Page 1
OWNER'S MANUAL
Series Q55LP and Q70LP
AIR-COOLED
Manual No. A4021
RECREATIONAL VEHICLE
GENERATORS
Model Nos. 9735-3 and 9736-3
CORPORATION
Revision 0 (6/17/97)
Printed in U.S.A.
Page 2
GENERAL SAFETY RULES
THE MANUFACTURER SUGGESTS THAT THESE “RULES" FOR SAFE OPERATION BE
COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHICLE.
SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF
THIS EQUIPMENT.
Study these SAFETY RULES carefully before operat
ing or servicing applicable equipment. Become familiar
with this Owners Manual and with your generator.
Safe, efficient and reliable operation can only be
achieved if generator is properly installed, operated
and maintained. Many accidents are caused by failing
to follow simple and fundamental rules or precautions.
The manufacturer suggests that these GENERAL
SAFETY RULES be copied and posted in potential
hazard areas of the recreational vehicle. Safety should
be stressed to all operators and potential operators of
equipment.
The manufacturer cannot possibly anticipate every cir
cumstance that might involve a hazard. The warnings
in this Manual and on tags and decals affixed to the
unit are, therefore, not all-inclusive. If you use a proce
dure, work method or operating technique Generac
does not specifically recommend, you must satisfy
yourself that it is safe for you and others. You must
also make sure the procedure, work method or operat
ing technique that you chose does not render the gen
erator to be unsafe.
WARNING:
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
For fire safety, the recreational vehicle generator
must be properly installed and maintained.
Installation must always remain in compliance with
applicable codes and standards. In addition, the
generator must be installed in comformance to the
manufacturer's detailed installation instructions.
Following installation, nothing must be done that
might render the generator in noncompliance with
such codes, standards and instructions.
The RV generator produces extremely high and
A
dangerous electrical voltages and can cause dan
gerous, and possibly ta\a\, electrical shock. Avoid
contact with bare wires, terminals, etc. while the
unit is running. If you must work around an operat
ing generator, stand on an insulated, dry surface
to reduce shock hazard.
Never work on this equipment or handle any elec
trical device while standing in water, while bare
foot, or while hands or feet are wet. Dangerous
electrical shock will result.
Have the generator properly grounded (bonded)
during installation onto the vehicle, either by solid
mounting to the vehicle frame or chassis or by
means of an approved bonding conductor. DO NOT
disconnect the bonding conductor, if so equipped.
DO NOT reconnect the bonding conductor to any
generator part that might be removed or disassem
bled during routine maintenance. If the grounding
conductor must be replaced, use only a flexible con
ductor that is of No. 8 AWG copper wire minimum.
In case of accident caused by electric shock, shut down
the source of electrical power down at once. If this can
not be done, free victim from live conductor. AVOID
DIRECT CONTACT WITH THE VICTIM. Use a dry
board, dry rope, or other non-conducting implement to
free the victim from live conductor.
Inspect fuel system frequently for leaks or dam
age. Repair or replace any damaged or leaking
component immediately. Never attempt to change,
alter or modify the generator fuel system in any
way that might affect safety or compliance with
applicable codes and standards.
The generator engine gives off DEADLY carbon
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concentra
tions, can cause unconsciousness or even death.
This exhaust system must have been properly
installed, in strict compliance with applicable codes
and standards. Following installation, you must do
nothing that might render the system unsafe or in
non-compliance with such codes and standards.
The generator compartment must be completely
vapor sealed from vehicle interior. There must be
no possibility of exhaust fumes entering the vehi
cle interior. Never operate this equipment with a
leaking or defective exhaust system.
Never use the generator or any of its parts as a
step. Stepping on the unit can stress and break
parts and may result in dangerous, fuel leakage,
oil leakage, etc.
Do not smoke around the generator. Wipe up any
fuel, and oil immediately. Never leave oily or fuel
soaked rags in the generator compartment or on the
generator itself. Keep the area around the generator
clean and free of debris.
Adequate ventillation is required to expel toxic
fumes and fuel vapors from the generator com
partment. Do not alter the installation of this equip
ment in any manner that might obstruct air and
ventillation openings. Such openings must be kept
clear and unobstructed.
Keep hands, feet, clothing, etc., away from drive
belts, fans and other moving parts or this equip
ment. Never remove any drive belt or fan guards
while the unit is operating.,
Inspect the generator periodically. Repair or replace
all damaged or defective parts immediately.
These generators use LP gas (propane) as a fuel.
Liquid Propane gas is highly EXPLOSIVE. The
gas is heavier than air and tends to settle in low
areas where even the slightest spark can ignite the
gas and cause an explosion.
Before performing any maintenance on the gener
ator set, disconnect its battery cables to prevent
accidental start up. Disconnect the cable from the
batteiy post indicated by a NEGATIVE, NEG or (-)
first. Reconnect that cable last.
Page 3
IDENTIFICATION RECORD
Please record the following information from the generator DATA PLATE or information decal.
1. Model Number
3.kW Rating.
5. Phase
___
________________
2. Serial Number
4. Rated Voltage.
6. Hertz
_______
____________________
Page 4
TABLE OF CONTENTS
GENERAL SAFETY RULES
IDENTIFICATION RECORD
.................
inside cover
.................................
1
READ THIS MANUAL THOROUGHLY
Operation and Maintenance
How to Obtain Service........................................................... 3
..................................................
GENERATOR FEATURES.................................... 4
GENERATOR FAMILIARIZATION
Generator Applicability.......................................................... 5
Installation.............................................................................. 5
Safety....................................................................................... 5
Generator AC Connection System
.......................................
OPERATING INSTRUCTIONS
Generator Control Panel
Optional Remote Start/Stop
Before Starting the Engine.................................................... 6
Starting.................................................................................... 7
Stopping the Generator......................................................... 7
Applying Loads to Generator................................................ 7
Don't Overload the Generator............................................... 8
Wattage Reference Guide...................................................... 8
Automatic Low Oil Pressure Shutdown............................... 9
High Temperature Shutdown................................................ 9
Over Voltage Protection
25-Hour Break In Period
.......................................................
..................................................
........................................................
........................................................
MAINTENANCE
Checking Engine Oil Level
Change Engine Oil................................................................11
Change oil filter.....................................................................11
Clean Air Intake Screen........................................................12
3
5
Engine Air Cleaner................................................................12
Engine Spark Plugs
Spark Arrestor Muffler..........................................................13
Cleaning the Generator
Battery....................................................................................13
Major Service Manual
Drive Belts
Exercising the Generator
Out of Service Protection
Return the Unit to Service after,Storage
.............................................................................
..................................................
..............................................................
........................................................
...........................................................
.....................................................
............
.........................................14
............................
11
12
13
13
13
13
14
TROUBLESHOOTING..........................................15
6
6
ELECTRICAL DATA
REPAIR PARTS
............................................
............................................
17-26
16
NOTES..................................................................27
CALIFORNIA EMISSIONS WARRANTY
.......
28 - 29
WARRANTY...............................................back page
9
9
SPECIFICATIONS
25-Hour Check Up
Operation in High Grass or Brush.......................................10
Fuel Requirements................................................................10
Engine Oil Requirements
Engine Specifications...........................................................10
Generator Specifications......................................................10
.................................................................
.....................................................
10
10
— 2
Page 5
READ THIS MANUAL THOROUGHLY
If you don't understand any portion of this manual,
contact Generac for a demonstration of actual start
ing, operating and servicing procedures.
Throughout this publication and on tags and decals
affixed to the generator, DANGER and CAUTION
blocks are used to alert you to special instruction
about a particular operation that may be hazardous if
performed incorrectly or carelessly. Observe them
carefully.
These safety warnings cannot eliminate the hazards
that they indicate. Strict compliance with the special
instructions while performing the service plus "com
mon sense" are major measures to prevent acci
dents.
The following definitions apply to DANGER, CAU
TION and NOTE blocks found throughout the manual.
DANGER: AFTER THIS HEADING YOU CAN READ
HANDUNG, INSTALLING, OPERATING OR SERVIC
ING INSTRUCTIONS THAT, IF NOT STRICTLY COM
PLIED WITH, MAY RESULT IN PERSONAL INJURY.
CAUTION: After this heading you can read instruc
tions for handling, instaliing, operating or servicing
the generator that, if not strictly complied with, may
result in damage to equipment and/or property.
NOTE: After this heading you can read explanatory
statements that require special emphasis.
These symbols indicate the following:
Points out important safety information and, if
not followed, could endanger personal safety
and/or property of yourself and others.
Potential explosion hazard
Potential fire hazard
The operator (driver) is responsible for proper and
safe use of the vehicle, equipment on the vehicle, and
the safety of all vehicle occupants. We strongly rec
ommend that the operator read this Owner's Manual
and thoroughly understand all instructions before
using this equipment. We also strongly recommend
instructing other occupants in the vehicle to properly
start and operate the generator. This prepares them if
they need to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all safety
checks; to make sure that all maintenance for safe
operation is performed promptly: and to have the
equipment checked by an Authorized Dealer periodi
cally. Normal maintenance service and replacement
of parts are the responsibility of the Owner/Operator
and, as such, are not considered defects in materials
or workmanship within the terms of the warranty.
