Generac Power Systems QT 5.4L Owner'S Manual Download Page 1

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STANDBY GENERATOR

OWNER'S MANUAL

This manual should remain with the unit.

A new standard of reliability

Serial Number

5.4L

100kW

Models

Cover008 Re

v. 0 08/05

Par

t No

. 0F3607

Summary of Contents for QT 5.4L

Page 1: ...STANDBY GENERATOR OWNER S MANUAL This manual should remain with the unit A new standard of reliability Serial Number QT 5 4L 100kW Models Cover008 Rev 0 08 05 Part No 0F3607 ...

Page 2: ...ernators 7 1 INSTALLATION 8 1 Installation 8 1 Preparation Before Start up 8 1 Transfer Switch 8 1 Fuel System 8 1 Generator Set Lubrication 8 1 Prior to Initial Start up 8 1 Initial Inspection for QT Genset Start up 8 2 Start up Inspection 8 2 OPERATION 9 1 Generator Control and Operation 9 1 Operating Unit with Automatic Transfer Switch 9 1 Operating Unit with Manual Transfer Switch 9 1 Engine S...

Page 3: ...rator is installed operated and serviced in accordance with the manufacturer s instructions and recommendations Following installation do nothing that might render the unit unsafe or in noncompliance with the aforementioned codes standards laws and regulations The engine exhaust fumes contain carbon monox ide gas which can be DEADLY This dangerous gas if breathed in sufficient concentrations can c...

Page 4: ...s will result in damage to the generator and may also result in injury or death to utility power workers due to backfeed of electrical energy Generators installed with an automatic transfer switch will crank and start automatically when normal utility source voltage is removed or is below an acceptable preset level To prevent such automatic start up and possible injury to person nel disable the ge...

Page 5: ...zard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equipment The manufacturer strongly recom mends that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment The manufacturer also strong ly recommends instructing other users to properly start and operate the unit This prepar...

Page 6: ...eking information Identification Code Use this code to obtain important information about the generator For example if the code is M Designates generators capable of paralleling NOTE Only 100kW and 150kW 6 8L units are currently available for this configura tion QT Quiet Test Generator Series 100 kw Rating 5 4 Engine Size in Liters A Voltage Code A 120 240 Single phase G 120 208 Three phase K 277 ...

Page 7: ...ay result in an engine failure NOTE For temperatures below 32 F it is strongly recom mended to use the optional Cold Weather Start Kit part number listed in the Specification Section The oil grade for temperatures below 32 F is 5W 30 synthetic oil COOLANT RECOMMENDATIONS Use a mixture of half low silicate ethylene glycol base anti freeze and deionized water Cooling system capacity is listed in the...

Page 8: ...ed as the low coolant level If the level of the engine coolant drops below the level of the low coolant level sensor the engine shutdown will be initiated OIL PRESSURE SENSING An analog Oil Pressure Sender OPS is used for monitoring the engine oil pressure This sender allows the control panel to measure and display the Engine oil pressure The OPS is a resistive device whose resistance changes base...

Page 9: ... supplier to make sure sufficient gas pressure is available to operate the primary regulator Gas pressure at the inlet to the fuel shutoff sole noid should not exceed approximately 14 inches water column 0 5 psi Optimum pressure at the fuel shutoff solenoid is 11 inches water column 0 4 psi PROPANE VAPOR WITHDRAWAL FUEL SYSTEM This type of system utilizes the vapors formed above the liquid fuel in...

Page 10: ...gulation 1 2 Adjustments Speed Selectable Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Cartridge Crankcase Oil Capacity 5 U S qts COOLING SYSTEM Type Closed Water Pump Belt Driven Fan Speed 1700 Fan Diameter 26 inches Fan Mode Puller Air Flow inlet air including alternator and combustion air 4800 ft3 min Coolant Capacity 4 0 U S gal Heat Rejection to Coolant 376 000 Btu h M...

Page 11: ...r 0F6148A is recommended The kit includes Battery Warmer 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 GROUND ONLY AT GENERATOR BOX GenSpec007 Rev C 11 05 ...

