Generac QT03542ANANR Manual

Generac Ikke kategoriseret QT03542ANANR

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STATIONARY EMERGENCY GENERATOR

OWNER'S MANUAL

This manual should remain with the unit.

A new standard of reliability

Serial Number 4.2L

35kW

Models

EPA Certified

Not intended for use in critical life support applications. 

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!

— — CAUTION

Cover148 Rev. A 10/08 Part No. 0H0995

Catalog Number OMASPEA035-045-1

1-1



DANGER











 

DANGER







 



1-2

ENGINE PROTECTIVE DEVICES

The Stationary Emergency Generator may be required

to operate for long periods of time without an opera-

tor on hand to monitor such engine conditions as

coolant temperature, oil pressure or rpm. For that

reason, the engine has several devices designed to

protect it against potentially damaging conditions by

automatically shutting down the unit when the oil

pressure is too low, the coolant temperature is too

high, the coolant level is too low, or the engine is run-

ning too fast.

NOTE:

Engine protective switches and sensors are men-

tioned here for the reader’s convenience. Also

refer to the applicable control panel manual for

additional automatic engine shutdown informa-

tion.

HIGH COOLANT TEMPERATURE SWITCH 

The switch will close if the temperature should

exceed approximately 140° C (284° F), initiating an

engine shutdown. The generator will automatically

restart and the LED will reset once the temperature

has returned to a safe operating level.

LOW COOLANT LEVEL SENSOR 

To prevent overheating, the engine has a low coolant

level sensor. If the level of engine coolant drops below

the level of the low coolant level sensor, the engine

automatically shuts down.

LOW OIL PRESSURE SWITCH 

This switch has normally closed contacts that are

held open by engine oil pressure during cranking and

operating. Should oil pressure drop below the 8 psi

range, switch contacts close, and the engine shuts

down. The unit should not be restarted until oil is

added, and the AUTO/OFF/MANUAL switch must be

turned to OFF and then back to AUTO.

OVERCRANK SHUTDOWN 

After a prespecified duration of cranking, this func-

tion ends the cranking if the engine has failed to

start. The overcrank LED will turn ON. Turn OFF the

AUTO/OFF/MANUAL switch, then turn switch back to

AUTO to reset the generator control board.

NOTE:

If the fault is not corrected, the overcrank feature

will continue to activate.

Approximate Crank Cycle Times

• 15 seconds ON

• 7 seconds OFF

• 7 seconds ON

• 7 seconds OFF

• Repeat for 45 seconds

Approximately 90 seconds total.

OVERSPEED SHUTDOWN 

A speed circuit controls engine cranking, start-up,

operation and shutdown. Engine speed signals are

delivered to the circuit board whenever the unit is

running. Should the engine overspeed above a safe,

preset value, the circuit board initiates an automatic

engine shutdown. Contact the nearest Authorized

Dealer if this failure occurs.

RPM SENSOR LOSS SHUTDOWN 

If the speed signal to the control panel is lost, engine

shutdown will occur.

DC FUSES 

Fuse F1 (15 amp) is located inside of the control

panel. It protects the panel wiring and components

from damaging overload. Always remove this fuse

before commencing work on the generator. The

unit will not start or crank if the fuse is blown.

Fuse F2 (25 amp) is located in the engine wire har-

ness adjacent to the DC alternator. It is used to pre-

vent circuit failure due to DC alternator falure. If this

fuse is blown, battery charging will not occur while

the engine is running. Replace these fuses with the

same size, type, and rating. (See the exploded views

and parts lists at the end of this manual for replace-

ment part number.)

4-1

Stationary Emergency Generator

Engine Protective Devices

EngProt001 Rev. B 09/08



5-1

6-3

Stationary Emergency Generator

Specifications

GenSpec042 Rev. D 10/08

3. Disconnect the power wires from the fuel sole-

noid located on top of the regulator assembly.

