Generac Power Systems 00862-2 User Manual

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POWER SYSTEMS, INC

Owner’s Manual and

Installation Instructions

Air-cooled Recreational

Vehicle Generators

• Model; 00862-2

Series QP55-G

INTRODUCTION

Thank you for purchasing this model of the product line by Generac Power Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles.

♦ READ THIS MANUAL THOROUGHLY

_________________

If you do not understand any portion of this manual, contact Generac or your nearest Generac Authorized Service Dealer for starting, operating and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARN ING, CAUTION and NOTE blocks are used to alert you to special instruction about a particular opera tion that may be hazardous if performed incorrect ly or carelessly. Observe them carefully. Their defi nitions are as follows:

DANGER

After this heading, you can read instructions that, if not strictly complied with, will result in personal injury or property damage.

--------

ik WARNING ik

After this heading, you can read instructions that,

if not strictly complied with, may result in personal injury or property damage.

---------ik CAUTION Jk

After this heading, you can read instructions that, if not strictly complied with, could result in damage to equipment and/or property.

-------------------

---------------------

NOTE;

After this heading, you can read explanatory statements that require special emphasis.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli ance with the special instructions while performing the service are essenhal to preventing accidents.

Four commonly used safety symbols accompany the DANGER, WARNING and CAUTION blocks. The

type of information each indicates follows:

This symbol points out important safety informa

tion that, if not followed, could endanger personal safety and/or property of you and others.

This symbol points out potential explosion hazard.

This symbol points out potential fire hazard.

This symbol points out potential electrical shock

hazard.

The operator (driver) is responsible for proper and

safe use of the vehicle and its equipment, and the

safety of all vehicle occupants. We strongly recom mend that the operator read this manual and thor oughly understand all instructions before using this equipment. We also strongly recommend instructing otirer occupants in the vehicle to properly start and operate the generator. This prepares them if they need to operate the equipment in an emergency.

♦ CONTENTS

____________________________________

This manual contains pertinent owner’s informa tion, including warranty, electrical diagrams, exploded views and lists of repair parts for genera tor model number 00862-2. In addition, the latter portion of this manual contains Information neces

sary for the proper installation of this generator.

♦ OPERATION AND MAINTENANCE

__________________

It is the operator’s responsibility to perform all safe ty checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by a Generac Authorized Seiwice Dealer. Normal maintenance service and replacement of parts are the responsi bility of the owner/operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operat ing habits and usage contribute to the need for maintenance service.

Proper maintenance and care of your generator ensure a minimum number of problems and keep operating expenses at a minimum. See your Generac Authorized Service Dealer for service aids and accessories.

♦ HOW TO OBTAIN SERVICE

_______________________

When your generator requires servicing or repairs,

simply contact a Generac Authorized Service Dealer

for assistance. Service technicians are factorytrained and are capable of handling all of your

service needs.

When contacting a Generac Authorized Service

Dealer or the factory about parts and service, always

supply the complete model number and serial num ber of your unit as given on its data decal, which is located on your generator.

Model No. Serial No.

AUTHORIZED SERVICE

DEALER LOCATION

To locate the GENERAC AUTHORIZED SERVICE

DEALER nearest you, please call this number;

Generac® Power Systems, Inc.

ONLY DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

Table of Contents

Series QP55-C Recreational Vehicle Generator

Part I - Owner's Manual

Introduction

Read This Manual Thoroughly Contents Operation and Maintenance

.............

.........................

.....

Inside Front Cover

..............................................

..................................'...............................................

..................................................

IFC

How to Obtain Service...........................................................IFC

Authorized Semce Dealer Ix>cator Number..........................IFC

Safety Rules Section 1 - General Information

1.1 Generator Identification

............

.......................................................... 2

............................................

.....................................................

1.2 Generator Applicability................................................... 5

1.3 Safety

1.4 Generator AC Connection System

.................................................................................

....................................

1.5 Specifications....................................................................5

1.5.1 Fuel Requirements

............................................

1.5.2 Fuel Consumption .............................................5

1.5.3 Engine Oil Requirements

1.5.4 Engine

..............................................................

