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STANDBY GENERATOR

OWNER'S MANUAL

This manual should remain with the unit.

A new standard of reliability

Serial Number

SG020 Series

1.6L

20kW

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

CAUTION



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ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

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Not intended for use in critical life support applications.

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Cover072 Re

v. 0 05/06

Par

t No

. 0G1553

Содержание SG020 Series

Страница 1: ...tandard of reliability Serial Number SG020 Series 1 6L 20kW CAUTION ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY Not intended for use in critical life support applications s Cover072 Rev 0 05 06 Part No 0G1553 ...

Страница 2: ... Start up Checklist 8 2 Preparation for Start up 8 2 Start up Inspection 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 Authorized Service Facilities 10 1 Every Three Months 10 1 Once Every Six...

Страница 3: ...rator is installed operated and serviced in accordance with 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 monox ide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can c...

Страница 4: ...s 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 ge...

Страница 5: ...zard 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 equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepar...

Страница 6: ...his 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 information 2 1 Standby Generator Sets General Information Identy 002 Rev B 05 06 WAUKESHA WI RATED KW RATED VOLTAGE POWER FACTOR ENGINE RPM...

Страница 7: ...ay 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 water Cooling system capacity is listed in the...

Страница 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...

Страница 9: ... and local codes To reduce gas pressure to a safe level before the gas enters a building a primary regulator is needed The natural gas supplier may or may not supply such a regulator It is the responsibility of the gas supplier to make 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 1...

Страница 10: ...s Steady 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 2550 Fan Diameter 16 inches Fan Mode Pusher Air Flow inlet air including alternator and combustion air 1528 ft3 min Coolant Capacity 2 0 U S gal Heat Rejection to Coolant...

Страница 11: ...witch inside the control panel must be in the LP or NG position when switching to differ ent fuels Figure 6 2 Reconfigure the Fuel System NG FUEL SYSTEM LP FUEL SYSTEM Port 1 Port 2 FUEL HOSE BRASS HOSE FITTING HOUSING PORTS OUT PORT 2 PLUG FUEL HOSE BRASS HOSE FITTING HOUSING PORTS PLUG OUT PORT 1 NOTE Port 1 is for NG only and Port 2 is for LP vapor only No provision for dual fuel has been made ...

Страница 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...

Страница 13: ...ifications 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 types and quantities of engine ...

Страница 14: ...essary 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 the generator terminals For 3 phase units check phase rotation at th...

Страница 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...

Страница 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...

Страница 17: ...r 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 fuel oil or coolant leaks INSPECT EXHAUST SYSTEM Inspect...

Страница 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...

Страница 19: ...he following procedure 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 hydrome...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 24: ...Standby Generator Sets Notes ...

Страница 25: ...Standby Generator Sets Notes ...

Страница 26: ...Standby Generator Sets Notes ...

Страница 27: ...Standby Generator Sets Notes ...

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Страница 29: ...T HEX 3 8 16 STEEL 20 022237 1 WASHER LOCK 3 8 21 057329 1 LUG SLDLSS 350 6 X 13 32 AL CU 22 057073 1 JUNCTION BLOCK 3 8 16 23 023484J 1 BUSHING SNAP SB 2000 26 24 0E3257 15 SCREW HWHTF M6 1 0 X 16 25 0E7890 REF BRKT CB MTG BACK 2P 0E6002 REF MTG TRACK BQ SIEMENS CB 3P 26 0A2077 REF CB 0125A 2P 240V S BQ2 LL 2 POLE 040532 REF CB 0100A 3P 240V S BQ3 LL 3 POLE 27 052619 REF SCREW HHC M5 0 8 X 20 G8 ...

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Страница 31: ...54B 4 BOLT STATOR X 16 LG 14 0A9375 4 SCREW RHM 10 24 X 2 15 022152 4 WASHER LOCK 10 16 0G0430 1 FLYWHEEL RING GEAR ASSY 1 6L 17 042558 1 KEY SQ 3 8 X 1 STEEL 18 0G1452 1 PLATE SPACER 1 6L 19 0G0965 1 PLATE FLEX 1 6L 20 053607 1 SCREW HHC M12 1 75 X 35 G8 8 21 051769 1 WASHER LOCK M12 22 049541 4 SCREW HHC M10 1 5 X 35 G8 8 23 046526 4 WASHER LOCK M10 24 045772 4 NUT HEX M10 1 5 G8 YEL CHR 26 0A88...

