Generac Power Systems QT 100 Owner's Manual
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Generac Power Systems QT 100 Owner's Manual

Qt series 6.8l 100 kw stationary emergency generator
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QT
Serial Number
6.8L
100kW
Models
STATIONARY EMERGENCY GENERATOR
OWNER'S MANUAL
A new standard of reliability
This manual should remain with the unit.

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Summary of Contents for Generac Power Systems QT 100

  • Page 1 Serial Number 6.8L 100kW Models STATIONARY EMERGENCY GENERATOR OWNER'S MANUAL A new standard of reliability This manual should remain with the unit.

  • Page 2: Table Of Contents

    Standby Generator Sets Table of Contents Fuel System ..............8-1 SECTION PAGE Generator Set Lubrication ........8-1 SAFETY RULES ..........1-1 Prior to Initial Start-up ..........8-1 INTRODUCTION .............1-3 Initial Inspection for QT Genset Start-up .....8-2 Read this Manual Thoroughly ........1-3 Start-up Inspection ...........8-2 Operation and Maintenance ........1-3 OPERATION ............9-1 How to Obtain Service ..........1-3...

  • Page 3: Safety Rules

    Safety Rules INTRODUCTION  This symbol points out potential electrical shock hazard. Thank you for purchasing this model of the Stationary Emergency The operator is responsible for proper and safe use of the equip- Generator set product line. ment. The manufacturer strongly recommends that the operator Every effort was expended to make sure that the information and read this Owner's Manual and thoroughly understand all instruc- instructions in this manual were both accurate and current at the...
  • Page 4 Safety Rules Save These Instructions – The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas. Safety should be stressed to all operators, potential operators, and service and repair technicians for this equipment. Study these SAFETY RULES carefully before installing, operating •...
  • Page 5 Safety Rules FIRE HAZARDS • If personnel must stand on metal or concrete while installing, operating, servicing, adjusting or repairing this equipment, place insulative mats over a dry wooden platform. Work on the • Keep a fire extinguisher near the generator at all times. Do NOT use any carbon tetra-chloride type extinguisher.

  • Page 6: Identification Record

    ROTOR STATOR WINDING INSULATION AT 25°C AMBIENT (Corrosion Resistant Aluminum Enclosure Material, Steel is Standard) GENERAC POWER SYSTEMS, INC. N — Emission Equipment: N = No Equipment; Y = WAUKESHA, WI Catalytic Converter and Air/Fuel Ratio Controller A — Industrial Dealer Product...

  • Page 7: Equipment Description

    Equipment Description EQUIPMENT DESCRIPTION COOLANT RECOMMENDATIONS This equipment is a revolving field, alternating current Stationary Use a mixture of half low silicate ethylene glycol base anti-freeze Emergency Generator. It is powered by a gaseous fueled engine and deionized water. Cooling system capacity is listed in the operating at 1800 rpm for 4-pole direct drive units, 3600 rpm for specifications.

  • Page 8: Engine Protective Devices

    Engine Protective Devices ENGINE PROTECTIVE DEVICES OIL PRESSURE SENSING The Stationary Emergency Generator may be required to operate An analog Oil Pressure Sender (OPS) is used for monitoring the for long periods of time without an operator on hand to monitor engine oil pressure.

  • Page 9: Fuel Systems

    Fuel System FUEL SYSTEM PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid FUEL REQUIREMENTS fuel in the supply tank. Approximately 10 to 20 percent of the tank capacity is needed for fuel expansion from the liquid to the vapor The Stationary Emergency Generator may be equipped with one of state.

  • Page 10: Specifications

    Standby Generator Sets Specifications SPECIFICATIONS Engine Lubrication System Type of Oil Pump ..............Gear Oil Filter .............Full Flow, Cartridge GENERATOR Crankcase Oil Capacity ............6 U.S. qts. Type ................Synchronous Rotor Insulation ..............Class H COOLING SYSTEM Stator Insulation ..............Class H Type ..................Closed Total Harmonic Distortion ............<...

  • Page 11: Cold Weather Kit

    Standby Generator Sets Specifications Figure 1 — Interconnections COLD WEATHER KIT For cold climates, optional cold weather kit (part num- ber 0F6148A) is recommended. The kit includes: • Battery Warmer • 4” Junction Box with hardware • 700 Cold Cranking Amp Battery •...

  • Page 12: 5.4L & 6.8L Ignition Description

    Standby Generator Sets Specifications 5.4L & 6.8L IGNITION DESCRIPTION NOTE: This single-fire Ignition is intended to operate with The ignition cover does not need to be removed to a 10-cylinder, 6.8L engine and an 8-cylinder, 5.4L see the LED. engine. IGNITION SHUTDOWN ON LOSS OF CRANK The 6.8L engine uses a 40-1 crank sensor, a mag- pickup CAM sensor and individual coil-on-plug coils...

