Generac Power Systems 00862-1 User Manual
Manual No. A9-12?
OWNER'S MANUAL
and Installation Instructions
Series QP55-G
AIR-COOLED
RECREATIONAL VEHICLE
GENERATORS
Model No. 00862-1
Revision 1 (1/5/99)
POWER SYSTEMS, INC
Printed in U.S.A.
GENERAL SAFETY RULES
COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHI- A
CLE. SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERA- Mk.
A
TORS OF THIS EQUIPMENT.
Study these SAFETY RULES carefully before operat
ing or servicing applicable equipment. Become familiar
with this Owner's 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 engine exhaust from this product
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.
For fire safety, the recreational vehicle generator
A
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 conformance 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 fataC 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
A
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 connect the bonding conductor
to any generator part that might be removed or
disassembled during routine maintenance. If the
grounding conductor must be replaced, use only a
flexible conductor that is of No. 8 AWG copper
wire minimum.
THE MANUFACTURER SUGGESTS THAT THESE "RULES” FOR SAFE OPERATION BE
In case of accident caused by electric shock, shut down
the source of electrical power at once. If this cannot 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 vic
tim from live conductor. If victim is unconscious,
apply first aid and get medical help.
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.
WARNING:
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
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 operating con
ditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
Do not smoke around the generator. Wipe up any
A
fuel and oil spills immediately. Never leave oily or
fuel soaked rags in the generator compartment or on
the generator itself. Keep the area around the gener
ator clean and free of debris.
Adequate ventilation 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
ventilation openings. Such openings must be kept
clear and unobstructed.
Keep hands, feet, clothing, etc., away from drive
belts, fans and other moving parts of this equip
ment. Never remove any drive belt or fan guards
while the unit is operating.
Inspect the generator periodically. Repair or replace
all damageo or defective parts immediately.
These generators can be converted to use LP gas
propane) as a fuel. LP 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 AND GENERATOR FEATURES
Please record the following information from the generator DATA DECAI- or information decal.
1.Model Number__________u
3.kW Rating.
5. Phase
______
__________ 2.Serial Number
4. Rated Voltage.
6. Hertz
_______________________
___________
■
1. Oil Filler Cap , .
2. Optional Remote Panel-Receptacle
3. Generator Air Intake Screen
4. . Winter/Summer Heat .Riser.
5.‘Air Cleaner . ' ^
6. Oil Dipstick
7. Engine Start/Stop Switch
8. Fuse
9. Circuit Breakers
REFERENCE NUMBER IDENTIFICATION
10. Fuel Primer Switch
11. Starter Contactor
12. Fuel Inlet
■■ ■. • ’ I.
.V. .
— 1
13. Fuel Pump
14. Oil Drain Hose
15. Oil Filter
16. Data Decal
17. Generator AC output leads (on rear, not shown)
TABLE OF CONTENTS
OPERATING INSTRUCTIONS
GENERAL SAFETY RULES
IDENTIFICATION RECORD AND
GENERATOR FEATURES................................................................. 1
READ THIS MANUAL THOROUGHLY
Operation and Maintenance
How to Obtain Service............................................... 3
Service Dealer Location
GENERATOR FAMILIARIZATION
Generator Applicability
Safety........................................................................... 4
Generator AC Connection System
OPERATING INSTRUCTIONS
Generator Control Panel........................................... 5
Automatic Choke
Before Starting the Engine........................................ 5
Starting....................................................................... 6
Stopping the Generator............................................. 6
Applying Loads to Generator
Attention Required After Submersion..................... 6
Operation in High Grass or Brush
Operating Precautions............................................... 7
SummerAA/inter Heat Riser System
Effects of Moisture and Dirt
Do Not Overload the Generator
ENGINE PROTECTIVE DEVICES
Automatic Low Oil Pressure Shutdown
High Temperature Shutdown................................... 8
Field Boost.................................................................. 8
Over Voltage Protection............................................ 8
Engine Overspeed...................................................... 8
SPECIFICATIONS
Fuel Requirements..................................................... 9
Engine Oil Requirements.......................................... 9
Engine Specifications................................................. 9
Generator Specifications........................................... 9
MAINTENANCE
Checking Engine Oil Level
Change Engine Oil....................................................10
Change Oil Filter
Engine Air Cleaner....................................................11
Engine Spark Plug
Fuel Filter..................................................................11
Spark Arrestor Muffler
Drive Belt
Battery
..................................................................