Individual operating habits and usage contribute to
the need for maintenance service.
Proper maintenance and care of your industrial
mobile generator assures a minimum number of prob
lems and keeps your operating expenses at a mini
mum. See your authorized Dealer/Distributor for ser
vice aids and accessories.
HOW TO OBTAIN SERVICE
When your industrial mobile generator set requires
servicing or repairs, simply contact an Authorized
Service Facility for assistance. Service technicians
are factoiy-trained and are capable of handling all of
your service needs.
When contacting an Authorized Service Facility or the
factory about parts and service, always supply the
complete model number and serial number of your
unit as given on its data plate.
The warranty on your generator is included in this
Owner's Manual, as well as listings for repair parts.
Potential electrical shock hazard
A
— 3 —
Page 6
GENERATOR FEATURES
REFERENCE NUMBER IDENTIFICATION
1. Generator Air Intake Screen
2. Engine Start/Stop Switch
3. 15 amp Fuse
4. 20 or 30 amp Circuit Breaker
5. Optional Remote Panel Receptacle
6. Generator AC Output Leads
7. 30 amp Circuit Breaker
8. Starter Contactor
9. Fuel Pump Primer Switch
10. Oil Filter
11. Oil Drain Plug
12. Oil dipstick and filler Tube
— 4 —
Page 7
GENERATOR FAMILIARIZATION
GENERATOR APPLICABILITY
These generators have been designed and manufac
tured for supplying electrical power for recreational
vehicles. You should not modify the generator or use
it for any application other than for what it was
designed. If there are questions pertaining to its
application, write or call the factory. Do not use the
unit until you have been advised by a competent
authority.
DANGER; FOR FIRE SAFETY, THE GENERATOR
MUST HAVE BEEN PROPERLY INSTALLED IN
A
COMPLIANCE WITH (1) ANS1119.2-1975/NFPA
501C-1974 "STANDARD FOR RECREATIONAL
VEHICLES", PART III, "INSTALLATION OF ELEC
TRICAL SYSTEMS." THE GENERATOR ALSO
MUST HAVE BEEN INSTALLED IN STRICT COM
PLIANCE WITH THE MANUFACTURER'S DETAILED
INSTALLATION INSTRUCTIONS. AFTER INSTALLA
TION, DO NOTHING THAT MIGHT RENDER THE
UNIT IN NON-COMPLIANCE WITH SUCH CODES,
STANDARDS AND INSTRUCTIONS.
You can use your generator set to supply the follow
ing electrical loads;
Q-55LP: 120 and/or 240 volts, single phase, 60 Hz
electrical loads. These loads can require up to 5500
watts (5.5 kW) of power, but cannot exceed 45.8 AC
amperes of current at 120 volts or exceed 22.9 AC
amperes at 240 volts.
Q-70LP: 120 and/or 240 volts, single phase, 60 Hz
electrical loads. These loads can require up to 7000
watts (7.0 kW) of power, but cannot exceed 58.3 AC
amperes of current at 120 volts or exceed 29.1 AC
amperes at 240 volts.
CAUTION; Do not overload the generator. Some
Installations may require that electrical loads be
alternated to avoid overloading. Applying exces
sively high electrical loads may damage the gener
ator and may shorten Its life. Add up the rated
watts of all electrical lighting, appliance, tool and
motor loads the generator will power at one time.
This total should not be greater than the wattage
capacity of the generator. If an electrical device
nameplate gives only volts and amps, multiply
volts times amps to obtain watts (volts x amps =
watts). Some electric motors require more watts
of power (or amps of current) for starting than for
continuous operation.
INSTALLATION
This Owner’s Manual has been prepared under the
assumption that a competent, qualified technician
installed the generator into a recreational vehicle. We
also assume the installer complied with all applicable
codes, standards and regulations pertaining to instal
lation.
An INSTALLATION MANUAL was shipped with the
generator. That manual contains manufacturer’s
instructions and recommendations for installing the
unit into a recreational vehicle. After installation,
installers should forward the Installation Manual to
Owners/Operators for their information.
Owners/Operators have the responsibility to make
sure that nothing is done that might render the instal
lation unsafe or in non-compliance with applicable
codes, standards and instructions.
SAFETY
Before usirig the generator set, carefully read GEN
ERAL SAFETY RULES inside the cover. Comply with
these RULES to prevent accidents and damage to
equipment and/or property. Generac suggests copy
ing and posting the GENERAL SAFETY RULES in
potential hazard areas of the recreational vehicle.
Safety should be stressed to all operators of this
equipment.
GENERATOR AC
CONNEaiON SYSTEM
These air-cooled Q Series generator sets are
equipped with dual stator AC power windings. These
two stator windings supply electrical power to cus
tomer electrical loads by means of a dual 2-wire con
nection system.
The generator may have been installed so that units
only power 120 volts AC loads (Figure 1); or you can
wire them to connect both 120 and/or 240 volts AC
electrical loads. Be sure to remove the jumper
between the circuit breakers when connecting for
120/240 volts.
Figure 1 — Connection for 120 Volts Only
5 —
Page 8
OPERATING INSTRUCTIONS
GENERATOR CONTROL PANEL
Mounted on the generator control panel (Figure 2) are
the following features:
■ START/STOP SWITCH_________________
To crank and start the engine, hold this switch at its
START position. Release the switch when the engine
starts. To stop an operating engine, press and hold
the switch in its STOP position until the engine shuts
off. The switch center position is the RUN position.
■ FUSE
Protects the engine DC control circuit against electri
cal overload. If the fuse element has melted open due
to overloading, the engine cannot be cranked. If you
must replace it, use only an identical replacement
fuse.
■ MAIN BREAKER______________________
Protects generator’s AC output circuit against overload,
i.e., prevents unit from exceeding wattage/amperage
capacity.
NOTE: If the Series Q-55LP or Q-70LP has been recon
nected for dual voltage AC output (120/240 volts), you
can install line breakers having an amperage rating that
is different than stated previously. The replacement main
breakers consist of two separate breakers with a con
necting piece between the breaker handles (so that both
breakers will operated at the same time). If the unit is
reconnected for dual voltage, it is no longer RVIA listed.
_______________________________
Figure 3 — Optional Remote Panel (Model 9042)
You can also order Model 9043, a remote panel
which includes the (a) start/stop switch, (b) the gener
ator run lamp and (c) an hourmeter. The hourmeter
provides a continuous indication of engine-generator
operating time. Use the hourmeter for checking of
periodic maintenance requirernents on the unit.
Figure 2 — Typical Control Panel
START
STOP FUEL
FUSE
15A BREAKER
PRIMER
MAIN
OPTIONAL REMOTE
START/STOP PANEL
Optional remote mounted panels are available which
permit you to crank and start the generator from any
convenient location in the recreational vehicle. Figure
3 shows the model 9042 remote panel which includes
(a) start/stop switch and (b) a generator run lamp.
BEFORE STARTING THE ENGINE
IMPORTANT: INSTRUCTIONS AND INFORMATION
IN THIS MANUAL ASSUME THE GENERATOR HAS
BEEN PROPERLY INSTALLED, CONNECTED,
SERVICED, TESTED AND ADJUSTED BY A QUALI
FIED INSTALLATION TECHNICIAN OF INSTALLA
TION CONTRACTOR.
■ INSTALLATION
Generator installation must have been properly com
pleted so it complies with all applicable codes, stan
dards and regulations and with the manufacturer's
recommendations.
■ ENGINE LUBRICATION
Have engine crankcase properly serviced with recom
mended oil before starting. Refer to "Maintenance"
and "Specifications" sections for oil servicing proce
dures and recommendations.
CAUTION: Any attempt to crank or start the engine before you have property serviced it with the recommended oil may result in engine failure.
_______________________
_________________
— 6 —
Page 9
FUEL SUPPLY
The engine must have adequate supply of proper fuel
to operate. Before starting, check that sufficient fuel is
available.
■ COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compart
ment must be open and unobstructed for continued
proper operation. Without sufficient cooling and venti
lating air flo\w, the engine-generator quickly overheats,
which causes it to quickly shutdown. Overheating
could also damage the unit or your vehicle.
ENGINE EXHAUST GAS
Before starting the generator engine, you should be
sure there is no way for exhaust gases to enter the
vehicle interior and endangering people or animals.
Close windows, doors and other openings in the vehi
cle that, if open, might permit exhaust gases to enter
the vehicle.