4. Loosen the spring clamp on the small fuel enrich-

ment line and remove the hose from the hose

barb.

5. Remove the black pipe assembly from the outlet

port of the demand regulator.

6. Remove the NG fuel jet (loosen counter clockwise)

from the outlet port.

7. Remove the LP fuel jet (loosen counter clockwise)

from the jet keeper port on the regulator housing.

Install this jet into the outlet port in the regulator

casting.

NOTE:

The jet sizes are stamped on the individual jets.

The larger jet size is used for running on NG.

8. Install the previously removed NG jet into the jet

keeper port on the regulator housing.

9. Install the previously removed black pipe onto

the outlet port of the demand regulator. Use pipe

sealant on pipe threads.

10. Reverse steps 1-4 in this procedure to reactivate

the demand regulator.

11. For LP vapor application, substitute LP fuel inlet

decal for NG fuel inlet decal.

12. The dip switch inside the control panel must be

in the LP or NG position when switching to dif-

ferent fuels (see Control Panel Manual for more

information).

DANGER

 Serious injury or damage may occur if not con-

figured properly. Please consult an Authorized

Dealer with any questions.

4.2L IGNITION DESCRIPTION

This single-fire ignition is intended to operate a 6-cyl-

inder, 4.2L, 1800rpm ignition. The 4.2L engine uses

a 36-1 crank sensor, a CAM sensor and coil-on-plug

coils for each spark plug. Engine Timing for the 4.2L,

1800rpm engine is 15 degrees BTDC for both LP and

NG.

 The Cam Sensor is factory set to the FULL coun-

ter-clockwise position. Tampering with the posi-

tion of the Cam Sensor could result in engine

failure.

IGNITION POWER-UP INPUT (“56 LINE INPUT) 

When battery voltage is applied to this input the igni-

tion will power-up. For the ignition to power itself

down, the battery voltage must be removed from this

input.

DIAGNOSTIC BLINK PATTERNS (RED LED) 

During normal ignition operation the RED LED,

located on the ignition control board, flashes at a 0.5

second ON and a 0.5 second OFF rate. This is con-

sidered one (1) blink.

RED LED Fault Codes with priority as shown:

1. Ignition cannot initialize: LED is ON continu-

ously during cranking.

2. Engine Overspeed: LED blinks four (4) times, is

OFF for three (3) seconds and then repeats.

3. No Crank Signal: LED blinks two (2) times, is

OFF for three (3) seconds and then repeats.

4. No Cam Signal: LED blinks three (3) times, is

OFF for three (3) seconds and then repeats.

Only one LED fault code is displayed at a time.

If multiple fault codes exist then the highest priority

fault must be resolved prior to a lower priority fault

code being displayed.

The LED fault code blink pattern is displayed for 60

seconds after a fault and then the ignition will power

itself down.

The Generator must have been in the OFF mode for

60 seconds prior to cranking for the Crank and CAM

LED fault diagnostics to be valid.

The Crank and CAM LED fault codes are not valid

during a re-crank.

NOTE:

The ignition cover does not need to be removed to

see the RED LED







8-1





8-2





Cam Sensor (turn

counter-clockwise)

Cam

Sensor

Stop

Retaining

Washer







10-1







10-5

11-3

Stationary Emergency Generator

Service Schedule

SrvSchd003 Rev. B 10/08

13-1

1 0F3137 1 PAN CB CONN BOX

2 0F3188 1 STAND RH CONTROL

3 0F3189 1 STAND LH CONTROL

4 023484N 1 BUSHING SNAP SB-2.5-31

5 0F6366B 1 XFMR DUAL 120V /16V (F OR 120/240V & 277/480V UNITS)

0F6366A 1 XFMR DUAL 104V/16V (FOR 120/208V UNITS )