  • Page 13: General Information

    General Information GENERATOR AC LEAD 3-PHASE ALTERNATORS ("Y" CONFIGURATION) CONNECTIONS The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alterna- See “Voltage Codes”. This Stationary Emergency Generator may tor power windings. These windings were connected at the factory be rated at any one of five voltages, either single-phase or three- to the main circuit breaker with a “Y”...

  • Page 14: 3-Phase Alternators

    General Information Figure 7.1 — Stator Power Winding 3-PHASE ALTERNATORS ("DELTA" CONFIGURATION) Connections - 3-phase, 346/600V (6 Lead) The Stationary Emergency Generator is designed to supply 3-phase electrical loads. Electric power is produced in the alterna- tor power windings. These windings were connected at the factory S1 E1 to the main circuit breaker with a “Delta”...

  • Page 15: Installation

    Installation INSTALLATION PRIOR TO INITIAL START-UP Refer to the separate “Installation Guide QT Product Line” supplied with the unit. Prior to initially starting the generator, it PREPARATION BEFORE START-UP must be properly prepared for use. Any attempt to crank or start the engine before The instructions in this section assume that the Stationary it has been properly serviced with the rec- Emergency Generator has been properly installed, serviced, tested,...

  • Page 16: Start-Up Inspection

    Installation START-UP CHECKLIST • Check voltage at the generator terminals. • For 3-phase units, check phase rotation at the transfer switch terminals. The generator phase rotation must match the utility phase rotation. Before working on the Stationary Emergency • Check for coolant, fuel, oil, and exhaust leaks. Generator, ensure the following: •...

  • Page 17: Operation

    Operation STATIONARY EMERGENCY GENERATOR CONTROL AND Do not crank the engine continuously for lon- OPERATION ger than 30 seconds, or the heat may damage the starter motor. Refer to the appropriate control panel operator’s manual for this • Let engine stabilize and warm up. unit.

  • Page 18: Maintenance

    Maintenance MAINTENANCE PERFORMED BY AUTHORIZED SERVICE DEALERS  The exhaust system parts from this product get extremely hot and remains hot after shut- down. High grass, weeds, brush, leaves, etc. must remain clear of the exhaust. Such mate-  Before working on the Stationary Emergency rials may ignite and burn from the heat of the Generator, ensure the following: exhaust system.

  • Page 19: Engine Coolant

    Maintenance ENGINE COOLANT INSPECT EXHAUST SYSTEM Check coolant level in coolant recovery bottle. See the Inspect the exhaust system at least once every three months. “Specifications” section. Check all exhaust system pipes, mufflers, clamps, etc. for condi- tion, tightness, leaks, security, damage. •...

  • Page 20: Changing The Engine Air Cleaner

    Maintenance SPARK PLUGS Remove OIL FILL CAP . Add recommended oil (see SPECIFICATIONS). DO NOT FILL ABOVE THE DIPSTICK “FULL” Reset the spark plug gap or replace the spark plugs as neces- MARK. Crankcase oil capacity is listed in the SPECIFICATIONS sary.
  • Page 21 Maintenance BATTERY Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause All lead-acid storage batteries discharge when not in use. Refer to severe burns. Do not permit fluid to contact specific instructions and warnings that accompany the battery. If eyes, skin, clothing, painted surfaces, etc.
  • Page 22 Service Schedule SERVICE SCHEDULE 22 KW - 150 KW GASEOUS STATIONARY EMERGENCY GENERATOR The following is a recommended maintenance schedule for Gaseous Stationary Emergency Generator sets from 22kW 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 need to be decreased (performed more frequently) if the unit is used in a severe application.
  • Page 23 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level 5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...
  • Page 24 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...
  • Page 25 Service Schedule Maintenance Level 1 Level 2 Level 3 Level 4 Level5 Tasks Recom- Task Required Task Required Task Task Required Task mended Comp. to be done Comp. to be done Comp. Required Comp. to be done Comp. to be done (Date- 3 months/ (Date-...