DANGER; THE GENERATOR ENGINE GIVES OFF
DEADLY CARBON MONOXIDE GAS THROUGH ITS
EXHAUST SYSTEM. THIS DANGEROUS GAS, IF
BREATHED IN SUFFICIENT CONCENTRATIONS,
CAN CAUSE UNCONSCIOUSNESS OR EVEN
DEATH. DO NOT OPERATE THE GENERATOR IF
ITS EXHAUST SYSTEM IS LEAKING OR HAS BEEN
DAMAGED. SYMPTOMS OF CARBON MONOXIDE
POISONING ARE (A) INABILITY TO THINK COHER
ENTLY, (B) VOMITING, (C) TWITCHING MUSCLES,
(D) THROBBING TEMPLES, (E) DIZZINESS, (F)
HEADACHE, (G) WEAKNESS AND SLEEPINESS. IF
YOU FEEL ANY OF THESE SYMPTOMS, MOVE
INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS
PERSIST, GET MEDICAL HELP.
STARTING
IMPORTANT: Read the vehicle manufacturer’s
instructions. The owner/operator should become
familiar with the vehicle in which this generator is
installed. Differences exist between vehicles. For
example, some vehicles may use a transfer switch to
isolate dockside power from the generator, while
other vehicles may use an isolating receptacle. Some
vehicles may be equipped with a DC converter which
allows the generator to power certain DC lighting and
other DC loads.
To crank and start the generator engine, proceed as
follows:
I.Turn OFF electrical loads, using whatever means provid
ed in your vehicle (such as a main line circuit breaker or
transfer switch.
NOTE: If you start the engine with the start/stop
switch on the generator control panel, turn OFF loads
by setting the panel’s main breakers to their “OFP or
“OPEN” positions. Electrical load circuits will be
turned ON after the generator has started, stabilized
and warmed up.
2. To crank and start the engine, hold the start/stop switch
at START. Release the switch when the engine starts.
CAUTION: If the engine does not start after it has
been cranking for 15 seconds, release the
start/stop switch and try again. Holding the switch
for longer than 15 seconds may damage the starter
motor.
3. Let the engine run at no-load for a few minutes to stabi
lize and warm up the engine.
4. Turn ON electrical loads, using whatever means provided
(such as a main circuit breaker or transfer switch),
NOTE: If you start a warm generator engine, you
may press the start switch only slightly to engage the
ignition system. However, you should press and hold
the starter switch for a minimum of two (2) seconds to
energize the field boost system. If you start the
engine without energizing the field boost system, the
generator produces no AC output.
STOPPING THE GENERATOR
1. Turn OFF all electrical loads, using whatever means pro
vided (such a main circuit breaker or transfer switch).
2. Let the generator run at no-load for a few minutes, to sta
bilize internal engine-generator temperatures.
3. Place start/stop switch in its STOP position.
APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator,
observe these guidelines:
• Before applying electrical loads, let the generator stabilize
and warm up for a minute or two.
• DO NOT overload the generator.
■ LEHING ENGINE STABILIZE
The generator supplies correct rated frequency and
voltage only at the proper governed speed. Some
electrical appliances may be extremely sensitive to
voltage and frequency. Incorrect frequencies and/or
voltages can damage those appliances.
If electrical loads are applied at reduced operating
speeds, such loads Imposed on the engine when suf
ficient power is not available may shorten engine life.
Never turn ON electrical loads until after the genera
tor engine has started and stabilized ON-speed.
_____________
— 7 —
Page 10
DO NOT OVERLOAD
THE GENERATOR
You can read the rated wattage/amperage capacity of
your generator on the generator data plate (see
“Identification Record” on Page 1).
Applying electrical loads in excess of the unit’s rated
capacity will cause the engine-generator to automati
cally shutdown.
To avoid overloading, add up the wattage of all con
nected electrical lighting, appliance, tool and motor
loads. This total should not be greater than the gener
ator’s rated wattage capacity.
• Most lighting, appliance, tool and motor loads indicate
their required watts on their nameplate or data plate. For
light bulbs, simply note the wattage rating of the bulb.
WAHAGE REFERENCE GUIDE
If a load does not show its rated wattage, multiply that
load’s rated VOLTS times AMPS to obtain WATTS.
Induction type motors (such as those that run the vehi
cle’s furnace fan, refrigerator, air conditioner, etc.) need
about 2-1/2 times more watts of power for starting than
for running (for a few seconds during motor starting). Be
sure to allow for this when connecting electrical loads to
the generator. First, figure the watts needed to start elec
tric motors in the system. To that figure, add the running
wattages of other items that will be operated by the gen
erator.
On a new generator do not apply heavy electrical loads
for the first two or three hours of operation.
RUNNING
WATTS
*Air Conditioner (12,000 Btu)
Battery Charger (20 amp)......................................................500
Belt Sander (3”)....................................................................1000
Chain Saw.............................................................................1200
Circular Saw (6-12”)
Coffee Maker........................................................................1000
‘Compressor (1 HP)
‘Compressor (3/4 HP)
‘Compressor (1/2 HP)
Curling Iron
‘Deep Freeze ..........................................................................500
Disc Sander (9”) ..................................................................1200
Edge Trimmer.........................................................................500
Electric Nail Gun..................................................................1200
Electric Range (one element).............................................1500
Electric Skillet .....................................................................1250
‘Furnace Fan (1/3 HP) .........................................................1200
Hair Dryer
Hand Drill (1”) ......................................................................1100
Hand Drill (1/2”)
Hand Drill (3/8”)
Hand Drill (1/4”)......................................................................250
Hedge Trimmer
Impact Wrench ......................................................................500
............................................................................
.............................................................................
..............................................
............................................................
..........................................................
..........................................................
....................................................
.....................................................................
......................................................................
............................................
800 to 1000
750 to 1000
1700
2000
1800
1400
700
1200
500
450
RUNNING
WATTS
‘Jet Pump............................................................800
Lawn Mower
.....................................................
1200
Light Bulb ...........................................................100
Microwave Oven.................................................700
‘Milk Cooler.......................................................1100
Oil Burner on Furnace..........
Oil Fired Space Heater (140,000 Btu)
Oil Fired Space Heater (85,000 Btu)
Oil Fired Space Heater (30,000 Btu)
..............................
................
..................
..................
300
400
225
150
‘Paint Sprayer, Airless (1/3 HP) .........................600
Paint Sprayer, Airless (handheld).......................150
Radio ..........................................................50 to 200
‘Refrigerator........................................................600
Slow Cooker
.......................................................
200
‘Submersible Pump (1-1/2 HP).........................2800
‘Submersible Pump (1 HP)..............................
‘Submersible Pump (1/2 HP)
...........................
2000
1500
Sump Pump........................................................600
‘Table Saw (10”) ...................................1750 to 2000
Television
..................................................
200 to 500
Weed Trimmer....................................................500
‘ Allow 2-1/2 times the listed watts for starting these
devices.
— 8 —
Page 11
AUTOMATIC LOW OIL
PRESSURE SHUTDOWN
The engine is equipped with a normally-open (N.O.)
oil pressure switch (Figure 4). Engine oil pressure
holds the switch open during cranking and operation.
Should oil pressure drop below about 8-10 PSI, the
switch contacts close and the engine automatically
shuts down.
Figure 4 — Switches for Engine Safety Shutdown
HIGH TEMPERATURE SHUTDOWN
An oil temperature switch (Figure 4) with normallyopen (N.O.) contacts is mounted near the oil filter. If
oil temperature were to exceed a preset temperature,
the switch contacts close and the engine shuts down.
FIELD BOOST
The Controller Circuit Board Houses a field boost
diode and resistor which are not part of the automatic
choke circuit. These two components are part of a
“field Boost’ circuit (Figure 5). During engine crank
ing only, a positive DC (battery) voltage is delivered
through the diode, resistor, brushes and slip rings,
and to the generator rotor. Application of this voltage
to the rotor “flashes the field” whenever it is started.
Flashing of the field each time the generator starts
makes sure that a sufficiently strong magnetic field is
available to produce the required “pick up” voltage in
the stator windings.
Figure 5 — Field Boost Circuit
OVER VOLTAGE PROTEaiON
A solid state voltage regulator (Figure 6) controls the
generator’s AC output voltage. This regulator sup
plies an excitation current to the rotor. By regulating
the rotor’s excitation current, the strength of its mag
netic field is regulated and, in turn, the voltage deliv
ered to connected electrcal loads is controlled. When
the AC frequency is 60 Hz, voltage is regulated at 120
volts (voltage-to-frequency ratio is 2-to1).
Figure 6 — Solid State Voltage Regulator
SENSING
0» ■ ■4(»U TO ROTOR
Oa.O<-)—/(DIRECT CURRENT)
&-2—]
The voltage regulator also incorporates a “voltage
surge protection circuit.” This circuit prevents trouble
some surges in the generator AC output voltage.
Voltage surge is a common cause of damage to electtronic equipment.
25-HOUR BREAK IN PERIOD
The first 25 hours of operation are for “breaking in”
the new generator. Correctly breaking in the genera
tor is essential to minumize fuel consumption and pro
vide maximum engine performance. During this 25hour break in period, comply with the following:
• Run the unit at varying electrical loads, to help seat the
engine piston rings properly.
