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Generac Power Systems QT100, Owner'S Manual, Page: 30 / 80

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Generac Power Systems QT100 Owner'S Manual Download Page 30

Summary of Contents for QT100

Page 1: ...STATIONARY EMERGENCY GENERATOR OWNER S MANUAL This manual should remain with the unit Serial Number QT 6 8L 100kW Models A new standard of reliability Cover010 Rev A 03 09 Part No 0F3605 ...

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: ...This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator is responsible for proper and safe use of the equip ment The manufacturer strongly recommends that the operator read this Owner s Manual and thoroughly understand all instruc tions before using this equipment The manufacturer also strongly recommends instructing other users to properl...

Page 4: ...on must be provided This should be considered prior to installing the generator The unit should be positioned to direct exhaust gasses safely away from any building where people animals etc will not be harmed Any exhaust stacks that ship loose with the unit must be installed properly per the manufacturer s instruction and in strict compli ance with applicable codes and standards Keep hands feet cl...

Page 5: ...empt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving ...

Page 6: ...g service ordering parts or seeking 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 avail able for this configuration QT Quiet Test Generator Series 100 kw Rating 5 4 Engine Size in Liters A Voltage Code A 120 240 Single phas...

Page 7: ...been properly serviced with the recom mended oil may result in an engine failure NOTE If not already equipped it is strongly recommended to use the optional Cold Weather Start Kit for temperatures below 32 F The part number for the Cold Weather Start Kit can be found in the Specifications section or by contacting an authorized dealer The oil grade for temperatures below 32 F is 5W 30 synthetic oil...

Page 8: ...anel and displayed 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 mea sure and display the Engine oil pressure The OPS is a resistive device whose resist...

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

Page 10: ...on 0 25 Adjustments Speed Selectable Engine Lubrication System Type of Oil Pump Gear Oil Filter Full Flow Cartridge Crankcase Oil Capacity 6 U S qts COOLING SYSTEM Type Closed Water Pump Belt Driven Fan Speed 1670 Fan Diameter 26 inches Fan Mode Puller Air Flow inlet air including alternator and combustion air 5500 ft3 min Coolant Capacity 4 5 U S gal Heat Rejection to Coolant 342 000 Btu h Maximu...

Page 11: ...148A is recommended The kit includes Battery Warmer 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 Generator Sets Specifications GenSpec009 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: ... rated voltage between each circuit breaker terminal 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 3 PHASE ALTERNATORS Y CONFIGURATION 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 ...

Page 14: ...lectric power is produced in the alterna tor power windings These windings were connected at the factory to the main circuit breaker with a Delta configuration as shown in Figures 7 5 The rated voltage between circuit breaker terminals E1 E2 E1 E3 and E2 E3 is 208V The rated voltage between E1 or E3 and the neutral point 00 is 120V Figure 7 5 Stator Power Winding Connections 3 phase 120 240V 12 Le...

Page 15: ...rator gearbox if so equipped prior to initial use and at the intervals indicated by the Service Schedule The recommended oil is SAE 90 gear lubricant Also if the engine is equipped with a mechanical governor make sure the governor is properly lubricated with clean engine oil PRIOR TO INITIAL START UP n Prior to initially starting the generator it must be properly prepared for use Any attempt to cr...

Page 16: ...ch to the MANUAL position 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 tra...

Page 17: ...s the utility source main line circuit breaker Set the transfer handle to its UTILITY NORMAL position with load circuits connected to the utility power supply Set the generator s main line circuit breaker to its OFF or OPEN position Start the generator nDo not crank the engine continuously for lon ger than 30 seconds or the heat may damage the starter motor Let engine stabilize and warm up Check a...

Page 18: ...n the generator compartment must be open and unobstructed for continued proper operation This includes such obstructions as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine gen erator quickly overheats which causes it to shut down The exhaust system parts from this product get extremely hot and remains hot after shut down High grass weeds brush ...

Page 19: ...oolant leaks INSPECT EXHAUST SYSTEM Inspect the exhaust system at least once every three months Check all exhaust system pipes mufflers clamps etc for condi tion tightness leaks security damage CHECK FAN BELT Inspect fan belts every three months Replace any damaged deteriorated worn or otherwise defective belt Check fan belt tension Thumb pressure exerted midway between pulleys should deflect abou...

Page 20: ...e spark plugs if worn or if reuse is questionable See the Service Schedule section for recommended inspection 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 1 14 mm 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...

Page 21: ...3 Have the state of charge and condition checked This should be done with an automotive type battery hydrometer Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explo sion can shatter the battery and cause blind ness or other injury Any a...

Page 22: ...to standby setup for normal operation 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 t...

Page 23: ...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 of the enclosure and radiator for debris Clean as necessary 7 Check the battery electrolyte level and specific...

Page 24: ...he engine valve clearance lash 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 least 1 hour looking for leaks loose co...

Page 25: ...is not enough 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 ...

Page 26: ...s as recommended 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 De...

Page 27: ...Notes ...

Page 28: ......

