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Generac Power Systems 20 Owner's Manual

1.6l 20/25/30 kw models standby generator
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1.6L

Serial Number

20/25/30 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 OMASPEA025-2
0G5244
No.
Part
09/07
B
Rev.
Cover113

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Summary of Contents for Generac Power Systems 20

  • Page 1: Serial Number

    1.6L Serial Number 20/25/30 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

    This type of system utilizes the vapors formed above the liquid fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor state. The vapor withdrawal system is generally best suited for smaller engines that require less fuel.

  • Page 10: Specifications

    Bearings ...Sealed Ball Coupling ...Flexible Disc Load Capacity (Standby Rating) ... 20/25/30 kW* * NOTE: Generator rating and performance in accordance with ISO8528-5, BS5514, SAE J1349, ISO3046 and DIN 6271 Standards. KW rating is based on LPG fuel and may derate with natural gas.

  • 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

    CHECKING FLUID LEVELS CHECK ENGINE OIL Check engine crankcase oil level (Figure 10.1) at least every 20 hours of operation, or prior to use. • Remove oil dipstick and wipe dry with a clean, lint- free cloth. •...

  • Page 17: Battery Fluid

    Maintenance EXERCISE SYSTEM Start the generator engine at least once every seven days and let it run at least 20 minutes. For more detailed exercise information, see the respective sec- tions in the Control Panel Technical Manual that is supplied with the unit.

  • 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 19. Check the engine spark plugs on gas engine driven units. Clean and re-gap or replace as necessary. 20. Perform a 5 minute no-load operational run of the unit looking for any post service problems. 21. Return the unit to standby setup for operation when required.

  • 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 SCREW HHC M12-1.75 X 35 G8.8 051769 WASHER LOCK M12 023365 WASHER SHAKEPROOF INT #8 (1) 23 0F3353 SCREW HHC M10-1.0 X 20 G10.9 072578 SPACER ROTOR SHAFT 0G3787 WASHER .41 ID .94 OD .12 THK 0A8830 WASHER FLAT .34 ID X .75 OD 077043E FLEX CONDUIT 1"...
  • Page 31 SCREW PHTT M4-0.7 X 12 ZYC 0C2264 WASHER LOCK #8-M4 0E7890 BRKT CB MTG BACK 0G4497 CIRCUIT BREAKER SUPPORT (BQ) 052619 SCREW HHC M5-0.8 X 20 G8.8 023897 WASHER FLAT #10 ZINC 049226 WASHER LOCK M5 051716 NUT HEX M5-0.8 G8 CLEAR ZINC 0E3257 SCREW HWHTF M6-1.0 X 16...
  • Page 33 HARN CTRL PNL R-200 LOW KW (NOT SHOWN) 0F2627 PLATE COVER H PANEL COMPONENTS INSTALLED PER THIS DRAWING 056739 RELAY SOLENOID 12VDC PNL MNT 022287 SCREW HHC 1/4-20 X 3/4 G5 022473 WASHER FLAT 1/4-M6 ZINC 022097 WASHER LOCK M6-1/4 022127 NUT HEX 1/4-20 STEEL 0F6145 SEAL WEATHER .45"DIA...
  • Page 35 TAPE FOAM 1 X 1 (24” LG) 022473 WASHER FLAT 1/4-M6 ZINC 022097 WASHER LOCK M6-1/4 0C8566 SCREW HHFC M6-1.0 X 20 G8.8 045771 NUT HEX M8-1.25 G8 CLEAR ZINC 0C2454A SCREW THF M6-1 X 12 N WA Z/JS 042568 SCREW HHC M6-1.0 X 20 G8.8...
  • Page 37 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...
  • 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 TIE WRAP UL 7.4" X .19" BLK 057821 SCREW HHC M8-1.25 X 40 G8.8 045771 NUT HEX M8-1.25 G8 CLEAR ZINC 022507 SCREW HHC 1/4-20 X 1/2 G5 022097 WASHER LOCK M6-1/4 022473 WASHER FLAT 1/4-M6 ZINC 090388 SCREW HHTT M6-1.0 X 12 ZINC...
  • Page 43 NUT LOCK HEX #10-32 NYL INS 0E1326 ASSY. CARBURETOR LINKAGE ROD 0G4451 BRACKET STEPPER MOTOR COOLANT 064526 SCREW TAP HWH #6-25 X 3/8 ZINC 029333A TIE WRAP 7.4"X.19" BLK UL 022507 SCREW HHC 1/4-20 X 1/2 G5 0E1694 SPRING ANTI LASH...
  • Page 47 RIGHT SIDE DOOR 1.6L C1 (1) 5 0G3335 FRONT DISCHARGE WRAP 1.6L C1 0F4487A ASSY ACCESS COVER 022127 NUT HEX 1/4-20 STEEL 022097 WASHER LOCK M6-1/4 022473 WASHER FLAT 1/4-M6 ZINC 0C2454 SCREW THF M6-1 X 16 N WA Z/JS...
  • 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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