• For the 75 hours of operation after the “break in” period,
avoid light electrical loads. Load the generator at 50% (or
more) of its rated wattage capacity. Repeated light loads
during the break in period can cause improper seating of
engine piston rings, which could cause blowby and high
oil consumption.
• During the break in period, check engine oil level fre
quently. It is normal for oil consumption to be high during
the breaking in period.
• After the 25-hour break in period, complete the tasks rec
ommended under “25-Hour Check Up.”
FROM STATOR
EXCfTATtON WINDING
(ALTERNATtNG CURRENT)
— 9 —
Page 12
SPECIFICATIONS
25-HOUR CHECK UP
After the 25-hour break in period, contact an autho
rized service facility for the follow/ing maintenance.
The vehicle owner is responsible for any charges:
• Change engine cranckcase oil and oil filter.
• Check all fluid levels.
• Inspect cooling and ventilation openings on the vehicle.
• Check engine carburetor adjustments.
• Check engine ignitions system.
• Inspect entire electrical system.
• Inspect the engine exhaust system.
OPERATION IN HIGH GRASS
OR BRUSH
Never operate the generator while the vehicle is
parked in high grass, weeds, brush or leaves. Such
materials can ignite and burn from the heat of the
exhaust system. The generator exhaust system
becomes extremely hot during operation and remains
hot for a long time after it has shut down.
FUEL REQUIREMENTS
These generators are equipped with a LP-vapour
withdrawal fuel system as standard equipment.
To operate normally the generator requires an inlet
pressure of 11° WC (0.39 PSI).
ENGINE OIL REQUIREMENTS
Use a high quality detergent oil classified “For Service
SP and with an oil viscosity rating of SAE 10W-30 oil.
Do not pour in any aditives to the recommended oil.
Engine crankcase capacity is 1.5 U.S. quarts. See
MAINTENANCE section for oil level check and filling
procedures.
ENGINE SPECIFOTIONS
Type of Engine
Q-55LP
Q-70LP
Cooling Method.........................................Air-cooled
Rated Horsepower
Q-55LP....................................................16 at 3600
Q-70LP
Displacement
Q-55LP..............................................................480CC
Q-70LP..............................................................570CC
Compression Ratio
Cylinder Block
Type of Governor
Engine Governed Speed
Air Cleaner
Starter
Ignition System
Recommended Spark Plugs
Champion....................................................RC12YC
AC.....................................................................R45S
Fram Autolite.........................................................65
Spark Plug Gap
.......................................................
.......................................................
..............................;..............
.........................................
...........
............................
.........................................
Aluminum with cast iron sleeve
.................
..........................................
..........................
Mechanical, fixed speed
.....J......................
..............
12 volts DC electric
0.030 inch (0.8mm)
GN-480
GN-570
19at3600rpm
8.6 to 1
2500 rpm
Paper element
Solid state
GENERATOR SPECIFICATIONS
SERIES
Rotor RPM 3600 3600
Rotor Poles 2 2
Engine RPM 2500 2500
Rated Max. Continuous AC Output* 5500 watts (5.5 kW) 7000 watts (7.0 kW)
Voltage 120
Rated Max. Continuous Current*
Phase 1 1
Frequency
Weight
Length
Width
Height
* All units are reconnectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVI/VANSI
when reconnected for dual voltage output.
t Rated maximum continuous current at 240 volts is 22.9 amps.
* Rated maximum continuous current at 240 volts is 29.1 amps.
Q-55LP Q-70LP
120
45.8 AC ampst 58.3 AC amps*
60 Hertz
215 pounds 222 pounds
25 inches
18.5 inches 18.5 inches
15.75 inches
— 10 —
60 Hertz
25 inches
15.75 inches
Page 13
MAINTENANCE
This section includes information about simple main
tenance which includes the following tasks:
• Checking engine oil ievei.
• Changing engine oil.
• Changing oil filter.
• Changing the air cleaner.
• Cleaning the air intake screen.
• Cleaning spark plugs.
CHECKING ENGINE OIL LEVEL
Check engine crankcase oil level at least every eight
hours of operation, or before each use (Figure 7).
Figure 7 — Oil Dipstick and Fill Tube
With engine still warm from running, clean area around
oil drain plug and remove oil drain plug (Figure 8). Drain
oil completely into a suitable container.
Figure 8 — Location of Oil Drain Plug
OIL DRAIN
PLUG
• When oil has drained, install and tighten drain plug.
• Remove oil dipstick and fill crankcase with the recom
mended oil (See Page 10). The engine crankcase can
hold about 1 quart (950ml). DO NOT FILL ABOVE “FULL"
MARK.
• Install and tighten dipstick cap before operating engine.
• Be sure the generator is as level as possible.
• Remove oil dipstick and wipe dry with clean, lint-free
cloth.
• Install and tighten oil dipstick, then remove again.
• Oil should be at dipstick FULL mark. If necessary, add
the recommended oil to the FULL mark only. DO NOT
FILL ABOVE “FULL” MARK.
• Install and tighten oil dipstick cap before operating the
engine.
NOTE: See “Engine Oil Requirements” on Page 10
for recommended oils.
CHANGE ENGINE OIL
Change engine oil after the first 25 hours of operation
(after the 25-hour break in period. Page 9).
Thereafter, change oil eve|y 50 operating hours.
Change oil more frequently if operating consistently
under heavy load or at high ambient temperatures.
• Warm up engine for at least five minutes, then shut down.
CHANGE OIL FILTER
Replace the engine oil filter after the first 25 hours of
operation, every 100 operating hours thereafter.
• Turn oil filter counterclockwise to remove (Figure 9).
Figure 9 — Replacing Engine Oil Filter
• Coat gasket of new filter with engine oil.
• Turn new filter clockwise until its gasket contacts tightly
with the filter adapter. Then tighten with an additional 3/4
to one turn by hand.
• Run engine and check for leaks.
NOTE: Check oil level and fill to full mark after
checking for leaks. Filter will retain some oil.
11 —
Page 14
CLEAN AIR INTAKE SCREEN
Clean all foreign
(Figure 10) at Tease once every 100 hours of opera
tion. Clean more often if necessary.
Inspect the area around the generator exhaust muffler
periodically and remove all grass, leaves, dirt, etc.
from this area.
Figure 10 — Areas to Clean on Air Intake Screen
ENGINE AIR CLEANER
Clean and re-oil the foam pre-cleaner every three
months or every 25 hours of operation, whichever
occurs first. Sen/ice the foam pre-cleaner more fre
quently if you operate the generator in extremely
dusty or dirty conditions (Figure 11).
• Turn KNOB counterclockwise to loosen.
• Remove COVER, FOAM PRE-CLEANER AND PAPER
FILTER.
• Remove foam pre-cleaner from cover.
• Wash foam pre-cleaner in liquid detergent and water.
• Wrap foam pre-cleaner in a cloth and squeeze dry.
• Saturate foam pre-cleaner in engine oil. Squeeze to
remove excess oil and to distrubute oil.
• Install foam pre-cleaner into cover, followed by paper filter.
Tabs at edges of paper filter must lock into slots on cover.
• Insert bottom locking tab of cover into slot. Install cover,
foam pre-cleaner and paper filter.
ENGINE SPARK PLUG
Clean engine spark plug and set gap to 0.030 inch
(0.76mm) every 100 hours of operation (Figure 12).
Clean by scraping or wire brushing and wasning with
commercial solvent. DO NOT BLAST CLEAN SPARK
PLUG.
CAUTION: Sparking can occur if wire terminal
does not fit firmly over spark plug terminal end. If
necessary, reform wire terminal to obtain a tight fit.
Figure 12 — Setting Spark Plug Gap
Fig ure 11 — Engine Air Cleaner
FOAM
PRE-CLEANER
PAPER
FILTER
— 12 —
COVER
Page 15
SPARK ARRESTOR MUFFLER
If the generator is not equipped with a spark arrestor
exhaust muffler and is to be used on any forest cov
ered, brush covered or grass covered unimproved
land, you may have to install a spark arrestor. The
spark arrestor must be maintained in effective work
ing order by the vehicle owner/operator.
For assistance in ordering, installing and maintaining
spark arrestor exhaust mufflers, contact your nearest
authorized service facility.
Exhaust mufflers supplied by Generac are spark
arrestor types. Generac exhaust mufflers for RV gen
erators do not have a spark arrestor screen, but are
the more efficient “toroid” or “swirl” type. To remove
carbon and combustion deposits from such mufflers,
remove the PLUG from the muffler and run the engine
for about 15 minutes. Shut engine down, let the muf
fler cool and install the plug.
WARNING: BE SURE TO RE-INSTALL THE PLUG
FROM THE MUFFLER TIGHTLY. ENGINE VIBRATION
A
____
COULD CAUSE A LOOSE PLUG TO FALL OUT.
WITHOUT THE PLUG IN PLACE, HOT ENGINE
EXHAUST IS DIRECTED OUT THE OPENING. THIS
HOT EXHAUST, DEPENDING ON THE INSTALLA
TION, COULD BE DIRECTED TO AREAS NOT ABLE
TO WITHSTAND THE EXTREME HEAT SUCH AS
WOODEN FLOOR BOARDS OR OTHER FUMMABLE MATERIALS. THIS COULD RESULT IN A FIRE.