6 043180 2 WASHER FL AT M4

7 022264 2 WASHER LOCK #8-M4

8 0C3990 2 SCREW PHTT M4-0.7 X 10 ZYC

(1) 9 057701 REF BLOCK TERM 20A 8 X 6 X 1100V

10 022155 4 WASHER LOCK #6

11 0C2428 4 SCREW PHTT #6- 32 X 1/2 ZY C

12 0F3824 1 DECAL UT IL S ENSE/CUST CONN

13 0A9457 1 DECAL NEUTRAL

14 057073 2 JUNCTION BLOCK 3/8-16

(2) 15 0D5466 REF BUS BAR NEUTRAL BLOCK 390

(2) 16 0A7822 REF LUG SLDLSS 600/250-1/0 X 1/4-28

17 022237 2 WASHER LOCK 3/8

18 022241 2 NUT HEX 3/8-16 STEEL

19 049226 6 WASHER LOCK M5

20 0C2266 6 SCREW PHTT M5-0.8 X 16 ZYC

21 0C2454 8 SCREW THF M6-1 X 16 N WA Z/JS

23 022473 8 WASHER FL AT 1/4-M6 ZINC

24 022097 4 WASHER LOCK M6-1/4

(1) 26 0D4698 REF BLOCK TERM 20A 6 X 3 X 1100V

27 0F4464 1 DECAL CUST CO NN 120V UTILITY

28 025433 1 LUG SLDLS S #6- 14 X 13/64 CU

29 024469 1 SCREW HHTT #10-32 X 3/8 CZ

30 067210A 1 DECAL GROUND LUG

31 0D6029 4 SCREW HHTT M6-1.0 X 16 Z YC

32 081008 1 GROMMET 1.25 X .25 X .75

33 077043J 1 CONDUIT FLEX 2.0" ID (36” LG)

34 051713 2 WASHER FL AT M5

35 0F6156 1 PLATE WIRE SNGL G ALV

36 029289 1 TAPE ELEC 1/2 FO AM (AS REQ’D)

37 047411 4 SCREW HHC M6-1.0 X 16 G8.8

(3) 39 0G0770 1 HARNESS, TRANSFORMER ADAPTER

(4) 40 0H0348 1 ASSY ENCLOSURE PCB 4.2L IGN MD

(4) 41 036943 2 SCREW PPHM #10/32 X 2

(4) 42 023897 4 WASHER FL AT #10 ZINC

(4) 43 022152 2 WASHER LOCK #10

(4) 44 022158 2 NUT HEX #10-32 STEEL

(4) 45 0C2454 1 SCREW THF M6-1 X 16 N WA Z/JS

(4) 46 055934D 1 CLAMP VINYL 1.06 X .406 Z

47 0F6145 A/R SEAL WEATHER .45"DIA

1) UL CIRCUIT BREAKER (ED)

A 0F3328 1 COVER ED CB SHORT STND

C 0D5552 1 CB 0050A 3P 480V S ED4 LL

0D5553 - CB 0060A 3P 480V S ED4 LL

0D5554 - CB 0070A 3P 480V S ED4 LL

0D5556 - CB 0090A 3P 480V S ED4 LL

0D9693 - CB 0125A 3P 480V S ED4 LL

D 0F0492 1 INS ULATOR CB S ( ED-3P)

E 048927 4 SCREW RHM #10-32 X 4- 1/2

F 023897 4 WASHER FL AT #10 ZINC

G 022152 4 WASHER LOCK #10

H 022158 4 NUT HEX #10-32 STEEL

J 0C2454 9 SCREW THF M6-1 X 16 N WA Z/JS

K 029289 1 TAPE ELEC 1/2 FO AM (AS REQ’D)

L 0F1733 1 DECAL CUS TOMER CONNE CT INSIDE

2) UL CIRCUIT BREAKER (FD)