.......................................................................
Exercising the Generator
Out of Service Protection
Return the Unit to Service after Storage
Major Service Manual
Service Dealer Location......................................3 & 12
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inside cover
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3&12
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INSTALLATION INSTRUCTIONS
INSTALLATION SAFETY RULES
GENERAL INSTALLATION INFORMATION
Purpose and Scope.......................................................14
Safety
............................................................................
Standards Booklets..................................................... 14
3
Equipment Description
Engine-Generator Operating Speed
Generator AC Connection System.............................14
LOCATION AND SUPPORT
4
Generator Location
Generator Support
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Suspended Mounting...................................................15
4
Generator Restraint
GENERATOR COMPARTMENTS
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Compartment Seams
5
Compartment Size
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Compartment Construction
Sound Insulating Materials
Acoustics.......................................................................18
6
7
7
7
8
Compartment Floor Cutouts.................................18-19
COOLING AND VENTILATION AIR
Generator Air Flow
.....................................................
Cooling Air Inlet Openings...................................20-21
Compensating for Restrictions
Testing the Installation
GASOLINE FUEL SYSTEM..............................................................22
EXHAUST SYSTEM...........................................................................23
ELECTRICAL CONNECTIONS
Electrical Junction Box...............................................24
Wiring...........................................................................24
Generator AC Connections.........................................24
Conduit....................................................................24-25
Isolating Different Power Sources
Power Supply Cord
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Ground Fault Circuit Interrupters............................25
BATTERY INSTALLATION............................................................. 27
OPTIONAL ACCESSORIES.............................................................28
POST INSTALLATION TESTS
INSTALLATION CHECK LIST.........................................................30
MAJOR FEATURES AND DIMENSIONS...................................31
TROUBLESHOOTING
ELECTRICAL DATA...........................................................................33
REPAIR PARTS............................................................................34-45
NOTES...........................................................................................46-47
CALIFORNIA EMISSIONS WARRANTY...............................48-49
WARRANTY......................................................
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— 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 decals affixed to
the generator, DANGER, WARNING, CAUTION and
NOTES are used to alert you to special instructions
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, WARN
ING, CAUTION and NOTES found throughout the
manual.
DANGER; After this heading you can read han
dling, installing, operating or servicing instruc
tions that, if not strictiy complied with, will result
in personal injury.
WARNING: After this heading you can read han
dling, installing, operating or servicing instruc
tions that, if not strictly complied with, may result
in personal injury.
CAUTION: After this heading you can read instruc
tions for handling, installing, operating or servic
ing the generator that, if not strictly complied with,
may result in damage to equipment and/or proper
ty-
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
A
Potential electrical shock hazard
A
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 usagé contribute to
the need for maintenance service.
Proper maintenance and care of you.r recreational
vehicle generator assures a minimum number of
problems and keeps-your operating expenses at à
minimum. See your authorized -Dealer/Distributor for
service aids and accessories.
HOW TO OBTAIN SERVICE
When your RV generator set-requires servicing or
repairs, simply contact an Authorized Service Facility
for assistance. Service technicians are factorytrained 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 sérial humber of your
unit as given on its data decal.
The warranty on your generator is included in this
Owner’s Manual, as well as listings for repair parts.
SERVICE DEALER LOCATION
TO LOCATE THE NEAREST GENERAC SERVICING DEALER, PLEASE CALL OUR 800 NUMBER.
ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER.
1-800-333-1322
— 3 —
GENERATOR FAMILIARIZATION
GENERATOR APPLICABILITY
These generators have been designed and manufac
tured for supplying electrical power tor 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 compliance with (1)
A
ANSI 119.2-1975/NFPA 501C-1974 "STANDARD
FOR RECREATIONAL VEHICLES", PART III,
"INSTALLATION OF ELECTRICAL SYSTEMS." The
generator also must have been installed in strict
compliance with the manufacturer’s detailed instal
lation instructions. After installation, do nothing
that might render the unit in non-compliance with
such codes, standards and instructions.
You can use this generator to supply electrical power
for operating 120 volt, single phase, 60 Hertz, electri
cal loads. These loads can require up to 5500 watts
(5.5 kW)of power, but cannot exceed 46.0 AC
amperes at 120 volts.
SAFETY
Before using 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
CONNECTION SYSTEM
This air-cooled QP Series generator set is equipped
with dual stator AC power windings. These two stator
windings supply electrical power to customer electri
cal loads by means of a dual 2-wire connection sys
tem.