CLEANING THE GENERATOR
Keep your generator set as clean and dry as possible.
Dirt and moisture that are permitted to accumulate on
electrical windings have an adverse affect on the
insulation resistance of those windings.
Moisture that is allowed to remain in contact with
windings will be retained in voids and cracks of the
windings. Dirt makes the problem worse, since it
tends to hold the moisture into contact with the wind
ings. Salt, as from sea air, worsens the problem since
it tends to absorb moisture from the air. The combina
tion of salt and moisture makes a good electrical con
ductor.
CAUTION! Do NOT use a forceful spray of water to
clean the generator. Water will enter the generator
interior and cause probiems, and may also conta
minate the generator fuei system.
BAHERY
All lead-acid storage batteries will discharge when not
in use. Inspect the generator battery as follows:
ONCE WEEKLY
Inspect battery posts and cables for tightness, corro
sion. Clean and^r tighten as necessary.
Also check battery fluid level, and, if necessary, fill
with DISTILLED WATER ONLY. DO NOT USE TAP
WATER IN BATTERY.
EVERY SIX MONTHS
Have the battery state of charge and condition
checked by an automotive service facility. This should
be done with an automotive type battery hydrometer.
DANGER: STORAGE BAHERIES GIVE OFF
EXPLOSIVE HYDROGEN GAS. THIS GAS CAN
A
FORM AN EXPLOSIVE MIXTURE AROUND THE
BAHERY FOR SEVERAL HOURS AFTER CHARG
ING. THE SLIGHTEST SPARK CAN IGNITE THE
GAS AND CAUSE AN EXPLOSION. SUCH AN
EXPLOSION CAN SHAHER THE BAHERY AND
CAUSE BLINDNESS OR OTHER INJURY. ANY
AREA THAT HOUSES A STORAGE BAHERY MUST
BE PROPERLY VENTILATED. DO NOT ALLOW
SMOKING, OPEN FLAME, SPARKS OR ANY
SPARK PRODUCING TOOLS OR EQUIPMENT
NEAR THE BAHERY.
DANGER: BAHERY ELECTROLYTE FLUID IS AN
EXTREMELY CAUSTIC SULFURiC ACID SOLUTION
THAT CAN CAUSE SEVERE BURNS. DO NOT PER
MIT FLUID TO CONTACT EYES, SKIN, CLOTHING,
PAINTED SURFACES, ETC. WEAR PROTECTIVE
GOGGLES, PROTECTIVE CLOTHING AND GLOVES
WHEN HANDLING A BAHERY. IF YOU SPILL THE
FLUID, FLUSH THE AFFECTED AREA IMMEDIATE
LY WITH CLEARWATER.
DANGER: DO NOT USE ANY JUMPER CABLES
OR BOOSTER BAHERY TO CRANK AND START
THE GENERATOR ENGINE. IF ANY BAHERY HAS
DISCHARGED, REMOVE IT FROM THE VEHICLE
FOR RECHARGING.
MAJOR SERVICE MANUAL
To obtain a service manual for your generator, order it
from your dealer/distributor or contact the factory. Be
sure to identify your unit’s MODEL NUMBER and
SERIAL NUMBER.
DRIVE BELTS
The engine drives the generaor rotor by means of a
pulley and drive belt arrangement. The drive train,
drive belt and pulleys are warranted for the life of the
generator. Drive belt tension was properly adjusted
before the unit was shipped from the factory. If you
suspect that drive belt tension is incorrect, contact an
authorized service facility.
EXERCISING THE GENERATOR
Generac recommends that you start and operate the
generator at least once every seven days. Let the unit
run for at least 30 minutes to “exercise” the engine.
-13-
Page 16
OUT OF SERVICE PROTECTION
If you cannot exercise the generator every seven
days and it is to be out of service longer than 30 days,
prepare the generator for storage as follows;
• Start the engine and let it warm up.
• While the engine is still warm from running, drain the oil
completely. Refill crankcase with recommended oil. See
“Specifications.”
• Attach a tag to the engine indicating the viscosity and
classification of the oil in the crankcase.
• Remove spark plug(s) and add about two or three table
spoons of clean, fresh engine oil into spark plug(s)
threaded opening(s). Crank engine several times to dis
tribute oil, then install and tighten spark plug(s).
• Remove the battery and store in a cool, dry room on a
wooden board. Never store the battery on any concrete
or dirt floor.
• Clean and wipe the entire generator.
• Shut off fuel supply.
RETURN UNIT TO SERVICE
AFTER STORAGE
To return the unit to service after storage, proceed as
follows:
• Check tag on engine for oil viscosity and classification.
Verify that the correct recommended oil is used in engine.
If necessary, drain and refill with proper oil.
• Check battery. Fill all cells to the proper level with distilled
water. DO NOT USE TAP WATER IN THE BATTERY.
Recharge battery to 100% state of charge, or, if defective,
replace the battery.
• Turn OFF all electrical loads, turn on fuel supply, then
start the engine.
• Let engine warm up.
• Apply electrical loads to at least 50% of the unit’s rated
wattage capacity. i
• When engine is thoroughly warmed up, turn off electrical
loads and, shut it down.
THE GENERATOR IS NOW READY FOR SERVICE.
SERVICE DEALER LOCATION
TO LOCATE THE NEAREST GENERAC SERVICING DEALER, PLEASE CALL OUR 800 NUMBER.
ONLY DEALER LOCATIONINFORMATION CA BE OBTAINED AT THIS NUMBER.
1-800-333-1322
— 14 —
Page 17
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSES REMEDY
Engine won1 crank. 1.
Engine cranks but woni start.
Engine starts hard, runs rough. 1. Air cleaner plugged or damaged 1.
Engine starts, shuts down
when Start/Stop switch is
released.
15 amp fuse is blown 1.
2. Loose corroded or defective 2.
battery cables. as necessary.
3. Defective engine Start/Stop switch. 3.
4. Defective starter contactor.
Defective starter motor.
5.
Low Battery Voltage.
6.
1. Out of fuel.
2. Fuel pump is defective. 2. Replace fuel pump.
Open Wire #14 from Eng. Control Bd.
3.
4.
Engine is flooded.
5. Spark plug defective. 5.
2. Defective spark plug. 2.
1.
Engine oil is low.
2. Engine is overheated. 2. Check adequate ventilation.
Defective Low Oil Pressure System 3.
3.
4.
Defective Engine Control Board
Defective Computer Control Board 5.
5.
Replace 15 amp fuse
Tighten, clean or replace
Replace Start/Stop switch.
4.
Replace contactor.
5. Replace starter motor.
6. Charge or replace battery.
1. Replenish fuel.
3. Reconnect wire.
4.
Wait 5-10 min. before trying.
Clean, regap or replace plug.
Clean or replace as needed.
Clean, regap or replace plug.
1.
Check oil; add as needed.
Have serviced/replaced.
4.
Have board serviced/replaced.
Have board serviced/replaced.
Start/Stop switch at Stop,
engine continues to run.
No AC output from generator.
1. Defective Start/Stop switch
Open/disconnected wire #18 between
2.
Start/Stop switch and Engine Control
Open/disconnected wire #0 between
3.
Start/Stop switch & Engine Control Bd.
4. Defective Engine Control Board
Check circuit breaker. 1. Reset to ON or CLOSED.
1.
2. Check vehicle circuit breaker & fuses.
Transfer sw. set to NORMAL position. 3. Set to GENERATOR position.
3.
4. Generator internal failure
1. Replace switch.
2. Reconnect or close wire.
3. Reconnect or close wire.
4.
Replace board.
2.
Reset and replace if necessary.
4.
Take generator to an
Authorized Generac facility.
— 15 —
Page 18
ELECTRICAL DATA
Drawing No. 92116
8-
S
i
— 16 —
Page 19
Drawing No. A4029
REPAIR PARTS — CARBURETOR
ITEM PART NO.
1 A1662A 1
2 57822 2 HOSE CLAMP
74994 1
3
4 26307 3 STREET ELBOWS
5 26915
6 75211 1
7
A2666
8 78864 1
9 49813 4 M6 HEX NUT
22097 4
10
11 47411 2
12 38750 2 ^^-plgl^pX 30MM HEX HD.
13
37398
14
74961 1
15
56893 5
16 47227 1
17
74962-C 1
18 66476 2
QTY.
1
1
1
DESCRIPTION
GARB. V-TWIN L/P
1/2“I.D. xIO" LONG HOSE
3/4" PIPE NIPPLE
GASEOUS FUEL REGULATOR
GASEOUS FUEL SOLENOID
REG. MOUNTING BRACKET
M6 LOCK WASHER
HEX LOCK NUT (NYLON)
GOV. ADJUSTER BRACKET
NO. 10-24 X 1/2" SCREW
GOV. ADJUSTER SCREW
GOVERNOR SPRING
M6-1.0 X 12MM HEX SCREW
W/LOCKWASHER
ITEM PART NO. QTY.