A 0F3138 1 COVER CB CONN BO X

C 0D5572 1 CB 0150A 3P 600V S FD6 LL

0D5573 - CB 0175A 3P 600V S FD6 LL

0D5574 - CB 0200A 3P 600V S FD6 LL

0D5575 - CB 0225A 3P 600V S FD6 LL

0D5576 - CB 0250A 3P 600V S FD6 LL

D 0F0199 1 INS ULATOR CB FD FRAME 30MIL

E 081320 4 SCREW SHC 1/4-20 X 4.5 G8.8 NZ

F 022473 4 WASHER FL AT 1/4-M6 ZINC

022097

WASHER LO CK M6

1/4

H 022127 4 NUT HEX 1/4-20 STEEL

J 0C2454 9 SCREW THF M6- 1 X 16 N WA Z/JS

K 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)

L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

3) UL CIRCUIT BRE AKER (JD+L D)

A 0F3329 1 COVER JD/LD CB SHRT STAND

C 0D5577 1 CB 0300A 3P 600V S JD6 LL

D 0F2353 2 INSULATOR CIRCUIT BR. JD/LD

E 022770 4 SCRE W RHM 1/4- 20 X 3

F 022473 4 WASHER FLAT 1/4-M6 ZINC

G 022097 4 WAS HER LOCK M6-1/4

H 022127 4 NUT HEX 1/4-20 STEEL

J 0C2454 9 SCREW THF M6- 1 X 16 N WA Z/JS

K 029289 1 TAPE ELEC 1/2 FOAM (AS REQ’D)

L 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

4) UL CIRCUIT BRE AKER (QN)

A 0F8135 1 COVER QN FRM CB

C 0E7283 - CB 0150A 2P 240V S QN2 LL

0E7284 - CB 0175A 2P S QN2 LL 240V

D 0E3664 1 BASE, QN CIRCUIT BRE AKE R

E 074908 2 SCRE W HHTT M5-0.8 X 10 BP

F 0F8140 1 COVER QN CB DISH

G 036261 4 RIVET POP .125 X .275 SS

H 0C2454 11 SCREW THF M6- 1X 16 N WA Z/JS

J 029289 1 TAP E ELEC 1/2 FOAM (AS REQ’D)

K 0F1733 1 DECAL CUSTOMER CONNECT INSIDE

(1) ITEM INCL UDED WIT H HARNESS

(2) ITEM INCL UDED WIT H 0D5464B

(3) ITEM USED WITH EARLY MODE L 208V UNITS ONLY

(4) ITEMS USED ON 4.2L MODELS O NL Y.

1 0G68030ST 03 1 WELDME NT RADIATOR SUPPORT C2

2 0F2608A 1 RADIATOR 598 X 568 X 49,CPL L H

3 0E3256 1 V-BELT A58 (60IN O .C.) DDC S60

4 046526 5 WASHER LOCK M10

(1) 5 059981 4 SCREW HHC M10-1.5 X 30 G 10.9

6 0F2776A 1 BRACKET, SIGNAL CONDITIONER (USED ONLY W ITH QTA

PRODUCT)

7 0F5050A 1 SHIELD RADIATOR C4

9 0F2573 1 PULLEY FAN V-GROOVE 9"

10 0F4011 1 FAN COOL 22" DIA 10 BLADE LH

11 0G56820ST 03 1 FLAT TENS IONER ARM

12 0G2990 1 SHO UL DER BO LT 3/8 X 1/2"

13 0F2862 1 S PRING TENSION CPL

14 0F2560 1 P ULLEY V-BELT 4" FLANGED

15 022131 4 WASHER FLAT 3/8- M10 Z INC

16 0E2507 1 PROBE COOLANT LEVEL 3/8NPTF

0H1827 1 PROBE COO LANT LEVEL 3/8-18NPTF (USE WITH I/N 72, P/N

0H1851)

17 035685 2 CLAMP HOSE #28 1.32-2.25

18 0F2561 1 HUB FLEX PLATE

19 0C8145 8 WASHER FLEX (THIN)

20 052250 2 TAPE FOAM 1 X 1 (26.75” LG)

