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Generac Power Systems QT 5.4L 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 5.4L 100kW Models Cover008 Re v . 0 08/05 Part No. 0F3607[...]

  • 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 EL SYST EM 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 o[...]

  • 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 • Thermostat; 20 deg “ON”, 40 deg “OFF” • 6 qt. pack 5W -30 synthetic oil (engine)  Figure 1 — Interconnections 6-2 Standby Generator Sets Specifications G[...]

  • 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 -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 . [...]

  • 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 Dipstic k Oil Filter 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 Filter Air [...]

  • Page 20

    Finally , have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low , the generator may require drying. 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 t[...]

  • Page 21

    SERVICE S CH EDU LE 30 KW - 1 5 0 KW ST AN DBY GA S ENGI N E DR IVEN GEN ER A T OR SE T 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 wi[...]

  • 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/ Ini[...]

  • 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/ Ini[...]

  • 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/ Ini[...]

  • Page 25

    TROU B LESHOO TING GU IDE 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 .* 5[...]

  • Page 26

    Standby Generator Sets Notes[...]

  • Page 27

    Standby Generator Sets Notes[...]

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    [...]

  • Page 29

    1 0F9952 1 ASSY ROT O R 2390 80KB 3 CPL 0F341 7 1 ASSY R OT O R 390 2P 100K BRSHL S 0F298 4 1 ASSY R OT O R 390 2P 150K BRSHL S 2 0F9949 1 ASSY STA TOR 80KW 1PH 2P BR SHLS 0F341 8 1 ASSY ST A TOR 390 2 P 100K BRSHL S 0F298 5 1 ASSY ST A TOR 390 2 P 150K BRSHL S UL 0F99 50 1 ST ATO R 23 90 8 0 GB 3 CPL 0F99 51 1 STATO R 2390 80 KB3 CP L 0F618 3 1 AS[...]

  • Page 30

    [...]

  • Page 31

    1 0F2885 1 PANEL CB CO NN B OX 2 0F2883 1 STAND RH CONTRO L 0F 9637 ( 4) 1 STAND RH CONTRO L, TWO HOLE (FOR 5 .4L 10 0KW & 4.6L 80 K W 1P H AS E) 3 0F3685 1 STAND LH CONTRO L C5 G RBX 4 02 34 84N 1 BUSHING 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 240 V 0676 1 7[...]

  • Page 32

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  • Page 33

    3.) UL CIRCUIT BRE AKE R (225A F) A 0F4173 1 CO VER CB C5 225AF 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 PO P .125 X .275 SS F 053640 4 SCREW RHM #8 -32 X 3 -1/4 G 038150 4 W ASHER FL AT # 8 ZINC H 022264 4 WASHER LO CK # 8-M4 J 022471 4 NU T HEX #8-32 STE[...]

  • Page 34

    [...]

  • Page 35

    1 0F2885 1 PANEL CB CO NN B OX 2 0G0171 1 STAND, RH CONTROL CP L C 5 0G0171A 1 STAND RH CONTRO L CPL C5 2 HOLE 3 0G0172 1 STAND, LH CO NTR OL CPL C5 4 02 34 84N 1 BUSHING SN AP SB-2. 5-31 5 0F46 77 1 AS SY P CB I NTE RF ACE 1P H 24 0V 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 WASHER[...]

  • Page 36

    [...]

  • Page 37

    1 0 F2687 1 WELDMENT RA D IA TOR SUPPORT 15 0 2 0 F2611 1 RADIATOR 680 X 680 X 70 CPL 3 0F5254 1 V-BELT 31 /6 4" X 62- 3/ 8" 0F52 53 1 V-BELT 31 /6 4" X 61- 3/ 8" (5. 4L 100 KW ONL Y ) 0F707 7 1 V-BE LT 1/2 " X 63-3/8 " (6.8 L 100 130K W) 4 046 526 12 WASH ER L OCK M10 5 0517 5 6 8 SCREW HH C M 10- 1. 5 X 20 G8. 8 6 0C[...]

  • Page 38

    [...]

  • Page 39

    1 0F3099 1 MTG BASE C P 5.4L 100K W DD 2 065 852 1 SPR I NG CLIP HOL D ER .37-.62 3 0522 52 5 DAMPENE R V IBR ATIO N 4 052 257 5 SPA CER .49 X .62 X 1.87 PWDR /ZINC 5 0522 59 5 WASHE R FL AT M 12 6 0555 97 5 SCREW HHC M 12- 1.75 X 8 5 G8. 8 7 05225 1A 5 DAMPE NE R VI BRAT ION 50 WHI TE 8 052860 4 N UT LOCKIN G M12-1 .75 9 0F2895 2 SUPPORT ENG 5.4L [...]

  • Page 40

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  • Page 41

    1 0F34 08 1 TRAY B ATTE RY 2 0F3411 1 S T RAP BA TTE RY RET AINM E NT 3 058208 1 B ATT 12V DC 24F 625 4 0221 31 1 WASHE R FL AT 3/8- M10 Z IN C 5 05033 1A 1 BAT T POS T COV ER RED + 6 050 331 1 B ATT POST COVER BLK - 7 03880 5U 1 CA BLE BAT T BLK #1 X 18 .0 0 8 03880 4U 1 CA BLE BAT T RE D #1 X 28.0 0 9 045771 1 N U T H EX M8-1 .25 G8 YEL CHR 10 02[...]