Page 12: ...ignition will stop firing the coils and will power down within approximately 2 seconds In the event that an ignition fault has occurred however the ignition will wait 60 seconds before powering down This allows time to view the diagnostic LED located on the ignition board NOTE The ignition cover does not need to be removed to see the LED IGNITION SHUTDOWN ON LOSS OF CRANK OR CAM SIGNALS The igniti...

Page 13: ...breaker ter minal is 240V The rated voltage between each circuit breaker terminal and the neutral point 00 is 120V Figure 7 1 Four lead Single phase Stator ALTERNATOR POWER WINDING CONNECTIONS 3 PHASE ALTERNATORS The generator is designed to supply 3 phase electri cal loads Electric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit...

Page 14: ...oil level in the generator gearbox if so equipped prior to initial use and at the intervals indicated by the Service Schedule The recom mended oil is SAE 90 gear lubricant Also if the engine is equipped with a mechanical gov ernor make sure the governor is properly lubricated with clean engine oil PRIOR TO INITIAL START UP Prior to initially starting the generator it must be properly prepared for ...

Page 15: ...ion The engine should now crank and start 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 Check for coolant fuel oil and exhaust leaks Close the generators main line circuit breaker Turn the generator set off Connect the UTILITY supply to the transfer switch Set the A...

Page 16: ...ransfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the standby generator s main line circuit break er to its OFF or OPEN position Start the generator Do not crank the engine continuously for longer than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check all applicable instrument and gauge read ings When...

Page 17: ...operation This includes such obstruc tions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down The exhaust system parts from this product get extremely hot and remain hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn fr...

Page 18: ...any damaged deteriorated worn or otherwise defec tive belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect about 3 8 to 5 8 inch Adjust belt tension as required INSPECT ENGINE GOVERNOR Visually inspect electronic governor DANGER Do not attempt to adjust the governor Only qualified service facilities should adjust the governor Excessively high operating speeds ar...

Page 19: ... 0 045 inch by carefully bending the ground electrode Figure 10 4 Figure 10 4 Setting the Spark Plug Gap COOLANT CHANGE Every year have an Authorized Service Facility drain flush and refill the cooling system See the Specifications section for cooling system recom mendations MISCELLANEOUS MAINTENANCE CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that a...

Page 20: ...ive type bat tery hydrometer DANGER Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charg ing The slightest spark can ignite the gas and cause an explosion Such an explosion can shat ter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow s...

Page 21: ...on when required 2 A wear in service inspection of the generator set to insure it is ready to operate and carry the load when required and to identify any potential problem areas Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit This inspection contains some maintenance tasks which require special tools equipment and or knowledge to ...

Page 22: ... 3 Check the engine coolant level Adjust as necessary 4 Check the engine coolant thermal protection level Correct as necessary 5 Check the natural gas delivery system for leaks and correct pressure on gas engine driven units Tighten connections as necessary 6 Check the air inlets and outlets for debris Clean as necessary 7 Check the battery electrolyte level and specific gravity if accessible Adju...

Page 23: ...and damage Replace as necessary 11 Check the engine valve clearance Adjust as necessary 12 Visually inspect the unit looking for leaks wear or damage loose connections or components and corrosion Correct as necessary 13 Test the engine and transfer switch safety devices Correct and or adjust as necessary 14 Initiate an automatic start and transfer of the unit to site load and exercise it for at le...

Page 24: ...gh for at least 2 hours looking for leaks loose connections or components and abnormal operating conditions Correct as necessary 19 Perform an engine oil analysis send a sample to a lab for results Change the engine oil and filters if the analysis results indicate this is required 20 Change the engine oil 21 Replace the engine oil filter s 22 Replace engine spark plugs Clean and re gap or replace ...

