GE A4021 User Manual
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.
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.
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
_______
____________________
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
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 —
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 —
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 —
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 —
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 —
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 —
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