  • Page 42

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  • Page 43

    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 RIVE T POP .12 5 X . 275 SS 5 0F 5763 1 ASSY P ROG RAMME D P M H-1 00 6 0F17 32 1 DECAL FUS ES LO CATE D I NSI DE 7 0E9764 1 RAI L SNAP TRA CK P CB HO LDE R BUL K (1 2” LG ) 8 0F17 25 C 1 ASSY PCB [...]

  • Page 44

    [...]

  • Page 45

    1 0F2807 C 1 PIPE EXH M A N R /H 6 .8L 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 E XH MA NIF OLD 4.6L RH 2 0F2807 B 1 PIPE EXH M AN L /H 6. 8L G/B CP L (6 .8L C5) 0F28 07D 1 PIP E EX H MA N L/H 5.4L G/ B & 2P (5. 4L C 5) 0F92 08 1 PIPE E XH MA NIF OLD 4.6L LH 3 0F4505 REF GLASS P ACK 23.5&[...]

  • Page 46

    [...]

  • Page 47

    1 0D 251 3D 1 AIR CL NR BTM PLT W /CP LR 8.1L 2 0F 5419 1 ELEMEN T AIR FI L TER 3 0F 4268 1 TOP PL ATE VENTU RI 4 0F4 270 A 1 HOL D DOW N AI R CL EA NER P LA TED 5 0 F 6977 1 PLATE AIR C LEAN TOP 5.4L/6 .8L 6 037561 1 NU T WING 1/4 - 20 NYLK 7 047411 4 SCR EW HHC M6-1 .0 X 16 G8.8 8 022097 4 WAS H ER LOCK M6 -1/4 9 049811 4 WAS H ER FLAT M6 10 0F4 [...]

  • Page 48

    [...]

  • Page 49

    1 * 0F3883 1 TUBE HEATER WATE R 2 * 0F196 0 1 ENGI NE 5 .4L FO RD 3 0F2842 8 IGNI TION C OIL ASSY F ORD 4 0F2843 1 GASKET THERMOSTAT HOUSING FORD 5 ** 0D5419 1 OIL F ILTER FORD V-1 0 ENGINE 6 0F2849 1 TUBE OIL LEVEL I NDICATO R FORD 7 0D34 88G 1 BELT SE RPE NTIN E 65 .0" ( 18 00 RP M) 0D3488L 1 SERPENTINE BELT ( 66.0") ( 2650 RPM ) 0D3488[...]

  • Page 50

    [...]

  • Page 51

    1 0 D9 913 1 6 SCR EW SHC M 8 -1.25 X 35 SS 2 0E9747 1 STAR TER 12 VOLT 3 0F351 4 1 SPACER FLEX PL ATE 5.4L /6.8L (1800 R PM ONLY) 4 0F39 03 C 1 F LE X PLA TE 2 PO LE 5. 4L & 6. 8L ( 18 00 RPM U NI TS O NLY ) 0F3 9 03C 2 FLE X P LA TE 2 PO LE 5. 4L & 6. 8L ( 36 00 R PM U NI TS O NLY ) 5 0F2 776 A 1 BRAC KET, S IGN AL CONDI TIO NER 6 0D 5417[...]

  • Page 52

    [...]

  • Page 53

    1 049 721 4 SCREW HHC M6-1.0 X 35 G8.8 BLK 2 0659 0 8 1 S UPP ORT N AT G AS SOL E NOI D 3 0F6 261G 1 REGUL ATO R AS SM 5 .4L 80K W N G 0F62 61C 1 REGUL ATO R AS SM 5.4L 1 00KW NG 0F62 61D 1 REGUL ATO R AS SM 6.8L 1 00KW NG 4 0526 17 2 S CREW HH C M 12-1. 75 X 20 G8. 8 5 0223 04 2 W ASHE R FL AT 1/2 Z IN C 6 02212 9 4 W ASHE R LO CK M8- 5/16 7 0457 [...]

  • Page 54

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  • Page 55

    1 0332 1 2 4 SCREW HH C 5/ 16- 18 X 1-1/ 4 G 5 2 0659 08 1 SUPPORT NAT GAS SOLE NOI D 3 0F6261H 1 REG ULATOR A SSM 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 [...]

  • Page 56

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    (2) 1 0 F58 73 1 REAR WR AP C5 (2) 2 0F5868 4 DOOR C5 (2) 3 0F5872 2 CENTER SUPPORT C5 (2) 4 0F58 71 2 DI S C HARG E DU CT L H & RH SIDE C5 (2) 5 0F5869 2 FRO NT CORNERS C5 (2) 6 0F5870 1 DI SC HARG E CENT E R DU CT C5 (2) 7 0F5867 1 ROOF C5 ALUM 11 0C 245 4 78 SCRE W THF M6- 1 X 16 N W A Z /JS 12 0F27 66 2 SP LITTE R 13 0F31 81 4 SPLITT ER SHO[...]

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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[...]