The generators have been installed so that units only
power 120 volt AC loads (Figure 1).
Figure 1 — Connection for 120 Volts Only
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.
QROUNDEO
NEJTRAL
-4-
OPERATING INSTRUCTIONS
GENERATOR CONTROL PANEL
Mounted on the generator control panel (Figure 2) are
the following features:
Figure 2 — Typical Control Panel
FUSE
FUEL PRIMER
Before starting a cold engine (it has not been started
in more than two weeks), you must press this switch
to bring fuel from the tank to the carburetor. This-rock
er type switch springs back to its original position
when you release it. ..
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 electrical
overload'. If the fuse element has melted open due to
overloading, the engine cannot be cranked. If you must
replace it, use only ari identical replacement fuse.
CIRCUIT BREAKERS
Protects generator's AC output circuit against over
load, i.e., prevents unit from exceeding
wattage/amperage capacity.
CIRCUIT
BREAKERS
CHOKE SOLENOID
During engine cranking (start/stop switch at START),
a solid state choke module signals the choke solenoid
to actuate and cycle (choke on/choke off) until engine
starts. The choke solenoid thus opens and closes the
carburetor choke valve only when the engine is crank
ing. When engine starts, the choke cycling stops. .
PRECHOKE
The choke system also has a temperature sensitive
metal strip that adjusts the choke valve angle accord
ing to ambient temperatures (i.e., in cold ambient
temperatures the choke-valve closes more). Once the
engine starts, an element .heats the temperature sen
sitive strip to a normal operating condition, opening
the choke valve system. This may take about three
minutes in cooler weather.
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 qualified installation technician or installation con
tractor.
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 istart the
engine before you have properly serviced it with
the recommended oil may result in engine faiiure.
FUEL SUPPLY
The engine must have adequate supply of proper fuel
to operate. Before starting, check that sufficient fuel is
available.
NOTE: On some installations, thè generator engine
may “share" the vehicle’s gasoline fuel tank with the
vehicle engine. Some installations may provide sepa
rate fuel tanks for generator and vehicle engine.
AUTOMATIC CHOKE
The engine is' equipped with an automatic choke that
consists of two main components — choke solenoid
and prechoke.
-5-
■ 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 flow, 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 of deadly
carbon monoxide gas through its exhaust system.
This dangerous gas, if breathed in sufficient con
centrations, 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 coherently, (B) vomiting, (C)
twitching muscles, (D) throbbing temples, (E) dizzi
ness, (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;
TTurn 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 circuit breakers to their “OFF” or
“OPEN” position. Electrical load circuits can be turned
ON after the generator has started, stabilized and
warmed up.
NOTE: You only need to use the fuel primer during
the initial startup, after the unit has not been used for
an extended period of time (two weeks) or the fuel
line has been disconnected. The primer is used to
prime fuel pump and carburetor.
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 yqu 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. Hold Start/Stop switch in its STOP position until engine
comes to a stop.
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.
■ LEniNG ENGINE STABILIZE
The generator supplies correctly 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.
AHENTION REQUIRED AFTER
SUBMERSION
If the recreational vehicle generator has been sub
merged in water, it must NOT be started or operated.
Following any submersion in water, have an autho
rized Generac Service Facility thoroughly clean and
dry the generator.
OPERAHON IN HIGH GRASS OR BRUSH
~T Never operate the generator while the vehicle
is parked in high grass, weeds, brush or
¿SzA leaves. Such materials can ignite and burn
^ from the heat of the exhaust system. The gen
erator exhaust system becomes extremely hot
during operation and remains hot for a long
time after it has shut down.
— 6
OPERATING PRECAUTIONS
Never operate the recreational vehicle genera
tor set while the vehicle is parked over dry
A
leaves, dry grass or any other combustible
substance. The generator's exhaust system
becomes extremely hot and can cause fire it it
is too close to combustible materials.
The generator’s exhaust system gives off
DEADLY carbon monoxide gas. This danger
ous gas, if breathed in sufficient concentra
tions, can cause unconsciousness and even
death. Never operate the generator set with
the vehicle inside any garage or other
enclosed area. Never operate the generator if
it has a leaky exhaust system. Close windows
in the vicinity of the generator exhaust outlet
and take any other steps to prevent exhaust
gases from entering rooms or areas occupied
by people or animals. .