21 0C7043 12 DISK F LEX

23 022473 8 WASHER FLAT 1/4- M6 ZINC

(1) 24 0C8146 4 SCREW HHC 5/16-24 X 1.124

25 022097 16 WASHER LOCK M6- 1/4

26 076749 1 TANK COOLANT RECOVERY

(2) 27 048031C 2(REF) CLAMP HOSE BAND 1/4

28 031971 1 BEARING #6205 2NSE C3 E SRI2 S

29 0F4028 1 PULLEY 6.5" DIA MACHINED

(1) 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 LO CK 1/2

34 022196 1 NUT HEX 1/2-13 STEEL

35 0F8651 8 SCREW HHFC M8-1.25 X 20 W/M6

36 070015 1 NUT HEX LOCK 5/16-18 NY INS SS

37 0F9867 1 SHAFT FAN DRIVE

38 0F2461 1 RETAINER BEARING

39 022145 15 WASHER FLAT 5/16-M8 Z INC

40 022129 12 WASHER LOCK M8- 5/16

(1) 41 039287 1 SCREW HHC M8-1.25 X 45 C8.8

42 082774 1 KEY WOODRUFF 4 X 19D

43 0G5465 1 HOSE RADIATOR LOWER F RONT

44 0G5459 1 HOSE RADIATOR UP PER F RO NT

45 049813 8 NUT HEX M6 X 1.0 G8 YEL CHR

46 052644 1 SPACER .5 X 1.5 X .25 STL/ZINC

47 0C8566 16 SCREW HHFC M6-1.0 X 20 G8.8

48 0C2454 3 SCREW THF M6-1 X 16 N WA Z/JS

49 090283 1 CAP RADIATOR 13 PS I

50 080713 1 BRACKET COOLANT TANK

51 0G4376 1 WASHER BELLEVILLE .75X.38X.028

52 0G5299 1 COUPLING FLEX HUB MACHINED

(1) 53 049821 3 SCREW SHC M8-1.25 X 30 G 12.9

54 099502 2 CLAMP HOSE #24 B1.06-2.00

61 0C8165 2 NUT HEX LOCK 5/16-24 NY INS

62 051698 1 SCREW HHC M8-1.25 X 75 C8.8

63 049820 3 NUT HEX LOCK M8-1.25 NY INS

64 0G6793AST03 1 BRACKET TENSIONER SPRING

65 039253 2 SCREW HHC M8-1.25 X 20 C8.8

66 0G56830ST03 1 TENSIO NER ARM SUPPORT BENT 90

67 022145 1 WASHER FLAT 5/16-M8 Z INC (USED ONLY WITH QTA

PRODUCT)

68 022129 1 WASHER LO CK M8- 5/16 ( USED ONLY WITH QTA PRODUCT)

69 0F8651 1 SCREW HHFC M8-1.25X20 W/M6 (USED ONLY WIT H QT A

PRODUCT)

70 029032 1 HO SE 9/32 ID (60” LG)

71 029333A 10 TIE WRAP UL 7.4” X .19” BLK (NOT SHOWN)

72 0H1851 1 ASSY PCB LCL SENSOR (USE WITH I/N 16, P/N 0H1827 ONLY)

(1) APPLY MEDIUM STRENG TH BLUE THREAD LOCKING FLUID

TO THREADS.

(2) INCLUDED WITH I/N 26.

BEARING PRESS NOTE:

APPLY LOCTITE 620 BEARING RETAINMENT CO MPOUND TO

BEARING SURF ACE ON ITEM 37 PRIOR TO PRESSING ITEM 28

ONTO ITEM 37.

ALSO APPLY LOCTITE 620 BEARING RETAINMENT COMPOUND

TO THE OUTSIDE OF 28 PRIOR TO INSTALL ING ITEM 28 INTO

IT EM 38.

