Generac Power Systems 1.6L 18 kW, Owner'S Manual

Page 1: ...reliability Serial Number 1 6L 18 kW Models Not intended for use in critical life support applications ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY CAUTION Cover114 Rev B 09 07 Part No 0G5244A Catalog Number OMASPEA018 1 ...

Page 2: ... Initial Inspection for Genset Start up 8 1 Start up Checklist 8 2 Preparation for Start up 8 2 OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine Start up and Transfer 9 1 Retransfer and Shutdown 9 1 Operating Unit with Automatic Transfer Switch 9 1 MAINTENANCE 10 1 Maintenance Performed by Service Facilities 10 1 Every Three Months 10 1 Once E...

Page 3: ... the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon mon oxide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death For that reason adequate...

Page 4: ...ns will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to person nel disable the g...

Page 5: ...al safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this e...

Page 6: ...r factor etc NOTE For actual information related to this particular model please refer to the Manual Drawing Listing located at the end of this manual or to the data label affixed to the unit Generator Model and Serial Number This number is the key to numerous engineering and manufacturing details pertaining to your unit Always supply this number when requesting service order ing parts or seeking ...

Page 7: ...n properly serviced with the recom mended oil may result in an engine failure NOTE For temperatures below 32 F it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for temperatures below 32 F is 5W 30 synthetic oil COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized...

Page 8: ...ng cranking and operating Should oil pressure drop below the 8 psi range switch contacts close and the engine shuts down The unit should not be restarted until oil is added and the AUTO OFF MANUAL switch must be turned to OFF and then back to AUTO OVERCRANK SHUTDOWN After a prespecified duration of cranking this func tion ends the cranking if the engine has failed to start The overcrank LED will t...

Page 9: ...e sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in the supply tank...

Page 10: ...ady State Regulation 25 Adjustments Speed Selectable Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Cartridge Crankcase Oil Capacity 4 U S qts COOLING SYSTEM Type Closed Water Pump Belt Driven Fan Speed 1550 Fan Diameter 17 7 inches Fan Mode Pusher Air Flow inlet air including alternator and combustion air 890 ft3 min Coolant Capacity 2 0 U S gal Heat Rejection to Coolant 117...

Page 11: ... into the outlet port in the regulator casting NOTE The jet sizes are stamped on the individual jets The larger jet size is used for running on NG 8 Install the previously removed NG jet into the jet keeper port on the side of the regulator housing 9 Install the previously removed black pipe onto the outlet port of the demand regulator 10 Reverse steps 1 4 in this procedure to reactivate the deman...

Page 12: ...breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS The generator is designed to supply 3 phase electri cal loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit...

Page 13: ...he dipstick ADD mark See Specifications and Engine Oil Recommendations NOTE This engine is shipped from the manufacturer with break in oil This oil should be changed after 30 hours of operation PRIOR TO INITIAL START UP Prior to initially starting the generator it must be properly prepared for use Any attempt to crank or start the engine before it has been properly serviced with the recommended ty...

Page 14: ...n the valve to the engine fuel line Bleed the fuel system of air necessary for long fuel lines Open the generator main line circuit breaker Connect a manometer to the gas line and record the static pressure It must be as listed in the Specifications Insert the fuse into the control panel Move the AUTO OFF MANUAL switch to the man ual position The engine should now crank and start Check voltage at ...

Page 15: ...ransfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the generator Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings When...

Page 16: ...obstructed for contin ued proper operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down See the installation diagram The exhaust system parts from this product get extremely hot and remains hot after shutdown High grass weeds brush leaves etc must re...

Page 17: ...e cooling system See Maintenance Schedule Check hoses for damage deterioration leaks etc Correct any discrepancies found Check hose clamps for tightness CHECK ENGINE COOLANT LEVEL See Checking Fluid Levels PERFORM VISUAL INSPECTION Complete a thorough visual inspection of the entire engine generator monthly Look for obvious damage loose missing or corroded nuts bolts and other fas teners Look for ...

Page 18: ...engine and check for oil leaks CHANGING THE ENGINE AIR CLEANER To replace the engine air cleaner simply remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover Figure 10 3 See the Service Schedule for air cleaner mainte nance Figure 10 3 Engine Air Cleaner Air Cleaner Doors Removed for Clarity SPARK PLUGS Reset the spark plug gap o...

Page 19: ...should be followed for inspection 1 Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary 2 Check the battery fluid level of unsealed batteries and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERIES 3 Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer DANGER Storage batt...