SUMMER/WINTER HEAT RISER
SYSTEM
Under certain weather conditions, it is possible for ice
to form in the venturi area of the carburetor. This con
dition can be very dangerous because it can prevent
the governor system from functioning properly, which
results in a “run-away” engine.
The most common weather-conditions leading to this
problem are temperatures in the range of 25° to 35°F,
along with high humidity. This ice formation can also
be attributed to the load being applied during these
weather conditions. Generators running with no load
or light loads applied usually have the most problems.
The SummerA/Vinter Lever (Figure 3) should be in the
WINTER position for ambient teniperatures below
40°F and in the SUMMER position for arnbieht tem
peratures above 40°F.
Figure 3 — Heat Riser System
When the heat riser is in the SUMMER (DOWN) posi
tion (Figure 3), air is drawn into the air cleaner from
the upper intake tube.
When the heat riser is in the WINTER (UP) position,
air is drawn from the lower intake tube, which is posi
tioned to draw the heated air near the exhaust mani
fold.
To prevent carburetor icing the owner/operator should
physically position the heat riser to the proper position
dependent on the temperature.
EFFECTS OF MOISTURE AND DIRT
Keep the generator set as clean and dry as possible.
Protect unit against excessive dust, dirt, corrosive
vapors, road splash, etc. Permitting dirt and moisture
to accumulate on generator windings will have an
adverse effect on the insulation resistance of those
windings.
When moisture is allowed to remain in contact with
windings, some of the moisture will be retained in
voids and cracks, in the insulation. This causes a
reduced insulation resistance and will eventually
cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with wind
ings. Salt (as from sea air) will also worsen the prob
lem since it tends to absorb moisture from the air.
Salt and moisture, when combined, form a good elec
trical conductor.
CAUTION! Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator interior and
cause problems, and may also contaminate the generator
fuel system.
DO NOT OVERLOAD THE
GENERATOR
You can read the rated wattage/amperage,capacity of.
your generator,on the generator data decal (see
“Identification Record” on Page 1). .
Applying electrical loads ,iri excess of the unit’s rated
capacity will cause-the engine-generator to discon
nect the AC output.
To avoid overloading, add. up the wattage of all conhected electrical lighting, appliance, tool and motor
loads. This total should not be greater than thé 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 noté the wattage rating of the bulb. '
• 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 vehicle’s
furnace fan, refrigerator, air conditioner, etc.) need about 2-
i/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 electric motors in the
system. To that figure, add the running wattages of other
items that will be operated by the generator.
• On a new generator do not apply heavy electrical loads
for the first two or three hours of operation.
-7-
ENGINE PROTECTIVE DEVICES
AUTOMATIC LOW OIL
PRESSURE SHUTDOWN
The engine is equipped with a normally closed (N.C.)
oil pressure switch (Figure 4).Engine oil pressure
holds the switch open during cranking and operation.
Should oil pressure drop below about 7.5-12 PSI, the
switch contacts close and the engine automatically
shuts down.
Figure 4 — Switches for Engine Shutdown
HIGH TEMPERATURE SHUTDOWN
A temperature switch (Figure 4) with normally closed
(N.C.) contacts is mounted near the oil filter. If the
temperature were to exceed about 284°F (140°C), 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 cranking
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 is started
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 controls
an excitation current to the rotor. By regulating the
rotor’s excitation current, the strength of its magnetic
field is regulated and, in turn, the voltage delivered to
connected electrical loads is controlled. When the AC
frequency Is 60 Hz, voltage is regulated at 120 volts
(voltage-to-frequency ratio is 2-to-1).
Figure 6 — Voltage Regulator
„ ~V- SENSING
11—'
TO ROTOR
(.) —1~ (DIRECT CURRENT)
FROM STATOR
EXCnATIONWINDMO
(ALTERNATING CURRENT)
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 elec
tronic equipment.
ENGINE OVERSPEED
If engine speed is increased manually or otherwise,
the circuit controller board will disable the system and
shut down the engine.
WARNING: Do NOT attempt to physically adjust or
control the engine speed. Equipment damage or
personal injury may result.
SPECIFICATIONS
FUEL REQUIREMENTS
This generator is equipped with a gasoline fuel sys
tem as standard equipment. Specific installations may
provide either a separate fuel tank for the generator,
or the generator may “share” the vehicle engine’s fuel
tank.