..................................

1.5.5 Generator............................................................6

Section 2 - Operation

...........................................................

...7

2.1 Generator Control Panel....................................................7

2.1.1 Fuel Primer.........................................................7

2.1.2 Start/Stop Switch.............................................. 7

2.1.3 Fuse....................................................................7

2.1.4 Main Breaker .....................................................7

2.2 Optional Remote Start/Stop Panels ...................................7

2.2.1 Remote Panel Plug-in Receptacle

2.2.2 Models 4057-0 and 4184-0

2.3 Automatic Choke

2.3.1 Choke Solenoid

.................................................................

..................................................

......................

................................

2.3.2 Prechoke.............................................................8

2.4 Before Starting the Engine

2.4.1 Installation

2.4.2 Engine Lubrication.............................................8

2.4.3 Fuel Supply

2.4.4 Cooling and Ventilating Air

2.4.5 Engine Exhaust Gas

2.5 Starting the Generator

2.6 Stopping the Generator

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...

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.......................

.....................................8

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2.7 Applying Loads to Generator ............................................9

2.7.1 Letting the Engine Stabilize

2.8 Summer.Winter Heat Riser System

2.8.1 Do Not Overload the Generator

2.9 Operating Precautions

.....................................................

............................

..................................

.......................

9 10

2.10 Protection Systems...........................................................10

2.10.1 Low Oil Pressure Switch..................................10

2.10.2 High Temperature Switch

...............................

2.10.3 Field Boost ......................................................10

2.10.4 Overvoltage Protection

....................................

2.10.5 Engine Oversjjeed............................................11

2.11 Additional Information

2.11.1 25-Hour Break-in Period

2.11.2 25-Hour Checkup.............................................11

2.11.3 AttenLion Required Alter Submersion ....11

2.11.4 Operation in High Grass or Brush

2.11.5 Effects of Moisture and Dirt

Section 3 - Maintenance............................

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..................

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11 11

3.1 Checking the Engine Oil Level .......................................12

3.2 Changing the Engine Oil and/or Oil Filter

3.3 Maintaining the Engine Air Cleaner

....................

................................

12 13

3.3.1 Cleaning the Foam Precleaner.........................13

3.3.2 Cleaning or Replacing the Paper Filter ..13

3.4 Clean Air Intake.'

...........................................................

3.5 Checking the Engine Spark Plug ............................14

3.6 Fuel Filter ........................................i

...............................

3.7 Spark Arrestor Muffler.....................................................14

3.8 Cleaning the Generator

3.9 Battery Maintenance

3.9.1 Weekly

3.9.2 Every Six Months

...................................................

.......................................................

.............................................................

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14 15 15 15

3.10 Major Service Manual......................................................15

3.11 Drive Belt.........................................................................15

3.12 Exercising the Generator .................................................15

3.13 Out of Service Procedure

3.13.1 Removal From Service

3.13.2 Return to Service

................................................

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16 16 16

Part II - Installation Instructions

Safety Rules............................................................................

Section 1 - General Information

1.1 Purpose and Scope of the Manual ...........................20

1.2 Safety................................................................................20

1.3 Standards Booklets ..........................................................20

1.4 Equipment Description.....................................................20

4 5

5 5 6

1.5 Generator Engine Operating Speed .................................20

1.6 Generator AC Connection System............................20

Section 2 - Installation

...............................................

2.1 Location and Support

2.1.1 Generator Location...........................................22

2.1.2 Generator Support

2.1.3 Generator Restraint

2.2 Generator Compartments

2.2.1 Compartment Size ...........................................23

2.2.2 Compartment Construction

2.2.3 Sound Insulating Materials

2.2.4 Acoustics

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...20

22 22

22 23

23 24

2.2.5 Compartment Floor Cutouts.............................25

2.3 Cooling and Ventilating Air

2.3.1 Generator Airflow

............................................

...........................................

25 26

2.3.2 Cooling Air Inlet Openings .............................26

2.3.3 Compe'nsating for Restrictions

2.3.4 Testing the Installation 7 7

8 8

8 9

2.4 Gasoline Fuel System.......................................................27

2.4.1 Fuel Tank

.........................................................