1 026915 2 NIPPLE CLOSE 3/4 X 1.375

2 075580 1 FLANGE FUEL INLET

3 0F6390E 1 REGULATOR ASSY 4.2L 48KW

0F6390F 1 REGULATOR ASSY 4.2L 35KW

4 039253 2 SCREW HHC M8-1.25 X 20 G8.8

5 022145 2 WASHER FLAT 5/16-M8 ZINC

6 022129 2 WASHER LOCK M8-5/16

7 045771 2 NUT HEX M8-1.25 G8 CLEAR ZINC

9 0E8286 1 STREET EL 45D 1/2 NPT BRASS

10 026812 2 ELBOW 90D 3/4 NPT

11 0F8379 1 NIPPLE PIPE 3/4 NPT X 7

13 057823 2 CLAMP HOSE #10 .56 - 1.06

14 059057 1 HOSE 3/4 ID SAE-30R2 (22” LG)

15 047527 1 BARBED STR 1/2 NPT X 3/4

16 0D1509 1 DECAL INLET PRESSURE

17 050279 1 DECAL FUEL INLET NG (NATURAL GAS APPLICATION)

050280 1 DECAL FUEL INLET LPG (LP VAPOR APPLICATION)

18 0F2119 1 O-RING 45.63 ID X 2.62 WIDTH

19 0E6586 1 GASKET BOSCH 32

20 0E4394 1 ACTUATOR BOSCH 40 GOVERNOR

21 040105 1 HOSE COOL 2 IN ID 20R4

22 0G4573B 1 MIXER ACTUATOR 40MM MACHINED

23 0F7790E 1 VENTURI THROTTLE 26MM

24 0E7121 1 O-RING 47.625 ID X 2.38 WIDTH

26 022097 8 WASHER LOCK M6-1/4

27 046580 4 SCREW SHC M6-1.0 X 45 G12.9

28 035685 2 CLAMP HOSE #28 1.32-2.25

29 0F6155 1 HARNESS CPL FUEL JUMPER

30 047290 1 HOSE 3/8 ID SINGLE BRAID (20” LG)

31 0E6123A 1 INTAKE ADAPTER 4.2L G3-BOSCH

32 048031J 2 CLAMP HOSE BAND .63

33 0G1462 1 HOSE BARB REDUCER 5/8"-3/8"ID

34 048031P 2 CLAMP HOSE BAND .88"

35 0G0321 1 HOSE COOL 5/8"ID 250#WP (2”LG)

36 047487 4 SCREW SHC M6-1.0 X 18 G12.9

RECONFIGURING THE FUEL SYSTEM

Note: All models are configured to run on natural gas from the factory.

To reconfigure the fuel system from NG to LP, follow these steps:

1. Turn the main gas supply off.

2. Remove the carburetor fuel hose from the outlet port of the demand regulator (See Detail “A”).

3. Disconnect the power wires from the fuel solenoid located on top of the regulator assembly.

4. Loosen the spring clamp on the small fuel enrichment hose and remove the hose from the hose barb.

5. Remove the black pipe assembly from the outlet port of the demand regulator.

6. Remove the NG fuel jet (loosen counter clockwise) from the outlet port.

7. Remove the LP fuel jet (loosen counter clockwise) from the jet keeper port on the side of the regulator housing.

Install this jet into the outlet port in the regulator casting.

Note: The jet sizes are stamped on the individual jets. The larger jet size is used for running on NG.

8. Install the previously removed NG jet into the jet keeper port on the side of the regulator housing.

9. Install the previously removed black pipe onto the outlet port of the demand regulator. Use pipe sealant on pipe

threads.

10. Reverse steps 1-4 in this procedure to reactivate the demand regulator.

11. For LP vapor application substitute LPG fuel inlet decal p/n 050280 for NG fuel inlet decal p/n 050279 (Item 17).

12. When switching fuel types, the proper dip switch settings must be made to the control panel. See owners

manual, fuel section, for more details.

Produkt Specifikationer

Mærke:	Generac
Kategori:	Ikke kategoriseret
Model:	QT03542ANANR

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