NOTE: Installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter than
the vehicle engine’s pickup tube. Such an arrange
ment causes the generator engine to “run but of gas”
while adequate fuel for the vehicle remains in the
tank.
To reduce lead and carbon deposits use high quality
UNLEADED gasoline with the generator. Leaded
REGULAR grade gasoline is an acceptable substi
tute.
NOTE: Using “Unleaded” gasoline contributes to
longer engine valve life by reducing lead and carbon
deposits.
CAUTION: Generac does not recommend using
any gasoline containing alcohol, it must not con
tain more than 10 percent ethanoi and it must be
removed from the tank during storage. Do NOT
use any gasoline containing methanol. If you use
gasoline with alcohol, inspect more frequently for
fuel leaks and other abnormalities.
ENGINE OIL REQUIREMENTS
Use only high quality detergent oil rated with API ser
vice classification SF, SG or SH. The recommended
oil weights include the following:
• During summer months: SAE 30. An. acceptable substi-
. tuteisSAE10W-30.
• During winter months: SAE 5W30. DO NOT USE SAE
10W-40.
Crankcase and oil filter capacity is about 1400ml or
about 1.5 U.S. quart. Use no special additives. See
“Maintenance” section for oil level check and fill pro
cedures.
ENGINE SPECIFICATIONS
Type of Engine
Cooling Method
Rated Horsepower
Displacement
Cylinder Block
Engine RPM
Type of Governor
Air Cleaner
Starter
Ignition System
Recommended Spark Plug
Spark Plug Gap
..........................................
Champion
AC:
...........................................
Autolite
.........................
.......................
......................
...............................
............................
................................
........................
..................................
........
............
................ ............
..........................
...........................
...........
'.GN-410, single-cylinder
...Air-cooled
14.5 at 3600 rpm
410cc
Aluminum with cast
iron sleeve
2571-2830
Electronic
Paper element with
foam pre-cleaner
12 volt DC electric
......
Solid state with
flywheel magneto
...RC12YC
R45S
65
0.030 inch (0.76mm)
GENERATOR SPECIFICATIONS
Rotor RPM
Rotor Poles
Rated Maximum Continuous
AG Power Output...'
Rated Voltage
Rated Maximum Continuous
Current at 120 volts
Phase
Rated AC Frequency
Weight (w/oil)
Width
Length............................................32.5 inches (825mm)
Height
Maximum Battery
Circuit Current;...
Recommended Battery
Cranking Current...........................................400AMPS
Battery Charge Current
Battery Charge Voltage
Fuel Consumption:
..............................................................
.........................................................
......................
...... ................................
.................
..........-.....
...........................................
............................................
.'.
....
,....-
........................
.................... ...........
.......... ................
.........
................................... 15 AMPS
.................................................
.................................
5500 watts (5.5 kW)
..........
'....■.271- pounds (93 kg)
.20.5 inches (520mm)
17.4 inches (442mm)
3600
............2
120 volts AC
46.0 AC amperes
...Single Phase
............60 Hz.
14 VOLTS
2 AMPS
LOAD
NO
HALF
FULL 0.77
GALLONS/HOUR
0.29
0.53
MAINTENANCE
This section includes information about simple main
tenance which includes the following tasks;
• Checking the engine oil level.
• Changing the engine oil.
• Changing the oil filter.
• Cleaning the air cleaner.
• Cleaning the spark plug.
• Changing the fuel filter.
• Cleaning the spark arrestor
• Servicing the drive belt.
Figure 7 — Oil Dipstick and Fill Cap
CHECKING ENGINE OIL LEVEL
Check engine crankcase oil level at least every eight
hours of operation, or before each use (Figure 7).
• 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 level should be within the cross-hatched area on the
dipstick. If necessary, remove oil fill cap and add the rec
ommended oil to the cross-hatched area only. DO NOT
FILL ABOVE CROSS-HATCHED AREA.
• Install and tighten oil dipstick and oil fill cap before oper
ating the engine.
NOTE: See “Engine Oil Requirements” on Page 9 for
recommended oils.
When oil has drained, install and tighten oil drain plug.
Remove oil fill cap (Figure 7) and fill crankcase with the
recommended oil (See Page 9). The engine crankcase
can hold about 1.5 U.S. quarts (1.6 liters). DO NOT FILL
ABOVE THE CROSS-HATCHED AREA.
Install and tighten oil fill cap before operating engine.
Figure 8 — Location of Oil Drain Plug
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).