19 81378-B 1
91351 1
91352 1
91352-A 1
20 75944 1
21 73130 1
22 70155 1
76242
23
24
70125 1 ANTI-LASH SPRING
25
70108
+
28739
+
55162 9cc PIPE SEALANT
26 81190 1
27
70103
28
61695
+NOT SHOWN
— 17 —
DESCRIPTION
AIR CLEANER DECAL-Q-55
AIR CLEANER DECAL-Q-70
GOV. SPRING BRACKET
FLYWHEEL ASSEMBLY
GOVERNOR LEVER
2 1/8" I.D. X 1/8" RIVET
1
GOV.-TO-CARB. ROD
4
4" LONG TIE WRAP
LP HOOK-UP FITTING
1
1
BARBED 90 DEG. 3/8" x 1/2"
Page 20
EXPLODED VIEW — BASE & PULLEYS
Drawing No. 95955
— 18 —
Page 21
Drawing No. 95955
REPAIR PARTS — BASE & PULLEYS
ITEM PART NO. QTY.
1 86318
90141 1
2
3 46911
4 25017 4
22237
5
6 22129
7
72391
8 77603
9 22259
10 52858
11
51730
12 29459 2
13 75215 2
14 73146
15 75209 2
73174 1
16
17
79678 2
18 55173
19 72383 2
20 90859
75224B 1
21
22 73106B
23 75216
24 49451 5
42633 1
25
77017
26
27 73118 1
28 74906 5
23152 4
29
30 72375
73185 1
31
22097
32
77682 1 CAPSCR., HEX HD.
33
1 BASE, MOUNTING
4 MOUNT, (RUBBER)
10
2 LOCKWASHER-M8
2
2
2 NUT, HEX-5/16-18
6
2 CAPSCR. HEX HD.
4 SLIDE (NYLON)
4 CAPSCR., HEX HD.
1 COVER PLATE -EXTERNAL
1
1
1 GUIDE, BLOWER HOUSING
1 HOUSING, BLOWER
6
DESCRIPTION ITEM
34
GROUND CABLE
CAPSCREW, HEX HD.
3/8"-16x1/2“
LOCKWASHER, 3/8
SKID, RUBBER MOUNT
SAFETY BOLT 5/16-18x31/2
NUT, FLANGED LOCK
M8-1.25
M8-1.25X60MM
SPRING, BELT TENSION
WASHER, SPRING CNTR
SUPPORT, NYLON SLIDE
MANIFOLD, EXHAUST
GASKET, EXHAUST
MANIFOLD
M8-1.25X20MM (GRADE 10.9)
GASKET, COLLECTOR PAN
PULLEY, ENGINE
PULLEY, ALT.
BELT (POLY V 4L)-40“
WASHER, PULLEY RETAINER
CAPSCR., HEX HD.
3/8"-24x1" (GRADE 5)
CAPSCR., HEX HD.
3/8”-24 X 2-1/4”
SCREW (TAPTITE)
M6-1.00 X 20
CAPSCR.,HEX HD.
3/8”-16X3/4”
SPACER, BLOWER
HOUSING
LOCKWASHER, M6
M5-0.80 X 80MM
35 49813 2
36 45757 2
42
43
44
45 67871 1
46
47 75711
56
57
58 60108 1
59
60
61
62 73134
63
64
65 68548 1 GASKET, OIL PAD
66
67
69 75281 1 SWITCH, HIGH TEMP.
70 74027 2 SCREW, PAN HEAD-M3-0.50
71 43182 2
73 75237 4 WASHER, SPRING
74
75 75474 1 CAP, VINYL-17Dx42Lx2H
76 90800 1 ELBOW, EXHAUST
77
78 75226 1 COVER, AIR
79 56893
80 75229 1
81 75227 1 SLIDE PAN
82
83 22473 4
85 72384C 1 COVER, EXHAUS
PART NO.QTY.
75242
26925
7571OA
74958 1
75712 1 0-RING, DRAIN
73179 1 OIL FILTER SUPPORT
70185
74948 3
74950
74951
38750 3 CAPSCREW, HEX HEAD
74949 1
62684
29289
77681
94670
14
79246 4
DESCRIPTION
4
SPRING, GEN. SET MT
NUT, HEX M6X 1.0
CAPSCR., HEX HD.
M6-1.0X25LONG
1
3/8 NPT OIL DRAIN
1
TUBE, OIL FILL AND DRAIN
CAP & DIPSTICK ASSEM.
0-RING, CAP
1
PIPE, OIL DRAIN ADAPTOR
1
FILTER, OIL (FRAM#PH3614)
10 PSI-SWITCH, OIL PRES.
FITTING-S/IS"
1
TUBE, OUTER OIL
1
TUBE, INNER OIL
1 ADAPTOR. OIL PAD
M6-1.00X30MM
FITTING, BARBED 90°-5/16"
1
LUG, GROUNDING
-
TAPE. FOAM-1/16"x1/2"
LOCKWASHER-M3
RETAINER
1
CAP, VINYL-LOS-2 WIRE
1
CLAMP-EXHAUST 1-1/8
SCREW (CRIMPTITE)
#10-24x1/2" LONG
SLIDE PAN, GASKET
CAPSCREW, HEX HEAD
M6-1.00X16MM W/LOCK
WASHER
FLATWASHER, M6
— 19 —
Page 22
EXPLODED VIEW — ALTERNATOR
Drawing No. 92118
— 20 —
Page 23
Drawing No. 92118
REPAIR PARTS — ALTERNATOR
ITEM PART NO. QTY.
75995
1
92605G
2
77005G
77005G
77004G
80095G
92604
3
87844G
87844G
87845G
87846G
4 73159
31971
5
72379
6
7 77006
52858
8
66386
9
66849
10
27756
11
86314
12
75234
13
14 22473
22097 5
15
74095
16
90141 2
17
22447
18
74906
19
92234
20
10-74260
21
22 22129
22259
23
24 86316
53650
25
20575
26
75244
27
66476
28
86729
29
75476 3
30
22264
31
65795
32
90987 2 M3-0.5 X 12 LG. CAPSCREW
33
4 STUD-STATOR
8
2 M5-0.8 X 16 LG. TAPTITE
4
1
3
4
2
2
1
1 CONNECTOR
2
4 M4 LOCK WASHER
DESCRIPTION
1 LOWER BEARING CARRIER
ROTOR ASSEM. 50 35 75235
1
ROTOR ASSEM. 52
1
1 ROTOR ASSEM. 55
ROTOR ASSEM. 66
1
ROTOR ASSEM. 72 & 70
1
STATOR ASSEM. 50
1
STATOR ASSEM. 52
1
1 STATOR ASSEM. 55
STATOR ASSEM. 66
1
STATOR ASSEM. 72 & 70
1
1 BALL BEARING
BALL BEARING
1
1 UPPER BEARING CARRIER
M8-1.25 FLANGE LOCK NUT
BRUSH HOLDER
1
NYLON WASHER
1 GENERATOR TOP HOUSING
RESISTOR
M6-FLAT WASHER
M6-LOCK WASHER
1 M6-1.0 X 60LG. CAPSCREW
GROUND CABLE
SHAKEPROOF LOCK WASHER
1
M6-1.0X20 LG. TAPTITE
CONTROLLER P.C.B.
1
STARTER CABLE
1
5/16 LOCK WASHER
5/16-18 HEX NUT
PANEL SHEET METAL
4-PIN CONNECTOR
1
REMOTE HARNESS
1
M6-1.0 X 12MM CAPSCREWW/LOCKWASHER
STARTER CONTACTOR
1
M4-0.7 X 16 LG. CAPSCREW
1 BATTERY CHARGE RECTIFIER
ITEM PART NO. QTY. DESCRIPTION
34 86317 1
36 82737
37 49813
38 49815
43182 2 M3-LOCK WASHER
39
41 53623
54502
42 67444 2 M5 SHAKEPROOF WASHER
43 83049
44
49226 6 M5-LOCK WASHER
45 51716
90144
46
90145
47
90145
48 25105
86315 1 PANEL COVER
49
90734 4
50
22985
51
52 32300
22676
53
54 87798
55 92113
7521OA 1 TERMINAL BLOCK
56
57 23365
51715
58
90157 1 DECAL, CB RATING 30A.
59
60 90156
89438A 1 DECAL, CUSTOMER
61
89438B
62 31791
23897 2
63
64
74908
65 23484S
75763-A
66
PANEL SUPPORT BRACKET
4
M5-0.8 X 30 LG. CAPSCREW
4
VIBRATION MOUNT
4
M6-1.0 HEX NUT
1
M5-08X16LG. HEX HD
CAPSCR.
