Generac GR160 User Manual

GR160

Liquid Cooled Diesel Engine Generator Sets

Standby Power Rating

133KW 60 Hz

Prime Power Rating

126KW 60 Hz

Sound Attenuated

Skid Mounted Generator

Shown With Optional Trailer

Power Matched

JOHN DEERE 8.1T ENGINE

Turbocharged

FEATURES

■ THE SUCCESS OF GENERAC POWER SYSTEMS STARTS WITH INNOVATIVE DESIGN AND PROTOTYPE TESTING. But

it doesn't stop there. Total commitment to component testing, reliability testing, environmental testing, destruction and life testing, plus testing to applicable CSA, NEMA, EGSA, and other standards, 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. This state-of-the-art power maximizing regulation system is standard on all Generac models. It provides optimized FAST RESPONSE to changing load conditions and MAXIMUM MOTOR STARTING CAPABILITY by electronically torquematching the surge loads to the engine.

■ 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.

■ EPA APPROVED DIESEL POWER. Your Generac power system is manufactured using the most up-to-date diesel engine technology. 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.

APPLICATION & ENGINEERING DATA

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 ✓

GENERATOR FEATURES

Four pole, revolving field generator, directly connected to the engine shaft through a heavy-duty, flexible disc for permanent alignment.

Generator meets temperature rise standards for Class "F" insulation as defined by NEMA MG1-22 and NEMA MG1-1.

Stator windings are "trickle" varnished and rotor windings are "rolldipped" for complete Class H impregnation.

All model designs pass a three-phase symmetrical short circuit test to assure system protection and reliability.

Unit tested for motor-starting ability by measuring instantaneous voltage dip with a waveform data acquisition system.

All models utilize an advanced wire harness design for reliable interconnection within the circuitry.

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.

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.

Alternator is of drip-proof guarded construction.

Fully life-tested protective systems, including "field circuit and thermal overload protection" and standard main-line circuit breakers capable of handling full output capacity.

System torsional acceptability confirmed during Prototype Testing.

* Rating definitions - Standby: Applicable for supplying emergency power for the duration of the utility power outage. No overload capability is available for this rating. (All ratings in accordance with BS5514, ISO3046

and DIN6271). Prime (Unlimited Running Time): Applicable for supplying electric power in lieu of commercially purchased power. Prime power is the maximum power available at variable load. A 10% overload capacity is available for 1 hour in 12 hours. (All ratings in accordance with BS5514, ISO3046, ISO8528 and DIN6271).

ENGINE SPECIFICATIONS

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

GR160

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