• Coat gasket of new filter with engine oil.
• Turn new filter clockwise until its gasket contacts lightly
with the filter adapter. Then tighten an additional 3/4 to
one turn.
• Run engine and check for leaks.
NOTE: Check the oil level and fill to the cross-hatched
area on dipstick after checking for leaks. The filter will
retain some oil.
Figure 9 — Replacing Oil Filter
CHANGE ENGINE OIL
Change engine oil after the first 25 hours of operation.
Thereafter, change oil every 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.
• With engine still warm from running, remove oil drain plug
(Figure 8). Drain oil completely into a suitable container.
— 10 —
ENGINE AIR CLEANER
Clean and re-oil the foam pre-cleaner every three
months or every 25 hours of operation, whichever
occurs first. Service the foam pre-cleaner more frequently
if you operate the generator in extremely dusty or dirty con
ditions (Figure 10).
• Turn the two screws counterclockwise to loosen.
• Remove COVER, FOAM PRE-CLEANER and PAPER
FILTER.
• Remove foam pre-cieaner from cover.
• Vt/ash 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 distribute oil (DO NOT TWIST).-
• Install foam pre-cleaner into cover, followed by paper fil
ter.
• Install cover, foam pre-cleaner and paper filter.
• Tighten the two screws to retain filter in place.
Once each year or every 100 operating hours
(whichever comes first), replace the paper filter. The
new replacement filter must be a flame retardant type.
Figure 10 — Engine Air Cleaner Assembly
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.
FUEL FILTER
Remove and replace fuel filter (Figure 12) every 100
operating hours or once each year, whichever comes
first.
Figure 12 — Fuel Filter
ENGINE SPARK PLUG
Clean or replace engine spark plug and set gap to
0.030 inch (0.76mm) every 100 hours of operation
(Figure 11). Clean by scraping or wire brushing and
washing with commercial solvent. DO NOT BLAST
CLEAN SPARK PLUG.
Figure 11 — Setting Gap on Spark Plug
SPARK ARRESTOR MUFFLER
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
of the more efficient “tproid" or “swirl” type. To remove
carbon and combustion deposits from such mufflers,
remove the PLUG from muffler and run engine for
about 15 minutes. Shut engine down, let the muffler
cool and install the plug.
WARNING: Be sure to re-install the plug from the
muffler tightly. Engine vibration 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 installation,
could be directed to areas not able to withstand
the extreme heat, such as wooden floor boards or
other flammable materials. This could result in a
fire.
DRIVE BELT
The engine drives the generator rotor by means of a
pulley and drive belt arrangement. The 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.
—11 —
BATTERY
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, corrosion. Clean and/or tighten as needed.
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 facili
ty. This should be done with an automotive type bat
tery hydrometer.
DANGER: Storage batteries give off expiosive
hydrogen gas. This gas can form an expiosive mix
ture around the battery for several hours after
charging. The slightest spark can ignite the gas
and cause an explosion. Such an explosion can
shatter the battery and cause blindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smoking,
open flame, sparks or any spark producing tools
or equipment near the battery.
DANGER: Battery electrolyte fluid is an extremely
caustic sulfuric acid solution that can cause
severe bums. Do not permit fluid to contact eyes,
skin, clothing, painted surfaces, etc. Wear protec
tive goggles, protective clothing and gloves when
handling a battery. If you spill the fluid, flush the
affected area immediately with clear water.
DANGER: Do not use any jumper cables or boost
er battery to crank and start the generator engine.
If any battery has discharged, remove it from the
vehicle for recharging.
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.
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.
• Close the fuel shutoff valve in the fuel supply line and let
the engine “run out of fuel."
• While the engine is still warm from running, drain the oil
completely. Refill crankcase with the required oil. See
Page 9 for engine oil requirements.
• Attach a tag to the engine indicating the viscosity and
classification of the oil in the crankcase.
• Remove spark plug and add about 1/2 ounce (15ml) of
clean, fresh engine oil into spark plug threaded opening.
Crank engine several times to distribute oil, then install
and tighten spark plug.
• Remove the battery and store in a cool, dry room on a
wooden board. Never store the battery on any concrete
or earthen floor.
• Clean and wipe the entire generator.
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. Use
primer switch to prime fuel, then start the engine.
• Let engine warm up.
• Apply electrical loads to at least 50% of the unit’s rated
wattage capacity.
• When engine is thoroughly warmed up, shut it down.