1
C/BREAKER 2.5A. ON 50, 52,
& 55
1
C/BREAKER 3.0A. ON 66, 70,
&72
1
REGULATOR VOLTAGE
4
M5-0.8 HEX NUT
1
C BREAKER 20A 50, 52, & 55
1
C/BREAKER 30A 66, 70, & 72
1
C/BREAKER 30A. ALL UNITS
4
#6-32 W/LOCK WASHER SCREW
M4-0.7X 16 LG. CAPSCR.
W/LOCKWASHER &
FLAT WASHER
1
M4 FLAT WASHER
1 FUSE HOLDER
1 FUSE AGC-15A.
1 SWITCH S.P.D.T. 6A
(START-STOP).
1 SWITCH S.P.D.T.-(FUEL PUMP)
1 M4 SHAKEPROOF WASHER
M4-0.7 HEX NUT
1
DECAL, CB RATING 20A.
1
CONNECTION-50, 52, & 55
1 DECAL, CUSTOMER
CONNECTION-66, 70, & 72
1 CLAMP, HOSE
M5 FLAT WASHER
M5x 10 LONG TAPTITE
1
1 BUSHING
BOOT, BATTERY CABLE
1
21 —
Page 24
EXPLODED VIEW — ENGINE
Drawing No. 79216
57
/
84-
83-
ri
s
_______
33
■— f -
T
-------------
K
________
1 — »_
/^
!
92v
[
«REOUnES SKOAL TOOLS TO MSTALL
SEE REPAR MSTRUCnON MAMJAL
fc:=2>G-^21
21 mr
63-
39
73
35-|
33-
1-41
0-59
60-i-38
—62
— 22 —
Page 25
Drawing No. 79216
EXPLODED VIEW — ENGINE
— 23 —
Page 26
EXPLODED VIEW — ENGINE
Drawing No. 79216
-51
90
101
2530-
94'
97-
28
-29
— 95
-45
42
96'
— 24 —
Page 27
Drawing No. 79216
PART NO. QTY. DESCRIPTION
ITEM
1 69331
2 69333
67805
3
79234 1
4
79235
5
70169
6
69332 2 GASKET-CYLINDER HEAD
7
72301
8
9 72315
70190 1 SCREW, BREATHER
10
11
70596
12 69336
13 69325
14
67888
72334 1 CRANK SHAFT ASSEMBLY
15
75247 1 OIL SUMP ASSEMBLY
16
17 67924 1
18 67878 9 BOLT, OIL SUMP
75248 2
19
20 75249 2 RING SET- PISTON-STANDARD 71
69327 4
21
22 75250 2 PISTON PIN-STANDARD
23 75251
24
72346
25 69316
69317 2 INTAKE VALVE
26
27 67816 4
69320 4 RETAINER, VALVE SPRING
28
70513 4 KEEPER,VALVE
29
70584 4 TAPPET, VALVE
30
70530 1 CAMSHAFT ASSEMBLY
31
32 72358 1 INTAKE MANIFOLD
33 69379 2
34
67895
70594 2
35
36 67158
37 68574 1
68554 1
38
39 68573
40
70506
41 70554
42 70568 4 STUD, ROCKER ARM
43
75253
44 67885 4
45 75254 4
46 70535
47
75255 1 STARTER MOTOR
48 75256 2
75257 4
49
50 67891 1
51 72356 2
. 1 CYLINDER ASSEMBLY
1 SLEEVE BEARING-30 DIA.
1
OIL SEAL-30 DIAMETER 54
CYLINDER HEADASSEM.-NO. 1 55 75260 1
1
CYLINDER HEADASSEM.-NO. 2
4
SEALING WASHER 57
1 BREATHER ASSEMBLY
1 GASKET, BREATHER
1 TUBE. BREATHER
1 GASKET, OIL SUMP
8 BOLT, CYLINDER HEAD
2 PLUG, OIL DRAIN-3/8" NPT
OIL SEAL-35 DIAMETER
PISTON ASSEMBLY-STANDARD
LOCKING RING, PISTON 72
2
CONNECTING ROD ASSEMBLY 74
4
BOLT, CONNECTING ROD
2 EXHAUST VALVE
VALVE SPRING 78
GASKET, CARBURETOR MNTG. 84 72300 1
2 GASKET, INTAKE MANIFOLD
BOLT, CARBURETOR MNTG.
4
BOLT, INTAKE MANIFOLD MNT. 87
PIPE-PLUG, 1/8" NPT
SEAL, GOVERNOR SHAFT
1
0-RING, OIL PUMP 90
1
0-RING, OIL GALLEY
1
SPACER, CARBURETOR 92 70547 1
4
SEAL, WASHER-VALVE COVER
NUT, NYLOK-M6
SCREW, VALVE ADJUST
1 SCREEN, OIL
BOLT, STARTER MOTOR
BRUSH ASSEMBLY
IGNITION ARMATURE ASSEM.
SCREW, IGNITION ARMATURE
REPAIR PARTS — ENGINE
ITEM PART NO. QTY.
52 72347 2
53 75258 1
75259
56 75261 1
66480 1
58
75269
59
72361 1
60 72362 1
61 70199 1
62 72366 1
63 72367 1
64
72365 1
65 68555 2
66
67806
67
75262 1
68
75263
75264
69
70
75265
75266 1
75267 1
73 68572 2
75272 2
75 70122 2
76
67910 2
77
67911 2 SEAT, EXHAUST VALVE
67813
79 75268 1 RETAINER AND PIN
80
75270
81 70592
82
73123
83
70593
67156 2
85
69341 1
86
80011
88 70597 1 TUBE, AIR INLET
89 69358
67920
91 69328
93 70536 1 GOVERNOR SLIDER
94 70577 4 PUSH ROD
95
70599
70567
96
97
70566
75271 1
98
99 67897 2 GASKET, EXHAUST
100 91481 1
101 91480 1 ROCKER ARM COVER
DESCRIPTION
SPARK PLUG-CHAMPION R12YC
GASKET KIT-ENGINE
1
WASHER, BREATHER SCREW
STARTER DRIVE ASSEMBLY
CLUTCH ASSEMBLY
GASKET, AIR CLEANER
1
ARMATURE ASSEMBLY
BUSHING, GOVERNOR SHAFT
BUSHING, GOVERNOR SHAFT
BAFFLE, BREATHER
COTTER PIN
GOVERNOR FORK
WASHER, GOVERNOR SHAFT
DOWEL, CRANKCASE
4
DOWEL, CYLINDER HEAD
SEAL, BREATHER SCREW
1
SEAL, BREATHER SCREW
1
STARTER GEAR
1
STARTER END CAP ASSEMBLY
COMMUTATOR CAP ASSEMBLY
STARTER HOUSING ASSEM.
SCREW, OIL PUMP
TERMINAL, SPARK PLUG
SEAL, VALVE STEM
SEAT, INTAKE VALVE
4
VALVE, GUIDE
1
ROLL PIN
1
AIR CLEANER BASE
1
AIR FILTER (FLAME RETARDENT)
1
COVER, AIR CLEANER
SCREW, AIR CLEANER COVER
SCREW, AIR CLEANER BASE
PRE-FILTER
1
SPRING, BRUSH SET
1
DEFLECTOR-BREATHER
2 GASKET, VALVE COVER
1
ROCKER ARM COVER
OIL PUMP ASSEMBLY
4 ROCKER ARM ASSEMBLY
2 SHAFT-ROCKER ARM
4 SUPPORT, ROCKER ARM
KIT-VALVE OVERHAUL
GASKET & CAP ASSEMBLY
25 —
Page 28
REPAIR PARTS — ENGINE SHEET METAL
Drawing No. 89403
ITEM
PART NO. QTY.
1
2 99258
67198-N 1
3
4 67890
5 87865
7 86313
8 56893 23 SCREW (CRIMPTITE)
10 87750
74916 1 COVER-BASE #2
11
12 74908 9
13 73190
14 78858 1
15 78859
74902 2
16
17 66476 5
19 73191
DESCRIPTION
1
SEE ENGINE EXPLODED
VIEW OF ENGINE
1
KEY, WOODRUFF-6 x 22MM
WASHER, BELLEVILLE
1
NUT, HEX-M20-1.50
1
PLUG, FLYWHEEL ACCESS
1
HOUSING, ENGINE TOP
N0.10-24x1/2" 26
1
SCROLL, FLYWHEEL
SCREW (TAPTITE)-M5 x 10MM 29 67866
1
WRAPPER-NO. 2 CYLINDER
COVER, VALLEY 31 73132 2 BOOT, SPARK PLUG
1
WRAPPER-NO. 1 CYLINDER 33
WRAPPER-BARREL
CAPSCREW, HEX HEAD
M6-1.00X12MM
W/LOCKWASHER
1
COVER, BASE #1 CYLINDER
ITEM PART NO.
20 42907 2
21
22129
22
75246
23
10-74260 1 WIRE ASSEMBLY-NO. 16
24
74900 1 COVER, STARTER
25
73186
81108
27
22717-B 1 GROMMET-RUBBER.
