Generac Power Systems GR160 User manual

Liquid Cooled Diesel Engine Generator Sets
Sound Attenuated
Skid Mounted Generator
Shown With Optional Trailer
Power Matched
JOHN DEERE 8.1T ENGINE
Turbocharged
GR160
FEATURES
■SINGLE SOURCE SERVICE RESPONSE from your Generac
dealer provides parts and service know-how for the entire unit,
from the engine to the smallest electronic component.
■EPAAPPROVEDDIESELPOWER. YourGeneracpowersystem
ismanufacturedusingthemostup-to-datedieselenginetechnology.
The generator set is in compliance with all EPA regulations and is
approved for operation in all 50 states including California.
■LONGER ENGINE LIFE. John Deere heavy-duty diesel engines
provide long and reliable operating life.
■GENERAC TRANSFER SWITCHES AND ACCESSORIES.
Long life and reliability is synonymous with GENERAC POWER
SYSTEMS. One reason for this confidence is that Generac
product includes its own transfer systems, accessories, and
engine controls for total system compatibility.
■FULL CAPACITY OUTPUT ON ALL VOLTAGES and
AUTOMATIC START/STOP CONTROL are standard features
found on the Generac GR Series generator sets.
■THE SUCCESS OF GENERAC POWER SYSTEMS STARTS
WITH INNOVATIVE DESIGN AND PROTOTYPE TESTING. But
it doesn't stop there. Total commitment to component testing,
reliabilitytesting,environmentaltesting,destructionandlifetesting,
plustestingtoapplicableCSA,NEMA,EGSA,andotherstandards,
allows you to choose GENERAC POWER SYSTEMS with the
confidence that these systems will provide superior performance.
■ TEST CRITERIA:
✓PROTOTYPE TESTED
✓SYSTEM TORSIONAL TESTED
✓ELECTRO-MAGNETIC INTERFERENCE
✓NEMA MG1-22 EVALUATION
✓MOTOR STARTING ABILITY
✓SHORT CIRCUIT TESTING
■SOLID-STATE, FREQUENCY COMPENSATED VOLTAGE
REGULATION. Thisstate-of-the-art powermaximizing regulation
system is standard on all Generac models. It provides optimized
FAST RESPONSE to changing load conditions and MAXIMUM
MOTOR STARTING CAPABILITY by electronically torque-
matching the surge loads to the engine.
Standby Power Rating
133KW 60 Hz Prime Power Rating
126KW 60 Hz

GENERATOR SPECIFICATIONS
TYPE .............................................................. Four-pole, revolving field
ROTOR INSULATION...............................................................Class F
STATOR INSULATION .............................................................Class F
TOTAL HARMONIC DISTORTION............................................... <3%
BALANCED TELEPHONE INFLUENCE FACTOR ........................ <50
ALTERNATOR......................................... Drip-proof guarded machine
BEARINGS (PRE-LUBED & SEALED) ................................................1
COUPLING ............................................................Direct, Flexible Disc
LOAD CAPACITY (STANDBY)* ................................................... 100%
LOAD CAPACITY (PRIME)*......................................................... 110%
NOTE: Emergency loading in compliance with NFPA 99, NFPA
110, paragraph 5-13.2.6. Generator rating and performance in
accordance with ISO8528-5, BS5514, SAE J1349, ISO3046 and
DIN6271 standards.
EXCITATION SYSTEM
PERMANENT MAGNET............... Magnetically coupled DC current ✓
Eight-pole exciter w/ battery-driven field boost ✓
Mounted outboard of main bearing ✓
REGULATION ................................................................. Solid-state ✓
+1% regulation ✓
ENGINE SPECIFICATIONS
APPLICATION
& ENGINEERING DATA
GENERATOR FEATURES
n Four pole, revolving field generator, directly connected to the
engine shaft through a heavy-duty, flexible disc for permanent
alignment.
n Generator meets temperature rise standards for Class "F"
insulation as defined by NEMA MG1-22 and NEMA MG1-1.
n Stator windings are "trickle" varnished and rotor windings are "roll-
dipped" for complete Class H impregnation.
n All model designs pass a three-phase symmetrical short circuit
test to assure system protection and reliability.
n Unit tested for motor-starting ability by measuring instantaneous
voltage dip with a waveform data acquisition system.
n All models utilize an advanced wire harness design for reliable
interconnection within the circuitry.
n Magnetic circuit, including amortisseur windings, tooth and skewed
stator design, provides a minimal level of waveform distortion and
an electromagnetic interference level which meets accepted
requirements for standard AM radio, TV, and marine radio
telephone applications.
n Voltage waveform deviation, total harmonic content of the AC
waveform, and balanced T.I.F. (Telephone Influence Factor) have
been evaluated to acceptable standards in accordance with NEMA
MG1-22.
n Alternator is of drip-proof guarded construction.
n Fully life-tested protective systems, including "field circuit and
thermal overload protection" and standard main-line circuit
breakers capable of handling full output capacity.
n System torsional acceptability confirmed during Prototype Testing.
