasks Recom- mended to be done monthly 10 Hrs. 13. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions.

  • Page 23: Troubleshooting

    TROUBLESHOOTING GUIDE PROBLEM CAUSE Engine won’t crank. Engine cranks but won't start Engine starts hard, runs rough. Engine starts then shuts down. AUTO/OFF/MANUAL Switch at OFF, engine continues to run No AC output from generator. Standby Generator Sets Troubleshooting 1. 15 amp fuse blown. 2.
  • Page 24 Standby Generator Sets Notes...
  • Page 25 Standby Generator Sets Notes...
  • Page 26 Standby Generator Sets Notes...
  • Page 27 Standby Generator Sets Notes...
  • Page 29 0G4827 ASSY RTR 104 KD1 HI EFF (18KW) 0G2927 RTR-102-20.0AD1 CPL (2006) (20KW) 0G2827 ASSY RTR 25KW 2P (2006) (25KW) 0G3451C RTR 102 30KD2 (2006) CPL CHI (30KW) 0G0820A HOUSING BLOWER LG PILOT 0G4452 BLOWER HOUSING SCREEN 020746 SCREW PPHM M5-0.8 X 8 ZINC 049226 WASHER LOCK M5 051713...
  • Page 31 UL BREAKER BQ2 0D5543 CB 0090A 2P 240V S BQ2 LL 0D5544 CB 0100A 2P 240V S BQ2 LL 0A2077 CB 0125A 2P 240V S BQ2 LL 0G4499 CB COVER 20-25K 1P (BQ2) 0C2265 SCREW PHTT M4-0.7 X 12 ZYC 0C2264 WASHER LOCK #8-M4 0E7890...
  • Page 33 COMPONENTS INCLUDED IN 0G4578E 0F1823A ENCL HSB CONTROL PANEL 0F3078 COVER CONTROL PANEL 0F2606 HINGE CONTINUOUS H-PANEL 036261 RIVET POP .125 X .275 SS 0E7358 SCREW PPPH HI-LO #4-24 X 3/8 052777 WASHER FLAT M3 0G3958C ASSY PCB R-200A CNTRL 1800 0F1262 HOLDER FUSE WICKMANN 178.6150 0F1263...
  • Page 35 0G3418 RADIATOR SUPPORT LH SIDE 1.6L 0G3421 VENTURI 1.6L 0G3419 RADIATOR SUPPORT RH SIDE 1.6L 0E9837B RADIATOR 1.6L CHY 0G3553 FAN COOL 450MM DIA 7 BLADE 0E3257 SCREW HWHTF M6-1.0 X 16 0G4080 HOSE LOWER RADIATOR 1.6L 099502 CLAMP HOSE #24 B1.06-2.00 0G4070 HOSE REAR COOLANT 1.6L 0G4072...
  • Page 37 0G3343 MOUNTING BASE 1.6L 2007 C1 027482 WASHER SHAKEPROOF EXT 5/16 STL 070936 DAMPENER VIBRATION 070936C VIB. ISO. 70-75 DURO 039253 SCREW HHC M8-1.25 X 20 G8.8 022145 WASHER FLAT 5/16 ZINC 022129 WASHER LOCK M8-5/16 045771 NUT HEX M8-1.25 G8 YEL CHR 071956 WASHER FLAT M8 051730...
  • Page 39 0F3408C BATTERY TRAY, C1 & C2 0F3411 STRAP BATTERY RETAINMENT 025507 WASHER SHAKEPROOF EXT 7/16 STL 059980 SCREW HHC M10-1.5 X 25 G10.9 046526 WASHER LOCK M10 077483 BATTERY 12VDC 75-AH 26 050331A BATTERY POST COVER RED + 050331 BATTERY POST COVER BLK - 038805J CABLE BATTERY BLACK #1 X 30.00 038804M...
  • Page 41 0G0207 ENGINE GENERAC 1.6L NG 0G0834 ENGINE PLATE 1.6L 0G0820 HOUSING BLOWER MACHINED 1.6L 0E9747 STARTER 12 VOLT 0G0839 ENGINE MOUNTING FOOT STAMPING 0G0781 EXHAUST MANIFOLD 1.6L MACHINED 0G0722 INTAKE MANIFOLD MACHINED 1.6L 0G4059 SHIELD 1.6L EXHAUST HEAT 0G4604 DC ALTERNATOR ADAPTER MACHINED 0G3424 PULLEY CRANKSHAFT MACHINED (3600RPM) 0G4863...
  • Page 43 098290 ASM MOTOR STEPPER 098941A HOUSING GOVERNOR CONNECTOR 098958A CONNECTOR INTERFACE ASSEMBLY 098942A COVER CONNECTOR HOUSING 098225 SCREW FHM #2 X 5/8 SELF TAP 043146 SCREW HHC M6-1.0 X 10 G8.8 022097 WASHER LOCK M6-1/4 084543A SCREW PHM M3-0.5 X 12MM 098783 LEVER STEPPER MOTOR 037398...
  • Page 47 (1) 1 0G3337 ROOF 1.6L C1 (1) 2 0G3336 REAR INTAKE WRAP 1.6L C1 (2) 3 077992 NUT HEX LOCK M6-1.0 SS NY INS (1) 4 0G3341 RIGHT SIDE DOOR 1.6L C1 (1) 5 0G3335 FRONT DISCHARGE WRAP 1.6L C1 0F4487A ASSY ACCESS COVER 022127...
  • Page 49 0F7366 MUFFLER C1 0F7647 MUFFLER SADDLE 0F8095 PIPE EXHAUST OUTLET 0G3576 EXHAUST PIPE LOWER 1.6L 0E3257 SCREW HWHTF M6-1.0 X 16 0F7644 MUFFLER STRAP 0C6119 BOLT U 5/16-18 X 2-1/4 036434 BOLT U 5/16-18 X 2.09 036449 SADDLE 2 INCH 022129 WASHER LOCK M8-5/16 022259...
  • Page 64 04/07 Rev. BackPg001...

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