Page 25: ...nded in SPECIFICATIONS Engine starts then shuts down 1 Engine oil level is low 1 Check oil and add oil as needed 2 Engine is overheated 2 Check cooling system for leaks 3 Defective Low Oil Pressure Switch 3 Replace switch 4 Defective Coolant Temperature Switch 4 Replace switch 5 Defective Control Module circuit board 5 Replace board 6 Coolant Level is Low 6 Repair leak Add coolant 7 Defective Low ...

Page 26: ...Standby Generator Sets Notes ...

Page 27: ...Standby Generator Sets Notes ...

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Page 29: ... 1 PHASE 27 0F2722 1 COVER EXCITER SHIELD 28 077043F 1 CONDUIT FLEX 1 25 ID 29 020151 1 CLAMP VINYL 312 X 203 Z 30 023365 3 WASHER SHAKEPROOF INT 8 31 033133 1 SCREW HHM 8 32 X 3 8 32 033143 2 SCREW HHM 8 32 X 7 8 33 086032 2 LUG RT ANG 10 10 12 34 090063 1 BRIDGE SUPPORT DIODE 15 35 090064 1 CAP END ROTOR 390MM 36 090152 1 ASSY BRIDGE RECTIFIER 37 022661L 1 SLEEVING UL 0 330 ID 3 LG 38 028739A 2 ...

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Page 31: ...100KW 4 6L 80KW 1 PHASE 35 0F6156 1 PLATE WIRE SNGL GALV 36 029289 1 TAPE ELEC 1 2 FOAM AS REQ D 3 37 0F8656 REF ASSY PCB 4 6L IGNITION MODULE 0F3113 REF ASSY PCB HSB CTRL IGN MODULE ALL OTHER APPLICATIONS EXCEPT 4 6L G3 38 047411 4 SCREW HHC M6 1 0 X 16 G8 8 39 036943 2 SCREW PPHM 10 32 X 2 40 023897 2 WASHER FLAT 10 ZINC 41 022152 2 WASHER LOCK 10 42 022158 2 NUT HEX 10 32 STEEL 1 UL CIRCUIT BRE...

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Page 33: ...225 400 A P 0A7822 3 LUG SLDLSS 600 250 1 0 X 1 4 28 R 022131 3 WASHER FLAT 3 8 M10 ZINC 1 S W CB 2 TERM COVER CB T 023334 6 SCREW HHC 1 4 28 X 1 2 G5 U 022097 6 WASHER LOCK M6 1 4 V 022473 6 WASHER FLAT 1 4 M6 ZINC 2 W W CB 2 3 SCREW SHC M10 1 5 X 25 G12 9 2 X W CB 2 3 WASHER LOCK M10 5 UL CIRCUIT BREAKER 800AF A 0F4176 1 COVER CB C5 800AF B 065469 1 DECAL DANGER HIGH VOLTAGE C 0F4167 REF CIRCUIT...

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Page 35: ...33 081008 1 GROMMET 1 25 X 25 X 75 34 077043J 3 CONDUIT FLEX 2 0 ID 35 0F6156 1 PLATE WIRE SNGL GALV 36 029289 1 TAPE ELEC 1 2 FOAM AS REQ D 37 0F3113 REF ASSY PCB HSB CTRL IGN MODULE 38 047411 4 SCREW HHC M6 1 0 X 16 G8 8 39 036943 2 SCREW PPHM 10 32 X 2 40 023897 2 WASHER FLAT 10 ZINC 41 022152 2 WASHER LOCK 10 42 022158 2 NUT HEX 10 32 STEEL 1 UL CIRCUIT BREAKER 800AF A 0G0173 1 COVER CB 803 C5...

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Page 37: ...RG SHAFT CPL FANDRIVE 29 0F4028 1 PULLEY 6 5 DIA MACHINED 6 8L 100KW 0F4030 1 PULLEY 6 DIA MACHINED 6 8L 130KW 0F4032 1 PULLEY 5 5 DIA MACHINED 5 4L 80KW 6 8L 150KW 0F4496 1 PULLEY 4 5 DIA MACHINED 5 4L 100KW 30 042911 1 SCREW HHC M10 1 5 X 30 G8 8 31 0F2872 1 SCREW HHC 1 2 13 X 2 G8 32 022304 2 WASHER FLAT 1 2 ZINC 33 022195 1 WASHER LOCK 1 2 34 022196 1 NUT HEX 1 2 13 STEEL 35 049813 8 NUT HEX M...

