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Generac Power Systems 6.8L manual

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Table of contents for the manual

  • Page 1

    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 QT 6.8L 100kW Models Cover010 Re v . 0 08/05 Part No. 0F3605[...]

  • Page 2

    Standby Generator Sets T able of Contents SECTION P AGE SAFETY RULES ................................................ 1-1 INTRODUCTION ..................................................... 1-3 Read this Manual Thoroughly ................................... 1-3 Operation and Maintenance ...................................... 1-3 How to Obtain Servic[...]

  • Page 3

    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. Many accidents are caused by failing to follow simple and fundamental ru[...]

  • Page 4

    • 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. Stepping on the unit can stress and break parts, and [...]

  • Page 5

    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. However , the manufacturer reserves the right to change, alter or otherwise improve this produ[...]

  • Page 6

    I DENTI F ICA TION R EC 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 gen- erator’s lower connection box, lists the unit ’s serial number and its rated voltage, amps, wattage capacity , phase, frequency , rpm, power f[...]

  • Page 7

    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. See the Specifications section for exact numbers. The unit comes com[...]

  • Page 8

    ENGI N E P RO TE CTIVE 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 or that reason, the engine has several devices designed to protect it against potentially damaging conditions by automatically shutti[...]

  • Page 9

    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 • Liquid propane (LP) fuel system The Manual Drawing Listing that is affixed to the unit includes the “Identification Code,” which may be used to identify the type[...]

  • Page 10

    SP ECIF ICA TIONS GEN ERA T OR T ype ............................................................................. Synchronous Rotor Insulation ................................................................... Class H Stator Insulation .................................................................. Class H T otal Har monic Distor tion ........[...]

  • Page 11

    COLD WEA THER KIT F or cold climates, optional cold weather kit (part num- ber 0F6148A) is recommended. The kit includes: • Battery W armer • 4” Junction Box with hardware • 700 Cold Cranking Amp Battery • 6 qt. pack 5W -30 synthetic oil (engine) • 1 qt. 75W90 synthetic gear oil (gear drive)  Figure 1 — Interconnections 6-2 Standby[...]

  • Page 12

    5.4L & 6.8L IGN ITION DES CR I PTION This single -fire Ignition is intended to operate with a 10- cylinder , 6.8L engine and an 8- cylinder , 5.4L engine. The 6.8L engine uses a 40-1 crank sensor , a mag- pickup CAM sensor and individual coil- on-plug coils for each spark -plug . The 5.4L engine uses a 36-1 crank sensor , a mag- pick -up CAM se[...]

  • Page 13

    GEN ER A T OR A C 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. If there are any q[...]

  • Page 14

    I NST ALL A TION Refer to the separate “Installation Guide QT Product Line” supplied with the unit. P R EP ARA TION B EFOR E S T ART -U P 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 .[...]

  • Page 15

    S T ART -U P CH ECKLIS T  Before working on the generator , ensure the fol- lowing: • The AUTO/OFF/MANU AL switch is in the OFF position. • The 120V AC supply to the battery charger is switched OFF . P REP AR A TION FOR S T ART -U P • Ensure that the 120V AC circuit breaker to the bat - tery charger is open. • Remove the fuse from the th[...]

  • Page 16

    GEN ER A T OR C ONTROL AND OP ER A TION Refer to the appropriate control panel operator’s manual for this unit. OP ER A TI NG U N IT WITH MAN U AL 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. A manually operated transfer switch is one th[...]

  • Page 17

    MAI NTENANCE P ER FOR M ED B Y AUTHOR IZED SERVICE F A CILITI ES  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 . EVER Y TH R EE MONTHS 1. Check battery state [...]

  • Page 18

    ENGI NE COOL ANT Check coolant level in coolant recovery bottle. See the “Specifications” section. • Add recommended coolant mixture as necessary . • Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly . Coolant should be at bottom of radiator filler neck. If coolant level is low , insp[...]

  • Page 19

    7. Start engine and check for oil leaks. Figure 10.2 - Oil Filter Oil Filter Oil Fill Oil Dipstic k CHANGI NG THE ENGI N E AI R CLEAN ER T o replace the engine air cleaner , (part number 0A4637), remove the air cleaner cover and replace the air filter making sure it is positioned properly before reattaching the cover . Figure 10.3 — Engine Air Fi[...]

  • Page 20

    BA TTER Y All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany the battery . If such information is not available, observe the following precautions when handling a battery: • DO NOT use jumper cables and a booster battery to crank or start the generator engine. • DO NOT recharge [...]