Page 20: ...ttery cable to prevent an over current condition from burning out sensitive control panel components and circuits Following all maintenance reverse these steps to insure the unit is returned to standby setup for normal operation when required 2 A break in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem ...

Page 21: ... gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level if accessible Adjust as necessary 8 Check the battery posts cables and charger for loose connections corrosion and proper operation Correct as necessary 9 Check the unit wiring for loose connections corrosion and damage Correct as necessar...

Page 22: ...nd exercise the unit at full rated load use a load bank if the site load is not enough for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 15 Change the engine oil 16 Replace the engine oil filter s 17 Replace the engine air filter s 18 Replace the engine fuel filter s on diesel engine driven units and re prime the fuel syst...

Page 23: ...ecommended in SPECIFICATIONS Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defectiv...

Page 24: ...Standby Generator Sets Notes ...

Page 25: ...Standby Generator Sets Notes ...

Page 26: ...Standby Generator Sets Notes ...

Page 27: ...Standby Generator Sets Notes ...

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Page 29: ...PL CHI 30KW 0G3684 1 STR 102 30 0GD2 CPL 30KW 0G3687 1 STR 102 30 0KD2 CPL 30KW 0G5909 1 ASSY STR 102 30AD2 10 30KW 0G6103 1 STR 102 30 0JD2 9 0A5382A 1 BEARING CARRIER REAR LG PILOT 10 075591 2 ASSY HOLDER BRUSH 11 051787 4 SCREW HHC M4 0 7 X 16 G8 8 12 0A5601A 1 COVER REAR BEARING 13 075554B 4 BOLT STATOR X 16 LG 20KW 25KW 075554E 4 SCREW HHC M8 1 25 X 463 G5 ZP 30KW 14 0A9375 4 SCREW RHM 10 24 ...

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Page 31: ...A 0E7283 1 CB 0150A 2P 240V S QN2 LL B 0G3474 1 CONBOX FRONT COVER 1 6L QN 2P C 074908 2 SCREW HHTT M5 0 8 X 10 BP D 0E3257 7 SCREW HWHTF M6 1 0 X 16 E 0E3664 1 BASE QN CIRCUIT BREAKER F 0G4112 1 BREAKER SUPPORT BRACKET 30KW 5 0A1354A 1 REGULATOR DC ALT 6 0G3473 1 CONBOX TOP PANEL SUPPORT 7 0F6366A 1 XFMR 208 TO 16V 6VA 208V ONLY 0F6366B 1 XFMR 240 TO 16V 6VA 240 480V 8 0G3524 1 COVER BELL HOUSING...

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Page 33: ...5V SPD 24 0E4494 1 SWITCH RKR DPDT ON OFF ON 25 0F3215 1 DECAL CONTROL HSB 26 0F6305 2 SEAL COVER 3 18 X 12 7 X 382 27 0F6305A 1 SEAL COVER 3 18 X 12 7 X 283 28 0F5886 3 SCREW HHPM M5 0 8 X 12 29 051713 14 WASHER FLAT M5 30 049226 14 WASHER LOCK M5 31 0F5752F 1 RES WW 15R 5 25W QK CONN 32 0F5884 2 SCREWPHTT M3 5 0 6 X 10 33 0F5896 2 SCREWPHTT M3 5 0 6 X 16 34 0C2265 4 SCREWPHTT M4 0 7 X 12 ZYC 35 ...

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Page 35: ... SCREW THF M6 1 X 12 N WA Z JS 19 042568 4 SCREW HHC M6 1 0 X 20 G8 8 20 0G3573 1 GUARD FAN LH C1 21 0G3574 1 GUARD FAN RH C1 23 0G3420 1 RADIATOR BLOCK OFF 24 080713 1 BRACKET COOLANT TANK 25 076749 1 TANK COOLANT RECOVERY 26 048031C 2 CLAMP HOSE BAND 1 4 27 029032 1 HOSE 9 32 ID 43 LG 28 0G4451 REF BRACKET STEPPER MOTOR COOLANT 29 055934N 2 CLAMP VINYL 1 31 X 281 Z 30 0F9504 1 GROMMET 5 8 X 1 1 ...

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Page 37: ...FLAT 5 16 ZINC 7 022129 12 WASHER LOCK M8 5 16 8 045771 4 NUT HEX M8 1 25 G8 YEL CHR 9 071956 4 WASHER FLAT M8 10 051730 4 SCREW HHC M8 1 25 X 60 G8 8 11 021991 1 EARTH STRAP 13 026850 1 WASHER SHAKEPROOF EXT 1 4 STL 14 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 15 055414 1 LUG SLDLSS 2 8 X 17 64 CU 16 047411 1 SCREW HHC M6 1 0 X 16 G8 8 17 022097 1 WASHER LOCK M6 1 4 18 022473 5 WASHER FLAT 1 4 M6 ZINC...