Page 29: ... 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 4 6L G3 5 4L G3 6 8L G3 0H0029 1 ASSY PCB HSB CTRL IGN MODULE 6 8L G3 100KW N G L P EMISSIONS 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 ...

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Page 31: ...0 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 Y 0G3259 1 DECAL TERMINAL SHOCK HZD BI 5 UL CIRCUIT BREAKER 800AF A 0F4176 1 COVER CB C5 800AF C 0F4167 REF CIRCUIT BREAKERS 800A FRAME D 0F8433 2 INSU...

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Page 33: ...ATOR CB E 3P KG 8 UL CIRCUIT BREAKER 3P FG A 0F4173 1 COVER CB G 225AF C5 C 0H5492 REF CB 0150 3P 480V E FG LL 0H5493 REF CB 0175 3P 480V E FG LL 0H5495 REF CB 0225 3P 480V E FG LL E 0H5721 4 SCREW PPHM 8 32 X 1 3 4 ZINC F 038150 4 WASHER FLAT 8 ZINC G 022264 4 WASHER LOCK 8 M4 H 022471 4 NUT HEX 8 32 STEEL J 0C2454 7 SCREW THF M6 1 X 16 N WA Z JS K 029289 1 TAPE ELEC 1 2 FOAM L 023897 6 WASHER FL...

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Page 35: ... FLAT M12 17 051769 3 WASHER LOCK M12 18 068406 3 SCREW HHC M12 1 75 X 60 G10 9 19 072878 1 KEY SQ 3 8 X 3 1 4 STEEL 20 087272 1 ASSY EXCITER 2 00 STK 21 068405C 1 EXITER FIELD 2 LG SPD CONN 22 092950 1 COLLAR SLIP FIT 390 MM 25 090063 1 BRIDGE SUPPORT DIODE 15 26 090152 1 ASSY BRIDGE RECTIFIER 27 023365 3 WASHER SHAKEPROOF INT 8 28 033143 2 SCREW HHM 8 32 X 7 8 29 090064 1 CAP END ROTOR 390MM 30 ...

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Page 37: ...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 C 0F4167 REF CIRCUIT ...

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Page 39: ...LD HD 28 0F6305 2 SEAL COVER 3 18 X 12 7 X 382 29 0F6305A 1 SEAL COVER 3 18 X 12 7 X 283 30 0G4329 1 HARNESS H PNL INTEGRATED SW NOT SHOWN COMPONENTS INCLUDED IN WIRE HARNESS A 0F1263 1 ADPTR RH SIDE WICKMANN 178 6191 B 0F1262 4 HOLDER FUSE WICKMANN 178 6150 C 0F1264 1 ADPTR LH SIDE WICKMANN 178 6192 D 0E9049B 1 ASSY PCB G PANEL RELAY 12VDC E 055911 1 BLOCK TERM 20A 12 X 6 X 1100V COMPONENTS NOT I...

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Page 41: ...43107 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 4 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 0536210410 1 ASSY WIRE 14 00 20 042909 1 SCREW HHC M8 1 25 X 30 G8 8 21 022261 2 WASHER SHAKEPROOF INT 3 8 22 022129 1 WASHER LOCK M8 5 16 23 022145 2 WASHER FLAT 5 16 M8 ZINC 24 ...

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Page 43: ...HR 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 1 X 16 N WA Z JS 14 0F3409 1 SUPPORT BATTERY TRAY 15 022097 2 WASHER LOCK M6 1 4 16 049813 2 NUT HEX M6 X 1 0 G8 YEL CHR 17 042568 2 SCREW HHC M6 1 0 X 20 G8 8 18 0G0783 1 SUPPORT 27F BATTERY NOTES UNLESS OTHERWISE SPECIFIED 1 SHEET METAL PARTS LISTED IN THE BOM TAB...

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Page 45: ...G RET 23 048189 2 PIN DOWEL M8X 24 24 095979 1 PLATE BEARING THRST 25 021159 1 SPACER STRESSPROOF 26 097557A 1 KEY 10 X 16X 40 27 057163 1 PLUG PIPE 3 8 MAGNETIC 28 0F6518 4 SCREW HHFC M10 1 5 X 25 G10 9 29 0F3201 1 COVER GEARBOX GUARD 30 020443 1 COUPLING INNER DRAWN 31 094666A 1 COUPLING OUTER MACHN 32 099828 8 DAMPER GB CPLRVIBRA 33 099828A 8 DAMPER GB CPLRVIBRA 34 026925 2 PLUG STDPIPE 3 8 STE...

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Page 47: ...1A 2 MFLR 7 X 9 X 25 2 2 5 IN 2 5 OUT 10 0F2962 2 MUFFLER STRAP 11 0C2454 4 SCREW THF M6 1 X 16 N WA Z JS 12 022097 8 WASHER LOCK M6 1 4 13 0F2830 2 MUFFLER BRACKET STIFFENER 18 0F2773C 2 EXHAUST BLANKET 900MM LONG 6 8L C5 0F2773D 2 EXHAUST BLANKET 850MM LONG 5 4L C5 19 0D3159 1 FLANGE EXHAUST 20 088775 6 WASHER FLAT 3 8 SS 21 0F2808 2 EXHUAST OUTLET PIPE CPL 22 0F5447 1 BRKT MUFFLER 23 022473 12 ...