  • Page 26: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE PROBLEM CAUSE CORRECTION Engine won’t crank. 1. 15 amp fuse blown. 1. Replace fuse. 2. Loose or corroded or defective 2. Tighten, clean or replace battery cables. battery cables as necessary. 3. Defective starter contactor. 3. Replace contactor.* 4.
  • Page 27 Notes...
  • Page 29 0F2885 PANEL CB CONN BOX 0F2883 STAND RH CONTROL 0F9637 (4) STAND RH CONTROL, TWO HOLE (FOR 5.4L 100KW & UL CIRCUIT BREAKER (FD) 4.6L 80KW 1PHASE) 0F2887 COVER FD FRM CB 0F3685 STAND LH CONTROL C5 GRBX 0D5572 CB 0150A 3P 600V S FD6 LL 023484N BUSHING SNAP SB-2.5-31 0D5573...
  • Page 31 UL CIRCUIT BREAKER (225AF) 0F4173 COVER CB C5 225AF UL CIRCUIT BREAKER (800AF) 0F4165$ CIRCUIT BREAKERS 200A FRAME 0F4176 COVER CB C5 800AF 0F4186 COVER CB DISH 225AF 0F4167$ CIRCUIT BREAKERS 800A FRAME 036261 RIVET POP .125 X .275 SS 0F8433 INSULATOR CB 800AF 053640...
  • Page 33 UL CIRCUIT BREAKER (JG) 0H5870 COVER CB E JG FRAME C5 0H5580 CB 0250 3P 600V E JG LL 022770 SCREW RHM 1/4-20 X 3 022473 WASHER FLAT 1/4-M6 ZINC 022097 WASHER LOCK M6-1/4 022127 NUT HEX 1/4-20 STEEL 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 029289 TAPE ELEC 1/2 FOAM...
  • Page 35 055173 SCREW HHC M8-1.25 X 20 G10.9 022129 WASHER LOCK M8-5/16 0E2747A FAN SAE ALTERNATOR (G/B) 0A3870 KEY SQ 3/8 X 1-9/16 STEEL 0A3009 HUB DRIVE 390 SAE GB 0F5564D RTR 390 100KB3 GB SAE TECHUM 0F5563D RTR 390 130KB4 GB SAE TECHUM 0A3881D RTR 390 80GB BR BRLSS 0A3881B...
  • Page 37 0F2885 PANEL CB CONN BOX 029289 TAPE ELEC 1/2 FOAM (AS REQ’D) 0G0171 STAND RH CONTROL CPL C5 37*** 0F3113 ASSY PCB HSB CTRL IGN MODULE 0G0171A STAND RH CONTROL CPL C5 2 HOLE 047411 SCREW HHC M6-1.0 X 16 G8.8 0G0172 STAND LH CONTROL CPL C5 036943...
  • Page 39 COMPONENTS INCL UDED IN 0G4139E 0F1823CST 03 ENCL H/G CO NTROL PANEL 0F1824AST 03 CO VER CONTRO L PANEL 0F2606 HING E CONT INUOUS H PANEL 036261 RIVET POP .125 X .275 SS 0F5763 ASSY PROGRAMMED H- 100 0F1732 DECAL FUSES LO CAT ED INSIDE 0E9764 RAIL SNAPTRACK PCB HO LDER BULK ( 12”...
  • Page 41 0F3384 BASE CPL 100-130KW 6.8L GB 065852 SPRING CLIP HOLDER .37-.62 052252 DAMPENER VIBRATION 052257 SPACER .49 X .62 X 1.87 PWDR/ZINC 052259 WASHER FLAT M12 055597 SCREW HHC M12-1.75 X 85 G8.8 052251A DAMPENER VIBRATION 50 WHITE 052860 NUT LOCKING M12-1.75 0F2895 SUPPORT ENG 5.4L LH/RH 6.8L RH 045764...
  • Page 43 EXPLODED VIEW: EV BATTERY 27F GEAR BOX GROUP C DRAWING #: 0G0775 ITEM PART# QTY. DESCRIPTION (1)1 0F3408AST0R TRAY BATTERY 27F 0F3411A STRAP BATTERY RETAINMENT 27F 058665 BATTERY 12VDC 90-AH 27F 022131 WASHER FLAT 3/8-M10 ZINC 050331A BATTERY POST COVER RED + 050331 BATTERY POST COVER BLK - 038805Z...
  • Page 45 0F2123 GEAR CASE ENG. MACHINED 0F2122 GEAR CASE ALT. MACHINED 095613 SEAL OIL 051756 SCREW HHC M10-1.5 X 20 G8.8 046526 WASHER LOCK M10 049814 SCREW HHC M10-1.5 X 25 G8.8 051735 SCREW HHC M10-1.5 X 70 G8.8 0F2097 GASKET 390 GEARBOX 072879 SPACER .69 X 2.75 X .37 ST/ZNC 097557B...