THE GENERATOR IS NOW READY FOR SERVICE.
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.
SERVICE DEALER LOCATION
TO LOCATE THE NEAREST GENERAC SERVICING DEALER, PLEASE CALL OUR 800 NUMBER.
ONLY DEALER LOCATION INFORMATION CA BE OBTAINED AT THIS NUMBER.
1 -800-333-1322
12 —
DANGER: For fire safety, installation of a generator into a recreational vehicle must comply
strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI All9.2-1975/NFPA 501C
‘‘STANDARD FOR RECREATIONAL VEHICLES” (PART 3, “INSTALLATION OF ELECTRICAL
SYSTEMS"). In addition, the manufacturer’s instructions and recommendations must be
complied with.
NOTICE TO INSTALLER
The Installation Instructions have been published by
Generac Corporation to aid in the installation of the
products described in this manual. Generac assumes
that installation personnel are familiar with the proce
dures for installing such products, or similar products
that Generac manufactures. Generac also assumes
that personnel have been trained in the recommend
ed installation procedures for these products and that
such training includes (a) use of common hand tools,
(b) use of special Generac tools, and (c) use of any
tools and/or equipment from other suppliers.
We could not possibly know of and adyise the recre
ational vehicle trade of all conceivable methods, pro
cedures or techniques by which to perform an installa
tion. We could not know, of the possible hazards that
might result from each installation method, procedure
or technique. We have not undertaken any such wide
evaluation. Therefore, people who use a method, procedüre or technique that Generac does not specifically
recommend must first completely satisfy themselvès
that their safety, the safety of the vehicle's occupants
and the product's safety is not endangered by the
method, procedure or tecnnique selected.
Information, illustrations, specifications, etc., con
tained in this Installation Manual are based on the lat
est information available at the time of publication.
Every effort has beeri expended to be sure that such
data is. both accurate and current. However, the man
ufacturer reserves the right to change, alter or other
wise improve this product at any time, without prior
notice.
SAFETY RULES
Gasoline is extremely FLAMMABLE and its
vapors are EXPLOSIVE. Do not permit smoking,
open flame, sparks or any source of heat in the
vicinity while handling gasoline. Comply with all
laws governing the storage and handling of gaso
line.
Fuel lines must be properly installed, properly
fastened and free of leaks. There must be no
possibility of gasoline vapors entering vehicle
interior.
You are required to install an approved, flexible,
non-conductive fuel line between the generator
fuel connection point and rigid fuel lines.
If the generator is equipped with a liquid propane
(LP) gas fuel system, install the unit so it com
plies with all codes, standards and regulations
pertaining to such systems. LP .gas is highly
explosive. The gas tends to settle in low areas
where even the slightest spark can ignite it and
cause an explosion. Do not allow gas vapors to
enter the vehicle.
Engine exhaust gases contain DEADLY carbon
monoxide gas. This dangerous gas, if breathed in
sufficient concentrations, can cause uncon
INSTALLATION SAFETY RULES
sciousness or even death. Install the exhaust
system in strict compliance with applicable
codes, standards and regulations. There must be
no possibility for exhaust gases entering the vehi
cle interior and endangering people or animals.
A The gerierator set produces dangerously high
electrical voltage, Contact with bare wires, bare
terminals, etc., will result in extremely hazardous
and possibly lethal electrical shock.
• All applicable electrical codes, standards and
regulations must be strictly complied with in the
installation and use of this equipment.
• The generator must be properly grounded (bond
ed) to the vehicle chassis or frame.
If the vehicle electrical circuits can be powered by
A
any .other source of electricity (such as a “dockside”
power receptacle), there must be no possibility of
connecting the diferent power sources to the vehi
cle circuits at the same time. The “dockside” (utility)
power source must be positively isolated from the
vehicle circuits whenever the generator is operat
ing. Failure to isolate the vehicle circuits from the
dockside power supply when the generator is run
ning may result in damage to the generator or seri
ous injUiy or death to dockside (utility) power work
ers due to backfeed of electrical energy.
Never work on the equipment while standing in
A
water, while barefoot, or while hands or feet are
wet. Dangerous electrical shock will result.
Jewelry conducts electricity, which can cause
dangerous electrical shock. Remove all jewelry
(such as rings, watches, or bracelets) before
working on this equipment. '
Thé generator requires an adequate flow of air
for cooling and ventilation. Without sufficient cool
ing air flow, the engine-generator quickly over
heats, which causes serious damage to the gen
erator, a fire or an explosion. Generator air inlet
and outlet openings must be provided in strict
compliance with the manufacturer's recommen
dations.