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Page 39: ...SHER SHAKEPROOF INT 1 4 12 061383 1 LUG SOLDERLESS 3 0 4 X 13 32 CU 13 043107 1 SCREW HHC M8 1 25 X 25 G8 8 14 022473 1 WASHER FLAT 1 4 M6 ZINC 15 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 16 057192 8 SCREW SHC M10 1 5 X 30 G12 9 17 022131 8 WASHER FLAT 3 8 M10 ZINC 18 046526 8 WASHER LOCK M10 19 0536210360 1 WIRE ASSEM 4GA GRD 20 042909 1 SCREW HHC M8 1 25 X 30 G8 8 21 022261 2 WASHER SHAKEPROOF INT 3...

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Page 41: ...ATT POST COVER RED 6 050331 1 BATT POST COVER BLK 7 038805U 1 CABLE BATT BLK 1 X 18 00 8 038804U 1 CABLE BATT RED 1 X 28 00 9 045771 1 NUT HEX M8 1 25 G8 YEL CHR 10 022129 1 WASHER LOCK M8 5 16 11 027482 1 WASHER SHAKEPROOF EXT 5 16 STL 12 075763 1 BOOT BATTERY CABLE 13 0C2454 8 SCREW THF M6 1X16 N WA Z JS 14 0F3409 1 SUPPORT BATTERY TRAY ...

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Page 43: ...VER 3 18 X 12 7 X 382 28 0F6305A 1 SEAL COVER 3 18 X 12 7 X 283 29 0F6277 1 ASSY HARNESS H PNL SW NOT SHOWN COMPONENTS INCLUDED IN WIRE HARNESS A 0F1263 1 ADPTR RH SIDE WICKMAN 178 6191 B 0F1262 4 HOLDER FUSE WICKMANN 178 6150 C 0F1264 1 ADPTR LH SIDE WICKMAN 178 6192 D 0E9049B 1 ASSY PCB G PANEL RELAY 12VDC E 055911 1 BLOCK TERM 20A 12 X 6 X 1100V COMPONENTS NOT INCLUDED IN 0F1826E OR WIRE HARNES...

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Page 45: ...6 N WA Z JS 12 022097 8 WASHER LOCK M6 1 4 13 0F2830 2 MUFFLER BRACKET STIFFENER 14 0F4462 REF RAIN CAP ALUM FOR 2 1 2 PIPE 15 0C2454 REF SCREW THF M6 1 X 16 N WA Z JS 16 0F4367 REF HEAT SHIELD EXHAUST STACK 17 0F4368 REF CAP HEAT SHIELD EXHAUST STACK 18 0F2773C 2 EXHAUST BLANKET 900MM LONG 6 8L C5 0F2773D 2 EXHAUST BLANKET 850MM LONG 5 4L C5 19 0D3159 2 FLANGE EXHAUST 20 088775 6 WASHER FLAT 3 8 ...

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Page 47: ...PLATE VENTURI 4 0F4270A 1 HOLD DOWN AIR CLEANER PLATED 5 0F6977 1 PLATE AIR CLEAN TOP 5 4L 6 8L 6 037561 1 NUT WING 1 4 20 NYLK 7 047411 4 SCREW HHC M6 1 0 X 16 G8 8 8 022097 4 WASHER LOCK M6 1 4 9 049811 4 WASHER FLAT M6 10 0F4269 1 GASKET MIXER BODY 11 022473 1 WASHER FLAT 1 4 M6 ZINC ...