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Страница 33: ...RKR DPST 125V 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 SCREW PHTT M3 5 0 6 X 10 33 0F5896 2 SCREW PHTT M3 5 0 6 X 16 34 0C2265 4 SCREW PHTT M4 0 ...

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Страница 35: ...M6 1 0 X 20 G8 8 20 0G0932 1 GUARD FAN LH C1 21 0G0933 1 GUARD FAN RH C1 22 0C7649 1 CLAMP HOSE 38 87 23 0F7320 1 BLOCK OFF UPPER 24 0F1433 1 BRACKET 2 5L FORD WATER BOTTLE 25 076749 1 TANK COOLANT RECOVERY 26 048031C 2 CLAMP HOSE BAND 1 4 27 029032 1 HOSE 9 32 ID 43 LG 28 050275 3 DECAL WARNING FAN 29 050276 1 DECAL RADIATOR DRAIN 30 029107 1 GROMMET 7 8 X 3 16 X 5 8 31 0G0568 1 ASSY FAN BEARING ...

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Страница 37: ...EF BATTERY 12VDC 75 AH 26 7 050331A 1 BATT POST COVER RED 8 050331 1 BATT POST COVER BLK 9 038805J 1 CABLE BATTERY BLK 1 X 30 00 10 038804N 1 CABLE BATT RED 1 X15 00 11 045771 REF NUT HEX M8 1 25 G8 YEL CHR 12 022129 REF WASHER LOCK M8 5 16 13 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 14 075763 1 BOOT BATTERY CABLE 15 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 16 022145 2 WASHER FLAT 5 16 M8 ZINC ...

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Страница 39: ...2129 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 12 0F7194 2 BRACKET PANEL SUPPORT 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 0E3257 4 SCREW HWHTF M6 1 0 X 16 17 022097 1 WASHER LOCK M6 1 4 18 022473 5 WASHER FLAT...

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Страница 41: ... 052858 14 NUT TOP LOCK FL M8 1 25 27 061652 1 SCREW HHC M10 1 5 X 85 G8 8 28 057644 4 SCREW HHC M10 1 5 X 100 G8 8 29 049541 4 SCREW HHC M10 1 5 X 35 G8 8 30 039414 1 SCREW HHC M8 1 25 X 35 G8 8 31 022129 4 WASHER LOCK M8 5 16 32 022145 4 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 SCR...

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Страница 43: ...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 0A7106 1 BRACKET STEPPER MOTOR 13 0G1381 1 OIL DIP STICK BRACKET 1 6L 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 17 064526 1 SCREW TAP HWH 6 25 ...

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Страница 45: ...5 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 38 0E0645 1 LEVER THROTTLE STOP 1 39 034339 1 BARBED EL 90 3 8 NPT X 5 8 40 059194 1 HOSE 5 8 ID LPG NG 16 LG 41 057823 2 CLAMP HOSE 10 56 1 06 42 048031G 2 CLAMP HOSE BAND 41 1 43 039450 1 BARBED EL 90 3 16 X 1 8 44 029470 1 HOSE 3 16 ID FUEL LINE 22 LG 46 0G1985 1 HOSE...

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Страница 47: ...Z JS 19 078115 20 WASHER SELF LOCKING DOME 20 0F3890B 2 RETAINER INSULATION 820 21 0F3890 4 RETAINER INSULATION 450 22 0F7365 2 INSULATION SIDE DOOR C1 23 0F7365B 1 INSULATION REAR DOOR C1 CPL 24 0F7365A 1 INSULATION ROOF C1 CPL 25 0F8869D 1 KEY VISE ACTIONLATCH SLOT CIR OPTIONAL COMPARTMENT MATERIALS ALL P N S WITH AN XX SUFFIX INDICATE A MULTIPLE MATERIAL AND COLOR OPTION USE THE FOLLOWINGLEGEND...

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Страница 49: ...TRAP 7 0C6119 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 8 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 0G1043 1 EXHAUST PIPE 1 6L 14 0F3794 1 EXHAUST BLANKET 600MM 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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Страница 64: ...taminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze 4 Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition and warranty 5 Units used for prime p...

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