2.4.2 Generator Fuel Supply Line

2.4.2.1 Rigid Fuel Lines

2.5 Exhaust System

2.5.1 Mufflers and Spark Arrestors ..........................29

2.4.2.2 Flexible Fuel Line

................................................................

2.5.2 Type of Exhaust System ..................................29

2.5.3 Exhaust System Ssifety

2.6 Electrical Connections

2.6.1 Electrical Junction Box

2.6.2 Wiring...............................................................30

2.6.3 Generator AC Connections

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.....................................

..............................................29

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27 27

28 28 28 28 28

29 30 30

2.6.4 Conduit.............................................................30

2.6.6 Power Supply Cord..........................................31

2.6.7 Ground Fault Circuit Interrupters

2.6.5 Isolating Different Power Sources

..................

....................

31 31

2.7 Battery Installation......................................................... 32

2.7.1 Recommended Battery

2.7.2 Battery Cables

....................................

.................................................

32 32

2.7.3 Battery Cable Connections...............................32

2.7.4 Battery Compartment

Section 3 - Post-installation Start-up

Adjustments....................

.......................................

............................

3.1 Post Installation Tests ......................................................33

3.2 Before Initial Start-up ......................................................33

3.3 Initial Start .......................................................................33

3.4 Testing Under Load .........................................................33

Section 4 - Troubleshooting

4.1 Installation Checklist........................................................34

4.2 Troubleshooting Guide.....................................................35

Section 5 - Electrical Data Section 6 - Exploded Views and Parts Lists

Section 7 - Warranties

...............................

.........

..........................................

....................................

..................34

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48-Back Cover

37-47

Generac’’ Power Systems, Inc.

Safety Rules Series QP55-C Recreational Vehicle Generator

SAVE THE^E INSTRUCTIONS - The manufacturer suggests that these rules for safe

operation be copied and posted in potential hazard areas of the recreational vehicle. Jk

Safety should be stressed to all operators and potential operators of this equipment.

WARNING:

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects or other reproductive harm.

I This product contains or emits chemicals I known to the state of California to cause

I cancer, birth defects or other reproductive harm.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this manual and with the unit. The generator can operate safely, efficiently and reli ably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

Generac cannot possibly anticipate every possi ble circumstance 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 procedure, work method or operating technique Generac does not specifically recom mend, you must satisfy yourself that it is safe for you and others. You also must make sure the pro cedure, work method or operating technique that

you choose does not render the generator unsafe.

Despite the safe design of this generator, operating this equipment imprudently, neglecting its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to operate or maintain this equipment.

Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot during operation. Exercise care near running generators.

WARNING:

DANGER

GENERAL HAZARDS ^

For safety reasons, Generac recommends

that the installation, initial start-up and mainte nance of this equipment is earned out by a Generac Authorized Service Dealer.

The engine exhaust fumes contain carbon

monoxide, which can be DEADLY. This danger ous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must be installed properly, in strict compliance with applicable codes and stan dards. Following installation, you must do noth ing that might render the system unsafe or in

noncompliance with such codes and standards. The generator compartment must be completely vapor sealed from the vehicle interior. There

must be no possibility of exhaust fumes entering

the vehicle interior. Never operate this equipment with a leaking or defective exhaust system.

Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never

remove any drive belt or fan guard while the unit

is operating. Adequate, unobstructed flow of cooling and ven

tilating air is critical to correct generator opera

tion and is required to expel toxic fumes and fuel vapors from the generator compartment. Without

sufficient cooling airflow, the engine/generator

quickly overheats, which causes serious damage

to the generator. Do not alter the installation or

permit even partial blockage of ventilation provi

sions, as this can seriously affect safe operation

of the generator.

When working on this equipment, remain alert at

all times. Never work on the equipment when you

are physically or mentally fatigued. Inspect the generator regularly, and contact your

nearest Generac Authorized Service Dealer imme

diately for parts needing repair or replacement.

