Instruction/ maintenance manual of the product 1.6L 18 kW Generac Power Systems
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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.
Standby Generator Sets T able of Contents SECTION P AGE SAFETY RULES ................................................ 1-1 INTRODUCTION ..................................................... 1-3 Read this Manual Thoroughly ..............................
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.
• 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.
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.
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 ge.
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.
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 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 .
SP E CI F ICA TIONS GEN ERA T OR T ype ............................................................................. Synchronous Rotor Insulation .................................................................... Class F Stator Insulation ..........
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 .
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.
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 .
• 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.
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.
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 .
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.
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.
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.
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.
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.
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.
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 .
Standby Generator Sets Notes.
Standby Generator Sets Notes.
Standby Generator Sets Notes.
Standby Generator Sets Notes.
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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.
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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.
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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 .
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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.
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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.
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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.
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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.
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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.
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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.
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(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.
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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.
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An important point after buying a device Generac Power Systems 1.6L 18 kW (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
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If you already are a holder of Generac Power Systems 1.6L 18 kW, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Generac Power Systems 1.6L 18 kW.
However, one of the most important roles played by the user manual is to help in solving problems with Generac Power Systems 1.6L 18 kW. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Generac Power Systems 1.6L 18 kW along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