MAKE .............................................................................. JOHN DEERE
MODEL.................................................................................6081TF001
CYLINDERS ..........................................................................................6
DISPLACEMENT ..................................................8.1 Liter (497 cu. in.)
BORE .........................................................................116 mm (4.56 in.)
STROKE.....................................................................129 mm (5.06 in.)
COMPRESSION RATIO ............................................................. 16.5:1
INTAKE AIR..................................................................... Turbocharged
NUMBER OF MAIN BEARINGS ..........................................................7
CONNECTING RODS.......................................... 6-Drop Forged Steel
CYLINDER HEAD ................................................................... Cast Iron
PISTONS.................................................................... 6-Aluminum Alloy
CRANKSHAFT.............................................................. Hardened Steel
VALVE TRAIN
LIFTER TYPE.................................................................................. Solid
INTAKE VALVE MATERIAL.................................. Heat Resistant Steel
EXHAUST VALVE MATERIAL..............................Heat Resistant Steel
HARDENED VALVE SEATS.............................................. Replaceable
ENGINE GOVERNOR
❐ELECTRONIC......................................................................Standard
FREQUENCY REGULATION, NO-LOAD TO FULL LOAD ... 0.5%
STEADY STATE REGULATION........................................... +0.25%
LUBRICATION SYSTEM
TYPE OF OIL PUMP .................................................................Gerotor
OIL FILTER .............................................................. Full flow, Cartridge
CRANKCASE CAPACITY......................................... 32 Liters (34 qts.)
COOLING SYSTEM
TYPE OF SYSTEM ................................Pressurized, closed recovery
WATER PUMP ................................................... Pre-lubed, self-sealing
TYPE OF FAN ............................................................................Pusher
NUMBER OF FAN BLADES.................................................................7
DIAMETER OF FAN .....................................................711 mm (28 in.)
COOLANT HEATER.................................................................. 1800 W
FUEL SYSTEM
FUEL .......................................................... #2D Fuel (Min Cetane #40)
(Fuel should conform to ASTM Spec.)
FUEL FILTER........................................................................... 8 Micron
FUEL INJECTION PUMP ..................................................... Stanadyne
FUEL PUMP ............................................................................... Electric
INJECTORS........................................................ Pintel Type, 2100 PSI
ENGINE TYPE ............................................................... Direct Injection
FUEL LINE (Supply) .................................................6.35 mm (0.25 in.)
FUEL RETURN LINE................................................6.35 mm (0.25 in.)
ELECTRICAL SYSTEM
BATTERY CHARGE ALTERNATOR ......................... 55 Amps at 12 V
STARTER MOTOR ........................................................................ 12 V
RECOMMENDED BATTERY .................... (1) 12 Volt, 135 A.H., 4DLT
GROUND POLARITY.............................................................. Negative
*Ratingdefinitions-Standby:Applicableforsupplyingemergencypowerforthedurationoftheutilitypoweroutage. Nooverloadcapabilityisavailableforthisrating. (AllratingsinaccordancewithBS5514,ISO3046
andDIN6271). Prime(UnlimitedRunningTime):Applicableforsupplyingelectricpowerinlieuofcommerciallypurchasedpower. Primepoweristhemaximumpoweravailableatvariableload. A10%overload
capacityisavailablefor1hourin12hours. (AllratingsinaccordancewithBS5514,ISO3046,ISO8528andDIN6271).