Before performing any maintenance on the gen

erator, disconnect its battery cables to prevent

accidental start up. Disconnect the cable from

the battery post indicated by a NEGATIVE, NEG

or (-) first. Reconnect that cable last. 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

conditions from leaking exhaust gases, fuel leak

age, oil leakage, etc.

Generac* Power Systems,

Safety Rules

Series QP55-G Recreational Vehicle Generator

SAFETY RULES

ELECTRICAL HAZARDS

The generator covered by this manual produces

dangerous electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and barriers are in place before operating the generator. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

During installation onto the vehicle, have the gen

erator properly grounded (bonded) 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 conduc tor 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 American Wire Gauge (AWG) copper wire minimum.

In case of accident caused by electric shock,

immediately shut down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a noncon ducting implement, such as a rope or board, to free the victim from the live conductor. If the vic tim is unconscious, apply first aid and get imme diate medical help.

Never wear jewelry when working on this equip

ment. Jewelry can conduct electricity resulting in electric shock, or may get caught in moving com ponents causing injury.

FIRE HAZARDS

For fire safety, the generator must be installed

and maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has estab lished. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that might alter a safe installation and render the unit in noncom pliance with the aforementioned codes, stan dards, laws and regulations.

Keep a fire extinguisher in the vehicle at all times.

Extinguishers rated “ABC” by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical sys tem. Keep the extinguisher properly charged and be familiar with its use. If you have any question pertaining to fire extinguishers, consult your local fire department.

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Ensure that no com bustible materials are left in the generator com partment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surround ing the generator clean and free from debris.

Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE. Do not permit smoking, open flame, sparks or any source of heat in the vicini ty while handling gasoline. Comply with all laws governing the storage and handling of gasoline.

This generator may use liquid propane (LP) gas 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.

Generac® Power Systems, Inc.

GENERAL

INFORMATION

Section 1 - General Information Series QP55-G Recreational Vehicle Generator

1.1 GENERATOR IDENTIFICATION

Please record the following information from the generator DATA DECAL or information decal.

Model Number

3. kW Rating 4.

Phase 6. Hertz

Serial Number Rated Voltage

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

4 Generac* Power

Systems,

Inc.

Reference Number Identification

10. Fuel Primer Switch

11. Starter Contactor

12. Fuel Filter

13. Fuel Pump

14. Oil Drain Hose

15. Oil Filter

16. Data Decal

17. Generator AC Output Leads (on rear, not shown)

Section 1 - General Information

Series QP55-G Recreational Vehicle Generator

GENERAL

INFORMATION

1.2 GENERATOR APPLICABILITY

These generators have been designed and manu

factured for supplying electrical power for recre ational vehicles. You should not modify the genera tor or use it for any application other than for what it was designed. If there are any questions pertain ing to its application, write or call the factory. Do not use the unit until you have been advised by a competent authority.

DANGER

-A

For fire safety, the generator must have been

properly installed in compliance with 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 installation instruc tions. After installation, do nothing that might render the unit in noncompliance with such codes, standards and instructions.

You can use this generator to supply electrical power

for operating 120 volt, single-phase, 60 Hertz, AC electrical loads. These loads can require up to 5,500

watts (5.5 kW) of power, but carmot exceed 46 AC

amperes of current at 120 volts.

1.4 GENERATOR AC CONNECTION SYSTEM

This generator set is equipped with dual stator AC

power windings. These two-stator windings supply

electrical power to customer electrical loads by means of a dual two-wire connection system. Note, however, that the neutral is grounded.

The generators have been installed so that it powers

120-volt AC loads (Figure 1.1).

Figure 1.1 - Connections for 120 Volts Only

-------Ml caution Jk

Do not overload the generator. Some installa

tions may require that electrical loads be alter nated to avoid overloading. Applying excessive ly high electrical loads may damage the genera tor 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 cur rent) for starting than for continuous operation.

---------------

1.3 SAFETY

Before attempting to use the generator set, careful ly read the “Safety Rules” section of this manual. Comply strictly with these rules to prevent acci dents and damage to equipment and/or property.