Never work on this equipment while physically or
mentally fatigued. Stay alert at all times.
Storage batteries give off EXPLOSIVE hydrogen
gas wnile charging. The battery used for cranking
and starting this generator should be installed in
its own vented compartment. Provide'adequate
ventilation for the battery, to prevent explosive
hydrogen gas from accumulating.
Never.insert any tool or other object through
openings in the generator interior, even if the unit
is not running. You might seriously injure yourself
or damage the equipment.
Staying alert and using “common sense” are
major measures for preventing accidents.
— 13 —
GENERAL INSTALLATION INFORMATION
PURPOSE AND SCOPE OF MANUAL
These Installation Instructions have been prepared
especially for the purpose of familiarizing installers
and owners of the applicable equipment with the pro
duct's installation requirements. Give serious consid
eration to all information and instructions in the manu
al, both for safety and for continued reliable operation
of the equipment.
Because of the different recreational vehicle models
and the variations between the models, it would be
extremely difficult, if not impractical, to provide
detailed instructions on every installation possibility.
For that reason, instructions and illustrations in this
manual are general in nature. Illustrations are not
intended to serve as detailed installation blueprints.
The installation should comply strictly with all applica
ble codes, standards and regulations pertaining to the
installation and use of this product. If any portion of
this manual appears to be in conflict with such codes,
standards or regulations, the applicable codes, stan
dards,or regulations must take precedence over the
manual.
SAFETY
Before handling, installing, operating or servicing this
equipment, be sure to read carefully the “Notice to
Installer” and “Safety Rules” at front of this manual.
Comply with all SAFETY RULES to prevent death,
personal injury or damage to equipment and/or prop
erty. Stress safety to all installers, operators and ser
vice technicians who work on this equipment.
EQUIPMENT DESCRIPTION
Instructions and information in this section pertain to
Generac air-cooled generators. These generators are
designed specifically for installing in recreational vehi
cles. They operate 120 volt, single phase, 60 Hertz, AC
electrical loads that require 46.0 amps at 120 volts.
ENGINE GENERATOR
OPERATING SPEED
The generator’s revolving field (rotor) is driven by a
single-cylinder, 4-cycle engine through a pulley and
drive belt arrangement. The generator supplies 120
volts AC at 60 Hertz when the rotor is operating at
3600 rpm.The drive belt arrangement allows the
engine to operate at a lower speed than the rotor.
GENERATOR AC CONNECTION
SYSTEM
The generator is equipped with dual stator power
windings as shown in figure 13.
Figure 13 — 120 Volt Single Voltage Connection
STANDARDS BOOKLETS
Installation, use and servicing of this equipment
should comply strictly with published standards, as
well as the manufacturer's recommendations. The fol
lowing standards booklets (latest revision) are avail
able from the sources indicated:
1. NFPA Standard 501C, “Standard for Recreational
Vehicles”, available from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
2. NFPA 70, “NFPA Handbook of the National Electric
Code”, obtained from same address as Item 1.
3. ANSI Cl-1975 and ANSI 119.2-1975, available from the
American National Standards Institute, 1430 Broadway,
New York, NY 10018.
4. ANSI A119.2/NFPA 501C, available from the
Recreational Vehicle Association, 1896 Preston White
Drive, Reston, VA 22090.
5. California Administrative Code, Title 25, available from
the State of California, Documents Section, P.O. Box
1015, North Highlands, CA 95660.
6. CSA Electrical Bulletin 946, available from the Canadian
Standards Association, Housing and Constructions
Materials Section, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3.
OROUNDED
NEUTRAL
• The AC connection system on all air-cooled QP series
generators uses a GROUNDED neutral.
• A separate green ground wire is connected to the recre
ational vehicle’s junction box.
• For these QP55 units, loads connected across T1 (red) to
T2 (white), MUST NOT exceed 30 amperes or 3600 watts
and loads connected across T3 (black) and T2 (white)
MUST NOT exceed 20 amperes or 2400 watts each at
120 volts. The combined loading of the two breakers
should not exceed 5500 watts.
IMPORTANT: DO NOT CONNECT LOADS IN EXCESS OF
CIRCUIT BREAKER RATINGS.
— 14 —
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