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Page 49: ...TOR 3600 RPM 28 0F3217 1 SPACER DC ALTERNATOR PULLEY 29 0F3287 1 BRKT DC ALTERNATOR UPPER 30 0F3017 1 BRKT DC ALTERNATOR LOWER 31 0F5991 1 HARN ENG 5 4L H 100 NOT SHOWN 32 051713 8 WASHER FLAT M5 33 042914 2 SCREW HHC M8 1 25 X 90 G8 8 34 051731 9 SCREW HHC M8 1 25 X 50 G8 8 35 022129 9 WASHER LOCK M8 5 16 36 022145 9 WASHER FLAT 5 16 M8 ZINC 37 051756 2 SCREW HHC M10 1 5 X 20 G8 8 38 046526 2 WAS...

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Page 51: ...30 G12 9 17 022129 4 WASHER LOCK M8 5 16 18 039253 1 SCREW HHC M8 1 25 X 20 G8 8 19 0D2244M 1 ASSY MAGPICKUP 3 8 24 MALE 20 044118 REF BARBED STR 1 2 NPT X 5 8 21 055934M 1 CLAMP VINYL 75 X 343 Z 22 047411 1 SCREW HHC M6 1 0 X 16 G8 8 23 071623 4 SCREW SHC M10 1 5 X 55 G12 9 24 0D6742 1 VALVE PCV FORD 6 8L 25 022097 1 WASHER LOCK M6 1 4 26 0F1820 2 MACHINED MANIFOLD EXHAUST 5 4L 27 0F1818 2 GASKET...

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Page 53: ... ADAPTOR THROTTLE BODY BOSCH 6 8L FORD GEARBOX 19 0E4390 1 GASKET GOVERNOR ACTUATOR 20 0E4392 1 ACTUATOR BOSCH 60 GOVERNOR 21 0F0960 1 REDUCER 3 0 TO 2 75 TURBO 22 0F3885 1 MIXER 40 60MM ACTUATOR ASSY 23 0F3694 2 O RING 2 7 8 X 3 1 16 X 3 32 24 0F3691C 1 VENTURI THROTTLE 38MM 5 4L 80KW 0F3691D 1 VENTURI THROTTLE 40MM 5 4L FORD 2 POLE 100KW 0F3691E 1 VENTURI THROTTLE 42MM 6 8L FORD GEARBOX 100KW 25...

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Page 55: ...0R2 45 LG 15 0D2698 1 GASKET ADAPTER THROT BODY 16 0D1509 1 DECAL INLET PRESSURE 17 050280 1 DECAL FUEL INLET LPG LP VAPOR APPLICATION 18 0D2696B 1 ADAPTOR THROTTLE BODY BOSCH 6 8L 0F2756A 1 MACHINING INTAKE ADAPTOR 60MM 5 4L 19 0E4390 1 GASKET GOVERNOR ACTUATOR 20 0E4392 1 ACTUATOR BOSCH 60 GOVERNOR 21 0F0960 1 REDUCER 3 0 TO 2 75 TURBO 22 0F3885 1 MIXER 40 60MM ACTUATOR ASSY 23 0F3694 2 O RING 2...

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Page 57: ... 2 RIVET POP 1875 X 450 SS 32 0F3949C 1 INSULATION ROOF TOP 33 0F3949D 4 INSULATION DOOR 34 0F3949G 1 INSULATION DISCHARGE DUCT 35 0F3949J 2 INSULATION CENTER SUPPORT 36 0F3949K 1 INSULATION DISCHARGE DUCT TOP 37 0F3949F 2 INSULATION INNER DUCT SIDE 38 0F3890B 4 RETAINER INSULATION 820 39 0F3890 14 RETAINER INSULATION 450 40 042568 4 SCREW HHC M6 1 0 X 20 G8 8 41 0912970088 2 ASSY WIRE 14 AWG 20 9...

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Page 76: ...failure caused by contaminated fuels oils coolants antifreeze or lack of proper fuels oils or coolants antifreeze 4 Units sold rated or used for Prime Power Trailer Mounted or Rental Unit applications as Generac Power Systems have defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Power Systems Distributor for Prime Power Trailer Mounted or Rental Unit definition and warranty 5 U...

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