We suggest copying and posting the “Safety Rules”

in potential hazard areas of the vehicle. Stress safe ty to all operators and potential operators of this equipment.

1.5 SPECIFICATIONS

#1.5.1 FUEL REQUIREMENTS

The generator is equipped with a gasoline fuel sys

tem as standard equipment. Depending on the installation, the generator may have either a sepa rate fuel tank, or it may “share” the vehicle engine’s

fuel tank.

NOTE:

Some 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 arrangement causes the generator engine to “run out 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 substitute.

# 1.5.2 FUEL CONSUMPTION

LOAD GALLONS/HOUR

No Half 0.48 Full

0.33

0.91

Generac" Power Systems, Inc.

GENERAL

INFORMATION

Section 1 - General Information Series QP55-G Recreational Vehicle Generator

NOTE:

Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits.

---------

Jk CAUTION Jk

Generac does not recommend using any

gasoline containing alcohol (such as "gasohol"). If you use any gasoline containing alcohol, it

must not contain more than 10 percent ethanol, and it must be removed from the generator during storage. Do NOT use any gasoline containing methanol. If you use gasoline with alcohol, inspect more frequently for fuel leaks and other abnormalities.

♦ 1.5.5 ENGINE OIL REQUIREMENTS

--------------------

* •

Use only high quality detergent oil rated with American Petroleum Institute (API) Service

Classification SF, SG or SH. The recommended oil

weights include the following:

• During summer months: SAE 30. An acceptable substitute is SAE lOW-30.

• During winter months: SAE 5W-30. DO NOT USE SAE 10-W40.

Crankcase and oil filter capacity is approximately

1,400 mL or 1.5 U.S. quarts. Do NOT use special additives. See Sections 3.1 and 3.2 (Page 12) for oil level check and fill procedures.

4 1.5.4 ENGINE

Type of Engine.........................................GNU 10, Single-cylinder

Cooling Method Rated Horsepower

Displacement

Cylinder Block.............................Aluminum w/Cast Iron Sleeve

Engine RPM ...............................................................2,571 - 2,830

Type of Governor

Air Cleaner

Starter ...............................................................12-volt DC Electric

Ignition System.........................SoUd-state w/Fl}?wheel Magneto

Recommended Spark Plug

Champion..........................................................................RC12YC

AC .......................................................................................... R45S

Fram Autolite...............................................................................65

Spark Plug Gap................................................0.030 inch (76 mm)

Recommended Minimum Battery

Maximum Battery Circuit Current

Battery Charge Current........................................................2 Amps

Battery Charge Voltage

# 1.5.5 GENERATOR

Rated Maximum Continuous

AC Output

Rated Voltage...............................................................120 Volts AC

Rated Maximum Continuous

AC Current.....................................................................................46 Amperes

Phase ........................................................................................Single

Rotor RPM Number of Rotor Poles Engine FÍPM

Rated AC Frequency................................................................60 Hz

Battery Charge Voltage..................................................14 Volts DC

Battery Charge Current

Weight.............................................................246 Pounds (112 kg)

Length............................................................32.9 Inches (837 mm)

Width..............................................................20.3 inches (517 mm)

Height ......................................................... 17.2 inches (437 mm)

................................................................

..............................................

...........................................................................

14.5® 3,600 rpm

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............................................................................

Paper Element w/Foam Precleaner

....................

......................................

........................................................

......................................................................

.........................................

400 Cold-cranking

Amperes

5,500 Watts (5.5 kW)

Air-cooled

Electronic

15 Amps

2 Amperes (max)

410cc

14 Volts

3,600

2,571

Generac* Power Systems, Inc.

Section 2 - Operation

Series QP55-G Recreational Vehicle Generator

OPERATION

2.1 GENERATOR CONTROL PANEL

The following features are mounted on the genera tor control panel (Figure 2.1):

Figure 2.1 - Generator Control Panel

START ISA BREAKER

♦ 2.1.1 FUEL PRIMER

Before starting a cold engine (if it has not been started in more than two weeks), you must press this switch for approximately five seconds to bring fuel from the tank to the carburetor or fuel regula tor (LP). This rocker type switch springs back into its original position when you release it.