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Page 49: ... 8 NPT 17 0D6658 1 DIPSTICK 6 8L FORD 3 1 18 029333A 2 TIE WRAP UL 7 4 X 19 BLK 19 022097 3 WASHER LOCK M6 1 4 20 022473 3 WASHER FLAT 1 4 ZINC 21 042568 3 SCREW HHC M6 1 0 X 20 G8 8 22 0D8027 4 BOLT WATER PUMP PULLEY 23 0D8025 1 BOLT GROOVED IDLER PULLEY 24 0D8026 3 BOLT BELT TENSIONER 25 0D8030 1 TENSIONER ENG AUTOMATIC BELT 26 0F2846 1 PULLEY WATER PUMP FORD 1800RPM UNITS 0D8029 1 PULLEY ENGINE...

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Page 51: ...2 22 022473 1 2 WASHER FLAT 1 4 ZINC 1 23 029333A 1 TIE WRAP UL 7 4 X 19 BLK NOT SHOWN 24 0D9913 18 SCREW SHC M8 1 25 X 35 SS 25 055596 1 BARBED STR 3 8 NPT X 3 8 26 069860E 1 HOSE DRAIN ASSY 28 27 0D4255 2 GASKET EXHAUST MANIFOLD 28 057772 1 WASHER NYLON 565 29 0D6686 1 ASSEMBLY 6 8L G BOX FLYWHEEL 30 0D3803 1 FLYWHEEL HOUSING MACH 6 8L V10 31 0D3805 1 COVER FLYWHEEL MACH 6 8L V 10 32 021113 1 PL...

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Page 53: ... 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 12 0A4256 1 INDICATOR FILTER MINDER ...

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Page 55: ...22304 1 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 M6 X 1 0 G8 YEL CHR 36 052677 1 WASHER NYLON 50 X 87 X 06 37 090283 1 CAP RADIATOR 13 PSI 38 0F2776A 1 BRACKET SIGNAL CONDITIONER 39 022145 4 WASHER FLAT 5 16 M8 ZINC 40 022129 2 WASHER LOCK M8 5 16 41 052644 1 SPACER 5 X 1 5 X 25 STL ZINC 42 035685 4 CLAMP HOSE 28 1 32 2 25 43 045764 1 SC...

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Page 57: ...0GS0R 1 PANEL LOWER FRONT 4 0G15290GS0R 1 PANEL C5 TOP 0H30010GS0R 1 PANEL C5 TOP 5 0G15330GS0R 1 PANEL C5 TOP MOUNT 6 0C2454 20 SCREW THF M6 1 X 16 N WA Z JS 1 7 0D3215B 2 ACCESS COVER 160 X 170 GALV 1 8 0C2454 8 SCREW THF M6 1 X 16 N WA Z JS 1 NOT REQUIRED FOR UNITS WITH CATALYST ...

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Page 59: ...PRESSURE 17 050280 1 DECAL FUEL INLET LPG 18 0H2353 1 ASSY ADAPTER THROTTLE BODY 0F2756A 1 MACHINING INTAKE ADAPTOR 60MM 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 0G3167 2 O RING 2 3 4 X 3 32 X 2 15 16 24 0F3691E 1 VENTURI THROTTLE 42MM 6 8L 100KW 0F3691F 1 VENTURI THROTTLE 44MM 6 8L ...

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Page 61: ...HROTTLE BODY 0F2756A 1 MACHINING INTAKE ADAPTOR 60MM 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 0G3167 2 O RING 2 3 4 X 3 32 X 2 15 16 24 0F3691E 1 VENTURI THROTTLE 42MM 100KW 0F3691C 1 VENTURI THROTTLE 38MM 25 026915 2 NIPPLE CLOSE 3 4 X 1 375 26 0A8064 2 BSHG RDCR HEX 1 1 4 3 4 27 02...

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Page 63: ...3890B 4 RETAINER INSULATION 820 39 0F3890 14 RETAINER INSULATION 450 40 042568 4 SCREW HHC M6 1 0 X 20 G8 8 42 022447 4 WASHER SHAKEPROOF INT 1 4 43 049813 4 NUT HEX M6 X 1 0 G8 YEL CHR 1 44 077992 28 NUT HEX LOCK M6 1 0 SS NY INS 45 0912970094 4 ASSY WIRE 14 AWG 34 8 GRN YEL 46 0F2766A 1 SPLITTER C5 47 0F3949M 1 INSULATION SPLITTER SHRT MPS 48 0F8869D 1 KEY VISE ACTION LATCH SLOT CIR 49 0E3257 6 ...

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Page 78: ...Notes ...

Page 79: ...Notes ...

Page 80: ...re 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 has defined Prime Power Trailer Mounted or Rental Unit Contact a Generac Dealer for Prime Power Trailer Mounted or Rental Unit definition 5 Units used for prime power in place of existing utili...

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