  • Page 47 0F2807C PIPE EXH MAN R/H 6.8L G/B CPL (6.8L C5) 0F2807E PIPE EXH MAN R/H 5.4L G/B & 2P (5.4L C5) 0F9207 PIPE EXH MANIFOLD 4.6L RH 0F2807B PIPE EXH MAN L/H 6.8L G/B CPL (6.8L C5) 0F2807D PIPE EXH MAN L/H 5.4L G/B & 2P (5.4L C5) 0F9208 PIPE EXH MANIFOLD 4.6L LH 0A6765...
  • Page 49 0F3017 BRACKET,D.C. ALTERNATOR LOWER 039253 SCREW HHC M8-1.25 X 20 G8.8 022129 WASHER LOCK M8-5/16 022145 WASHER FLAT 5/16-M8 ZINC (2) 5 0D5419 OIL FILTER, FORD V-10 ENGINE 0D7055 DIPSTICK TUBE, FORD 6.8L 0D3488G BELT SERPENTINE (65.0" LG) (1800 RPM) 0D3488J BELT SERPENTINE (65.3"...
  • Page 51 0D5418 STARTER MOTOR FORD V-10 ENGINE 052625 SCREW SHC M10-1.5 X 35 G12.9 (2) 4 047411 1 / 2 SCREW HHC M6-1.0 X 16 G8.8 0D5623 HEAT SHIELD EXHAUST 0D2608 SCREW HHC 5/16-18 X 1/2 SSTL 070006 WASHER LOCK M8 SSTL 070008 WASHER FLAT M8 SS 055934M...
  • Page 53 0D2513D AIR CLNR BTM PLT W/CPLR 8.1L 0D2513E PLATE AIR CLEANER W/COUPLER 0F5419 ELEMENT AIR FILTER 0F4268 TOP PLATE VENTURI 0F4270A HOLD DOWN AIR CLEANER PLATED 0F6977 PLATE AIR CLEAN TOP 5.4L/6.8L 037561 NUT WING 1/4-20 NYLK 047411 SCREW HHC M6-1.0 X 16 G8.8 022097 WASHER LOCK M6-1/4 049811...
  • Page 55 0J01150ST03 WELDMENT RADIATOR SUPPORT C5 0H20620ST03 ARM BELT TENSIONER 0F2611 RADIATOR 680 X 680 X 70 CPL (2) 12 0H2051 SHOULDER BOLT 1/2 X 2-1/4" 0F5254 V-BELT 31/64" X 62-3/8" 0F2862 SPRING TENSION CPL 0F7077 V-BELT 1/2" X 63-3/8" (6.8L, 100KW & 130KW) 0F2560 PULLEY V-BELT 4"...
  • Page 57 0G15310GS0R PANEL C5 FRONT SIDES 0G15320GS0R PANEL C5 REAR SIDES 0G15300GS0R PANEL LOWER FRONT 0G15290GS0R PANEL C5 TOP 0H30010GS0R PANEL C5 TOP 0G15330GS0R PANEL C5 TOP MOUNT 0C2454 SCREW THF M6-1 X 16 N WA Z/JS (1) 7 0D3215B ACCESS COVER 160 X 170 GALV (1) 8 0C2454 SCREW THF M6-1 X 16 N WA Z/JS...
  • Page 59 033212 SCREW HHC 5/16-18 X 1-1/4 G5 065908 SUPPORT NAT GAS SOLENOID 0G9191L REG ASSY 6.8L 130KW DUAL LP QT 0G9191M REG ASSY 6.8L 150KW DUAL LP QT 0G9190A REG ASSY 6.8L 100KW LPV CPL 0G9239A REG ASSY 5.4L 80KW LPV CPL 052617 SCREW HHC M12-1.75 X 20 G8.8 022304...
  • Page 61 033212 SCREW HHC 5/16-18 X 1-1/4 G5 065908 SUPPORT NAT GAS SOLENOID 0G9240A REG ASSY 5.4L 80KW NG CPL 0G9190B REG ASSY 6.8L 100KW NG CPL 052617 SCREW HHC M12-1.75 X 20 G8.8 022304 WASHER FLAT 1/2 ZINC 022129 WASHER LOCK M8-5/16 045773 NUT HEX M12-1.75 G8 YEL CHR 022195...
  • Page 63 (2) 1 0F58730ST01 REAR WRAP C5 (2) 2 0F58680ST01 DOOR C5 (2) 3 0F58720ST01 CENTER SUPPORT C5 (3) 4 0F58710AL01 DISCHARGE DUCT LH & RH SIDE C5 (2) 5 0F58690ST01 FRONT CORNERS C5 (2) 6 0F58700ST01 DISCHARGE CENTER DUCT C5 (3) 7 0F58670AL01 ROOF C5 ALUM...
  • Page 78 Notes...
  • Page 79 Notes...
  • Page 80 COMMERCIAL STATIONARY EMERGENCY PRODUCT 50kW AND ABOVE For a period of two (2) years from the date of sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part(s) which, upon examination, inspection, and testing by Generac or an Authorized/Certified Generac Dealer, or branch thereof, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.

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