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Page 39: ...COVER BLK 9 038805J 1 CABLE BATTERY BLACK 1 X 30 00 10 038804M 1 CABLE BATTERY RED 1 X 21 00 11 045771 REF NUT HEX M8 1 25 G8 YEL CHR 12 022131 1 WASHER FLAT 3 8 M10 ZINC 13 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 14 0F3976 1 BOOT CONTACTOR CABLES 15 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 16 022145 REF WASHER FLAT 5 16 M8 ZINC NOTE WHEN INSTALLING BATTERY TUCK BATTERY S LIFTING STRAP ALONG THE LEF...

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Page 41: ...0 1 5 X 40 G10 9 30 039414 1 SCREW HHC M8 1 25 X 35 G8 8 31 022129 4 WASHER LOCK M8 5 16 32 022145 3 WASHER FLAT 5 16 M8 ZINC 33 029333A 1 TIE WRAP UL 7 4 X 19 BLK 34 057821 3 SCREW HHC M8 1 25 X 40 G8 8 35 045771 3 NUT HEX M8 1 25 G8 CLEAR ZINC 36 022507 2 SCREW HHC 1 4 20 X 1 2 G5 37 022097 2 WASHER LOCK M6 1 4 38 022473 5 WASHER FLAT 1 4 M6 ZINC 39 090388 3 SCREW HHTT M6 1 0 X 12 ZINC 40 0A5768...

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Page 43: ... 3 SCREW HHC M6 1 0 X 10 G8 8 7 022097 5 WASHER LOCK M6 1 4 8 084543A 1 SCREW PHM M3 0 5 X 12MM 9 098783 1 LEVER STEPPER MOTOR 10 037398 2 NUT LOCK HEX 10 32 NYL INS 11 0E1326 1 ASSY CARBURETOR LINKAGE ROD 12 0G4451 1 BRACKET STEPPER MOTOR COOLANT 13 064526 1 SCREW TAP HWH 6 25 X 3 8 ZINC 14 029333A 10 TIE WRAP 7 4 X 19 BLK UL 15 022507 2 SCREW HHC 1 4 20 X 1 2 G5 16 0E1694 1 SPRING ANTI LASH ...

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Page 45: ...0795 2 SCREW HHC 5 16 18 X 1 G5 29 0F6155 1 HARNESS FUEL JUMPER SINGLE REG 1 30 0E1104 1 GASKET AIR CLEANER ADAPTER 1 31 0E0668 1 O RING 2 028 1 38 X 1 50 X 06 1 32 0E0590A 1 VENTURI 20MM 3600RPM 0E0590 1 VENTURI 18MM 1800RPM 1 33 0C5133 1 O RING 29 82 X 2 62 1 34 0E0665 1 SCREW THROTTLE PIN STOP 1 35 0E1108 1 THROTTLE ARM REWORK 1 36 033138 1 SCREW HHM 10 32 X 5 8 1 37 022152 1 WASHER LOCK 10 1 3...

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Page 47: ... 4 WIDE X 3 16 THK 294 LG 15 078115 18 WASHER SELF LOCKING DOME 16 0G4029 2 INSULATION SIDE DOOR C1 17 0G4029A 1 INSULATION ROOF C1 18 0F3890 5 RETAINER INSULATION 450 19 0E3257 4 SCREW HWHTF M6 1 0 X 16 20 0912970090 2 ASSY WIRE 14AWG GRN YEL 32 25 LG 21 0G4029B 1 INSULATION REAR C1 22 0F3890B 4 RETAINER INSULATION 820 1 REFER TO CHART BELOW FOR COLOR AND MATERIAL TYPE 2 ALUMINUM ENCLOSURE NOTE A...

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Page 49: ...C6119 1 BOLT U 5 16 18 X 2 1 4 8 036434 3 BOLT U 5 16 18 X 2 09 9 036449 3 SADDLE 2 INCH 10 022129 6 WASHER LOCK M8 5 16 11 022259 6 NUT HEX 5 16 18 STEEL 12 038750 1 SCREW HHC M6 1 0 X 30 G8 8 13 0G3575 1 EXHAUST PIPE UPPER 1 6L SS 14 0F3794A 1 EXHAUST BLANKET 500MM LONG 15 022097 1 WASHER LOCK M6 1 4 16 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 17 022473 6 WASHER FLAT 1 4 M6 ZINC ...

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