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.
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.
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...
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.
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.
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.
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 ............<...
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...
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”...
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”...
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,...
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: •...
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.
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.
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. •...
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 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 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 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.