  • Page 21

    SERVICE S CH EDU LE 30 KW - 1 50 KW S T ANDBY GA S ENGI N E DR IVEN GEN ER A T OR SET S The following is a recommended maintenance schedule for standby gas engine driven generator sets from 30kW to 150 kW in size. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will[...]

  • Page 22

    Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask Required T ask Required T ask T ask Required T ask mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Init[...]

  • Page 23

    Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask Required T ask Required T ask T ask Required T ask mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Init[...]

  • Page 24

    Maintenance Level 1 Level 2 Level 3 Level 4 Level5 T asks Recom- T ask Required T ask Required T ask T ask Required T ask mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date- Semi- (Date- to be done (Date- Bi- (Date- monthly/ Initials) Break-in Initials) annually/ Initials) Annually/ Init[...]

  • Page 25

    TROU B LESHOO TING GU I DE P ROB LEM CAUSE C OR R ECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse . 2. Loose or corroded or defectiv e 2. Tighten, clean or replace batter y cables . batter y cables as necessary . 3. Defectiv e star ter contactor . 3. Replace contactor .* 4. Defectiv e star ter motor . 4. Replace starter motor .* [...]

  • Page 26

    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    Standby Generator Sets Notes[...]

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    [...]

  • Page 31

    1 0F2885 1 PANEL CB CON N BOX 2 0F2883 1 STAND RH CONTR O L 0F 9637 ( 4) 1 S TAND RH CONTRO L, TWO HOLE (FOR 5 .4L 10 0KW & 4.6L 80 K W 1P H AS E) 3 0F3685 1 STAND L H CONTRO L C5 GRBX 4 02 34 84N 1 BUSH ING SN AP SB-2. 5-31 02348 4N 2 BUSH IN G SN AP S B-2 .5-3 1 (F OR 5.4L 1 00KW & 4.6L 80KW 1PHA SE) 5 086961 1 INTERFACE 1 PH 240V 0676 1 [...]

  • Page 32

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  • Page 33

    3.) UL CIRCUIT BRE AKE R (225A F) A 0F4173 1 COVER CB C5 2 25AF B 065469 1 DECAL DANGER HIGH V OLT AGE C 0F4 165$ RE F CIRCU IT BRE AKERS 200A FRAME D 0 F4186 1 COVER CB DI SH 225AF E 036261 4 RIVET POP .125 X .27 5 SS F 053640 4 SCREW RHM #8- 32 X 3 -1/4 G 038150 4 WAS HER FL AT # 8 ZINC H 022264 4 W ASHER LO CK # 8-M4 J 022471 4 NUT HEX #8 -32 ST[...]

  • Page 34

    [...]

  • Page 35

    1 0551 7 3 6 SCREW HHC M 8- 1. 2 5 X 20 G10. 9 2 0221 29 6 W ASHE R LO CK M8- 5/16 4 0E274 7A 1 FAN SAE ALTE RN ATOR ( G/ B) 5 0A3870 1 KEY SQ 3/8 X 1-9/16 STEEL 6 0 A3 009 1 HUB DRIV E 390 SAE GB 7 0F5564D 1 RTR 390 100KB3 GB SAE TECHUM 0F55 63D 1 RTR 390 13 0KB4 GB SAE T E CHUM 0A3881 D 1 RTR 390 80GB BR BRLSS 0A3881 B 1 RTR 390 80GB 1P BRLS S 0A[...]

  • Page 36

    [...]

  • Page 37

    1 0F2885 1 PANEL CB CO NN BOX 2 0G0171 1 STAND, RH CONT ROL CPL C 5 0G0171A 1 S TAND RH CO NTR O L CPL C5 2 HOLE 3 0G0172 1 STAND, LH CO NTR OL CPL C5 4 02 34 84N 1 BUSH ING SN AP SB-2. 5-31 5 0F4 677 1 AS SY PCB IN TERF A CE 1P H 240V 0676 1 7 0 30A - INTERF A C E 3P H S 41 6/ 4 80V 0676 1 7 0 30B - INTERF A C E 3P H S 20 8/ 2 40V 6 043180 4 WASHE[...]

  • Page 38

    [...]