GR160

OPERATING DATA
GR160
STANDBY PRIME
GR160 GR160
GENERATOROUTPUTVOLTAGE/KW-60HzSTANDBY
240V, 1-phase, 1.0 pf kW 133 126
120/208V,3-phase,0.8pf kW 133 126
139/240V,3-phase,0.8pf kW 133 126
277/480V,3-phase,0.8pf kW 133 126
AMPERAGE
Singlephase240V Amps 554 525
Threephase208V Amps 461 437
Threephase240V Amps 400 379
Threephase480V Amps 200 189
MOTORSTARTINGKVA 416V 480V 416V 480V
Maximumat35%instantaneousvoltagedip 60 Hz - kVA 680 950 680 950
FUEL
Fuelconsumption60 Hz Load 25% 50% 75% 100% 25% 50% 75% 100%
gal/hr 4.4 6.6 8.8 9.3 3.5 5.3 7.0 7.4
liters/hr 16.7 25.0 33.3 35.2 13.4 20.0 26.6 28.2
COOLING
Coolantcapacity System lit (US gal) 22(5.8) 22(5.8)
Engine lit (US gal) 14(3.7) 14(3.7)
Radiatorlit(USgal) 8(2.1) 8(2.1)
Coolantflow/min. 60 Hz - lit (US gal) 270(71.3) 270(71.3)
Heatrejectionto coolant BTU/hr 344,000 309,600
Inlet air 60 Hz - cu meters/min (cfm) 120(4500) 120(4500)
Max.inlet airtemperature °F 110 110
COMBUSTIONAIRREQUIREMENTS
Flowatratedpower 60 Hz - cu meters/min (cfm) 8.9(314) 8.0(283)
EXHAUST
Exhaust flow at rated output 60 Hz cu meters/min (cfm) 31.6(1115) 28.4(1003)
Maximumrecommendedbackpressure Kpa("H2O) 7.5(30) 7.5(30)
Exhausttemperatureat ratedoutput °C(°F) 496(925) 446(835)
ENGINE
RatedRPM 60 Hz 1800 1800
RatedHP 60 Hz 194 175
Pistonspeed 60 Hz - m/min (ft/min) 464(1524) 464(1524)
BMEP (psi) 60 Hz 171 155
POWERADJUSTMENTFORAMBIENTCONDITIONS
Temperature -3% for every 10°C above - °C 25 25
-1.5% for every 10°F above - °F 77 77
Attitude -3.0% for every 300 m above - m 1523 1523
-3.0% for every 1000 ft above - ft 5000 5000

Bulletin 0160830SBY / Printed in USA 2.99 rev: 06.02
GENERAC®POWER SYSTEMS, INC. • P.O. BOX 8 • WAUKESHA, WI 53187
262/544-4811•FAX[phone]
Design and specifications subject to change without notice. Dimensions shown are approximate. Contact your Generac dealer for certified drawings. DO NOT USE THESE DIMENSIONS FOR INSTALLATION PURPOSES.
* with trailer, without fuel
GROSS WEIGHT: 8220 lbs.* TONGUE WEIGHT: 910 lbs.
GR160
■High Coolant Temperature Automatic Shutdown
■Low Coolant Level Automatic Shutdown
■Low Oil Pressure Automatic Shutdown
■Overspeed Automatic Shutdown (Solid-state)
■Crank Limiter (Solid-state)
■Control Console
■Automatic Start System
■Fault Indicator Lamp
■AC Metering Package
• Volt, Amp, & Frequency Meters
• Phase Selector Switch
• Voltage Adjust Rheostat
STANDARDENGINEFEATURES
Distributed by:
STANDARDUNITFEATURES
■12 Volt, Solenoid-activated Starter Motor
■Air Cleaner (Dual Stage)
■Factory-installed Cool Flow Radiator
■Fan Guard
■Critical Muffler (mounted inside enclosure)
■Isochronous Governor
■Oil Drain Extension
■Radiator Drain Extension
■Closed Coolant Recovery System
■Battery Charge Alternator
■Battery Cables
■Battery Tray
■Vibration Isolators
■135 AH 4 DLT Battery
■Sound Attenuated Enclosure (68 dBA @ 7 meters)
■GFCI Protected Outlets
■Heavy Duty Single Point Lifting Eye
■CSA Compliance
■10 Amp Battery Charger
■Voltage Connection Panel
• Low Voltage Panel (208/240V) w/ Safety Shutdown Switch
• High Voltage Panel (480V) w/ Safety Shutdown Switch
• Safety Shutdown on Panel Door
• (2) Hi/Low Voltage Main Line Circuit Breakers
• (2) 50A 120/240V Hubbel Outlet #CS6369
• (1) 20A 120V GFCI Duplex Outlets
• (1) 20A 120V GFCI Twistlock
STANDARDCONTROLFEATURES
■Jacket Water Heater
■Engine Gauges
• Oil Pressure
• Water Temperature
• Battery Charging Ammeter
• Engine Hour Meter
■264 Gallon Base Tank
■2 5/16" Ball Hitch
■4 Prong Connector
■85R 16 Tires
■Tongue Jack
OPTIONALROADREADYTRAILER
©2002GeneracPowerSystems,Inc.Allrightsreserved.Allspecificationssubjecttochangewithoutnotice.