28 22717-A 3
30
77001
87858A 1 GROUND WIRE ASSEMBLY
34
29289
35 87858B 1 GROUND WIRE ASSEMBLY
36 50277 1 DECAL, OIL DRAIN
QTY. DESCRIPTION
CAPSCREW, HEX HEAD
M8-1.25X 16MM
2
LOCKWASHER-M8
4 SCREW(TAPTITE)
3/8''-16x 1-1/4"
1
WRAPPER, CRANKCASE
1 BUSHING, SNAP
GROMMET-RUBBER
1
0-RING
1
PLUG, OIL FILL
CYL. #1
2FT.
1
FOAM TAPE
CYL. #2
— 26 —
Page 29
NOTES
— 27 —
Page 30
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (“CARB“) and Generac Corporation are pleased to explain the Emission Control Systen
Warranty on your new recreational vehicle generator engine. In California, new utility and lawn and garden equipment“
engines must be designed, built and equipped to meet the State's stringent anti-smog standards. Generac Corporation will
warrant the emission control system on your recreational vehicle generator for the periods of time listed below provided
there has been no abuse, neglect, unapproved modification, or improper maintenance of your recreational vehicle genera
tor engine.
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Also included
may be the compression release system and other emission-related assemblies.
Where a warrantable condition exists, Generac Corporation will repair your recreational vehicle generator engine at no cost
to you for diagnosis, parts and labor.
MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1995 and later model year utility and lawn and garden equipment engines are warranted for
two years as hereinafter noted. If, during such warranty period, any emission-related part on your engine is defective in
materials or workmanship, the part will be repaired or replaced by Generac Corporation.
OWNER'S WARRANTY RESPONSIBILITIES:
As the recreational vehicle generator engine owner, you are responsible for the performance of the required maintenance
listed in your owners manual. Generac Corporation recommends that you retain all receipts covering maintenance on your
recreational vehicle generator engine, but Generac Corporation will not deny warranty solely due to the lack of receipts or
for your failure to provide written evidence of the performance of all scheduled maintenance.
As the recreational vehicle generator engine owner, you should, however, be aware that Generac Corporation may deny
you warranty coverage if your recreational vehicle generator engine or a part thereof has failed due to abuse, neglect ,
improper maintenance or unapproved modifications.
You are responsible for presenting your recreational vehicle generator engine to a Generac Corporation Authorized Servic
Outlet as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceeo
30 days.
Warranty service can be arranged by contacting either a Generac Corporation Authorized Service Outlet or by contacting
Generac Corporation at:
GENERAC CORPORATION PH: (414) 544-4811
P.0.B0X8 FX: (414) 544-0179
WAUKESHA, Wl 53187
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (“ECS Warranty”) which is provided to you by Generac Corporation pursuant to California law. See also the
Generac Corporation Limited Warranties for Generac Corporation which is enclosed herewith on a separate sheet and also is
provided to you by Generac Corporation. The ECS Warranty applies only to the emission control system of your new engine.
To the extent that there is any conflict in terms between the ECS Warranty and the Generac Corporation Warranty, the ECS
Warranty shall apply except in any circumstances in which the Generac Corporation Warranty may provide a longer warran
ty period. Both the ECS Warranty and the Generac Corporation Warranty describe important rights and obligations with
respect to your new engine.
Warranty service can only be performed by a Generac Corporation Authorized Service Outlet. At the time of requesting
warranty service, evidence must be presented of the date of the sale to the original purchaser. The purchaser shall pay any
charges for making service calls and/or for transporting the products to and from the place where the inspection and/or war
ranty work is performed. The purchaser shall be responsible for any damage or loss incurred in connection with the trans
portation of any engine or any part(s) thereof submitted for inspection and/or warranty work.
IF YOU HAVE ANY QUESTIONS REGARDING YOUR WARRANTY RIGHTS AND RESPONSIBILITIES, YOU SHOULD CONTACT
GENERAC CORPORATION AT 1-800-222-3136
Page 31
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty ("ECS Warranty") for 1995 and Later Model Year Utility and Lawn and Garden Equipment
ngines:
L Applicability: This warranty shall apply to 199S and later model year utility and lawn and garden equipment engines. The
II
ECS Warranty Period ("ECS Warranty Period") shall begin on the date the new engine or equipment is delivered to its origi
nal, end-use purchaser and shall continue for 24 consecutive months thereafter.
B. General Emissions Warranty Coverage: Generac Corporation warrants to the original, end-use purchaser of the new engine
or equipment and to each subsequent purchaser that each of its utility and lawn and garden equipment engines is:
1. Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pur
suant to its authority, and
2. Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, will cause a warrant
ed emissions - related part to fail to be identical in all material respects to the part as described in the engine manufac
turer's application for certification.
C. The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
1. Any warranted, emissions-related parts which are not scheduled for replacement as required maintenance in the Owner's
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be
repaired or replaced by Generac Corporation according to Subsection (4) below. Any such part repaired or replaced under
the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period.
2. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the Owner's Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of "repair or
replace as necessary" shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for any remainder of the ECS Warranty Period.
3. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner's Manual
shall be warranted for the period of time prior to first scheduled replacement point for that part. If the part fails prior to
the first scheduled replacement, the part-shall be repaired or replaced by Generac Corporation according to Subsection (4)
below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder
of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
4. Repair or Replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge
to the owner at a Generac Corporation Authorized Service Outlet.
Fs.The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS
Warranty is in fact defective, provided that such diagnostic work is performed at a Generac Corporation Authorized
Service Outlet.
6. Generac Corporation shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission-related part covered by the ECS Warranty.
7. Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to
rneetthe expected demand for such emission-related parts.
8. Any Generac Corporation authorized and approved emission-related replacement part may be used in the performance
of any ECS warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce
Generac Corporation ECS warranty obligations.
9. Unapproved add-on modified parts may not be used to modify or repair a Generac Corporation engine. Such use voids
this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac Corporation shall not
be liable hereunder for failures of any warranted parts of a Generac Corporation engine caused by the use of such an
unapproved add-on or modified part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1. Carburetor assembly and its internal components.
a. Fuel filter
b. Carburetor gaskets
c. Fuel pump (if so equipped)
2. Air cleaner assembly
a. Air filter element
b. Intake pipe/manifold
3. Ignition system including:
a. Spark plug
b. Ignition module
4. Catalytic muffler (if so equipped)
a. Muffler gasket (if so equipped)
b. Exhaust manifold (if so equipped)
5. Crankcase breather assembly and its components,
a. Breather connection tube
Page 32
GENERAC’S THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE “Q” GENERATORS
Generac warrants to the original purchaser that its generators will be free from defects in materials or workman
ship for the period set forth below from date of original purchase. During said warranty period, Generac will, at its
option, repair or replace any part which, upon examination by Generac or Generac Authorized Distributors and/or
Dealers, is found to be defective under normal use and service.
THREE-YEAR WARRANTY SCHEDULE
1. All Q-Series generators used in a recreational vehicle shall be warranted for a period of three (3) years or 2,000
hours of operation, whichever occurs first. All parts, labor, removal and reinstallation shall be covered for the first
two years. Parts and labor on selected generator and engine parts shall be covered during the third year or 2,000
hours, whichever occurs first. These selerted parts are limited to: the main Rotor and Stator with regard to the
generator; the Cylinder Block, Cylinder Head, Crankshaft, Piston, Valve, Valve Lifter, and Manifolds with regard to
the engine.
2. The drive train belt and pulleys (if so equipped) on Q-Series air-cooled generators used in recreational vehicles
shall be warranted against failure due to defective materials or normal usage for the life of the generator. For the
original owner, this drive train warranty shall include parts an labor plus $50.00 payment upon return of the failed
belt or pulley by the original owner. For succeeding owners, this power train warrantyishall cover belt or pulley
parts only.
3. Rental units, demonstrators, prime power, or commercial applications, such as construction or utility, are warrant
ed for (1) one year or 2,000 hour, whichever comes first.
All warranty expense allowances are subject to the conditions defined in the published "GENERAC POLICIES AND
PROCEDURES" manual.
THIS WARRANTY DOES NOT COVER:
Costs of maintenance, installation and startup.
Failures due to (a) normal wear and tear from GN engine, or (b) accident, misuse, abuse, negligence or improper
installation.
Products which are modified or altered in a manner not authorized by Generac in writing.
Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay
in repair or replacement of defective parts.
Failure due to misapplication.
Telephone, telegraph, teletype or other communication expenses.
Living or travel expenses of persons performing service.
Any and all transportation/travel expenses.
Rental equipment used while warranty repairs are being performed.
Overtime labor.
Starting batteries, fuses, light bulbs, and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. SPECIFICALLY, GENERAC MAKES
NO OTHER WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. GENERAC'S
ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PARTS AS STATED ABOVE. IN NO EVENT SHALL GEN
ERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A RESULT OF
GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential dam
ages, so the above limitation may not apply to you. Buyer agrees to make no claims against Generac based on neg
ligence.
This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state,
generac corporation, p.o. Box 8, hwy. 59 and hillside road, Waukesha, Wl.53187
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