  • Page 39

    1 0F2687 1 WELDMEN T RA D IA TOR SUPPORT 15 0 2 0F2611 1 RADIATO R 68 0 X 680 X 70 C PL 3 0F5254 1 V - BEL T 31 /6 4" X 62- 3/ 8" 0F52 53 1 V -BE LT 31 /6 4" X 61- 3/ 8" (5. 4L 100 KW ONL Y ) 0F707 7 1 V-BELT 1/2 " X 63-3/ 8" (6.8L 10 0 130K W) 4 046 526 12 WA SH ER LOCK M10 5 0517 5 6 8 SCREW HHC M 10- 1. 5 X 20 G8.8 [...]

  • Page 40

    [...]

  • Page 41

    1 0F3384 1 BAS E CP L 100- 1 3 0KW 6.8L GB 2 065 852 1 SPRING C LIP HOL D ER .37-.62 3 0522 52 4 DAMPENE R VI BRAT ION 4 052 257 4 SPAC ER .49 X .62 X 1.87 PWDR/ZIN C 5 0522 59 8 WASHER F LAT M 12 6 0555 97 4 SCREW HH C M 12-1. 75 X 85 G 8.8 7 05225 1A 4 DAMPE NE R VI BRATIO N 50 WHITE 8 052860 4 NUT LOCK ING M12-1 .75 9 0F2895 1 SUPP ORT ENG 5.4L [...]

  • Page 42

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  • Page 43

    1 0F3408 A 1 TRAY B ATTERY 27F 2 0F 3 4 11 A 1 STRAP BAT TE RY RET AI NM E NT 2 7F 3 05 86 65 1 BATT E RY 1 2V DC 9 0- AH 27 F 4 02 213 1 1 WASHE R FL AT 3/8-M 10 Z IN C 5 05033 1A 1 BATTE RY PO ST COVE R RE D + 6 05 033 1 1 BATTERY POS T COVE R BLK - 7 03 88 05Z 1 CABLE BAT TE RY BA CL K #1 X 26 . 00 8 03880 4U 1 CABLE BAT TE RY RE D # 1 X 28 .0 0[...]

  • Page 44

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    1 0F2123 1 GEAR CASE ENG. MACHIN ED 2 0F21 22 1 GEAR C ASE ALT. M ACHINE D 3 095613 1 SEAL O IL 4 05 175 6 2 SCREW HHC M 10- 1. 5 X 20 G 8.8 5 0465 26 44 WASHE R LO CK M1 0 6 04 981 4 4 SCREW HHC M 10- 1. 5 X 25 G 8.8 7 05 173 5 8 SCREW HHC M 10- 1. 5 X 70 G 8.8 8 0F2 09 7 1 GAS K ET 39 0 GE AR BOX 9 072879 1 SPAC ER . 69 X 2.75 X .37 S T /ZNC 10 0[...]

  • Page 46

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  • Page 47

    COMP ONENTS INCLUDED IN 0F1826 E 1 0F18 23 1 ENCL H CONTROL PANE L 2 0F18 24 1 COVER CONT ROL PANE L 3 0F26 06 1 HINGE CONT IN UOUS H-PN L 4 03626 1 6 RIVET PO P .1 2 5 X .2 75 SS 5 0F 5763 1 ASSY PROG RAM ME D PM H- 100 6 0F17 32 1 DECAL FUS ES LO CATE D I NSI DE 7 0E9764 1 RAI L SN APTR ACK P CB HOLDE R B ULK ( 12” LG) 8 0F17 25 C 1 ASSY PCB 2A[...]

  • Page 48

    [...]

  • Page 49

    1 0F2 807 C 1 PIPE E XH MA N R /H 6.8 L G/ B CP L (6. 8L C5) 0F28 07E 1 P IPE EXH MA N R /H 5 .4L G/ B & 2P (5 .4L C5) 0F92 07 1 PIPE EXH M ANIF OL D 4.6L R H 2 0F2 807 B 1 PIPE E XH MA N L /H 6. 8L G/ B CP L (6 .8L C 5) 0F28 07D 1 PIP E EX H MA N L/H 5.4L G/B & 2P (5. 4L C 5) 0F92 08 1 PIPE EXH M ANIF OL D 4.6L LH 3 0F4505 REF GLASS PACK 2[...]

  • Page 50

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  • Page 51

    1 0F3017 1 BR AC KET, D.C . AL TE R NA T OR LOWE R 2 0392 5 3 3 SCREW HHC M 8- 1. 2 5 X 20 G8.8 3 0221 29 4 WASHER L OCK M8- 5/ 16 4 0221 45 4 WASHER FL AT 5/ 16-M 8 Z IN C 5 * * 0D541 9 RE F OIL FILTE R, FO RD V -1 0 ENG INE 6 0D705 5 1 DI PS TI CK TUBE , F OR D 6.8L 7 0D3488G 1 BELT SERPEN TINE (65. 0" LG) (1800 RP M) 0D34 88J 1 BE LT SE RPE[...]

  • Page 52

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    1 039253 1 SCR EW HHC M8-1 .25 X 20 G8.8 2 0D54 18 1 STARTER M OTO R FOR D V- 10 E NGINE 3 052625 11 SCREW S H C M1 0-1.5 X 35 G 12.9 4 047411 1 SCR EW HHC M6-1 .0 X 16 G8 .8 5 0D5 623 2 HEAT SHIE LD EXHAUST 6 0D2 608 10 SCREW H HC 5 /16-1 8 X 1 /2 SSTL 7 070006 30 WASH ER L OC K M8 SSTL 8 070008 10 WASHER F LAT M8 SS 9 055 934 M 1 CLA MP VINYL .75[...]

  • Page 54

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  • Page 55

    1 0D2513D 1 AIR CL NR B TM P LT W /CPL R 8. 1L 2 0F 5419 1 ELEMENT AIR FILTER 3 0F 4268 1 TOP PLATE VEN TURI 4 0F4 270 A 1 HOL D DOW N AI R CL EA NER P LA TED 5 0F 6977 1 PLATE AI R CLEAN TO P 5.4L /6 .8L 6 037561 1 NUT WING 1/4 -20 NYL K 7 047411 4 SCREW HHC M6 -1 .0 X 16 G8 .8 8 022097 4 WASHER LOC K M6 -1/4 9 049811 4 WASHER FLA T M6 10 0F4 269 [...]

  • Page 56

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  • Page 57

    1 049 721 4 SCREW HHC M6-1 .0 X 35 G8.8 BLK 2 0659 0 8 1 S UPPORT N AT GAS SOLE NOI D 3 0F62 61G 1 RE GUL ATO R AS SM 5 .4L 80K W N G 0F62 61C 1 REGUL ATO R AS SM 5 .4L 10 0KW NG 0F62 61D 1 REGUL ATO R AS SM 6 .8L 10 0KW NG 4 0526 17 2 S CREW HHC M12- 1. 75 X 20 G8.8 5 0223 04 2 WAS HE R FL AT 1/ 2 Z INC 6 02212 9 4 WAS HE R LOCK M8- 5/ 16 7 0457 7[...]

  • Page 58

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  • Page 59

    1 0332 1 2 4 SCREW HHC 5/ 16- 18 X 1-1/ 4 G5 2 0659 08 1 SUPPORT NAT G AS SO LE NOI D 3 0F6261H 1 REGULAT OR ASSM 5.4 L 80KW LPV (5.4L 80 KW) 0F62 61J 1 RE GUL ATOR ASSM 5.4L 10 0KW LPV (5.4 L 100 KW) 0F626 1K 1 REGU LATOR ASSM 6. 8L 100K W LPG (6.8L 100KW) 0F62 61L 1 REGUL ATO R AS SM 6 .8L 13 0KW LP V (6 .8L 130KW ) 0F62 61M 1 REGUL ATO R AS SM 6[...]

  • Page 60

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    (2) 1 0F5873 1 REAR W RAP C5 (2) 2 0F5868 4 DOOR C5 (2) 3 0F5872 2 CENTER SUPPORT C 5 (2) 4 0F58 71 2 DISC HA RG E DUCT L H & RH SIDE C5 (2) 5 0F5869 2 FRONT CORNERS C5 (2) 6 0F5870 1 DISC HA RGE CE NTE R DU CT C5 (2) 7 0F5867 1 ROOF C5 ALUM 11 0C 245 4 78 S CREW THF M6- 1 X 16 N WA Z/JS 12 0F27 66 2 S PLITT ER 13 0F31 81 4 SPLI TTER SHO RT 14 [...]

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    Standby Generator Sets W arranty Printed in U.S.A. GENERA C PO WER SYSTEMS ST ANDARD LIMITED W ARRANTY FOR COMMERCIAL PRODUCT 50kW AND ABO VE For a period of two (2) y ears from the date of sale, or start-up by A uthorized/Cer tified Generac P ow er Systems Dealer , or branch thereof , Generac P ow er Systems, Inc. will, at its option, repair or re[...]