♦ 2.1.2 START/STOP SWITCH

To crank and start the engine, hold this switch in

the START position. Release the switch when the engine starts. To stop an operating engine, press and hold the switch in the STOP position until the engine shuts off. The switch center position is the

RUN position.

FUSE MAIIV

2.2 OPTIONAL REMOTE

START/STOP PANELS

♦ 2.2.1 REMOTE PANEL PLUG-IN RECEPTACLE

A plug-in receptacle (Figure 2.2) is provided on the

generator set, above the muffler enclosure. Use this receptacle to connect an optional remote-mounted start/stop panel to the generator. Installation of such a panel will permit you to start and stop the generator engine from any convenient location Inside the vehicle.

Figure 2.2 — Remote Panel Plug-in Receptacle

WIRE #18 (STOP)

WIRE #14 (ENGINE RUN SIGNAL)

♦ 2.2.2 MODELS 4057-0 AND 4184-0

WIRE #17 (CRANK)

___________________

These remote panels mount a rocker type switch, a

“Generator Run” lamp and an hourmeter (Figure

2.3). The hourmeter should be used in conjunction with the maintenance operations found in Part I of this manual.

WIRE #0 (GROUND)

♦ 2.1.3 FUSE

The fuse protects the engine’s 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 the fuse, use only an identical replacement.

4 2.1.4 MAIN BREAKER

The main breaker protects the generator’s AC out

put circuit against overload or exceeding

wattage/amperage capacity.

Figure 2.3 — Models 4057-0 and 4184-0

Remote Panel

Generac* Power Systems, Inc.

OPERATION

(jti

Section 2 - Operation Series QP55-C Recreational Vehicle Generator

2.3 AUTOMATIC CHOKE

The engine is equipped with an automatic choke that consists of two main components: a choke

solenoid and prechoke.

♦ 2.3.1 CHOKE SOLENOID

_______________________

During engine cranking (Start/Stop switch at START), a solid-state choke module signals the

choke solenoid to activate and cycle (choke on/choke off) until the engine starts. The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking. When the engine starts, the choke stops cycling,

♦ 2.3.2 PRECHOKE

_______________________________

The choke system also has a temperature-sensitive metal strip that adjusts choke valve angle accord ing to ambient temperatures (i.e., in cold ambient temperatures, choke valve closes more). Once the engine starts, an element heats the temperaturesensitive strip to a normal operating condition, opening the choke valve. This may take about three minutes in cooler weather.

2.4 BEFORE STARTING THE ENGINE

NOTE:

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 contractor.

♦ 2.4.1 INSTALLATION

Generator installation must have been properly completed so it complies with all applicable codes, standards and regulations and with the manufac turer's recommendations.

__________________________

NOTE:

Depending on the installation, the generator may have either a separate fuel tank, or it may

“share” the vehicle engine’s fuel tank.

♦ 2.4.4 COOLING AND VENTILATING AIR

Air inlet and outlet openings in the generator com partment must be open and unobstructed for con tinued proper operation. Without sufficient cooling and ventilating airflow, the engine/generator quick ly overheats, which causes it to shut down and may damage the generator,

♦ 2.4.5 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 endanger people or animals. Close windows, doors and other openings in the vehicle 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 concentra tions, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYS TEM IS LEAKING OR HAS BEEN DAMAGED. SYMP TOMS OF CARBON MONOXIDE POISONING ARE (a) inability to think coherently; (b) vomiting; (c) twitching muscles; (d) throbbing temples; (e) dizzi ness; (f) headaches; (g) weakness; and (h) sleepi ness. IF YOU FEEL ANY OF THESE SYMPTOMS,

MOVE INTO FRESH AIR IMMEDIATELY. IF SYMP

TOMS PERSIST, GET MEDICAL HELP.

♦ 2.4.2 ENGINE LUBRICATION________________

______

Have the engine crankcase properly serviced with the recommended oil before starting. Refer to Section

1.5.4 (Page 6) and Sections 3.1 and 3.2 (Page 12) for

oil servicing procedures and recommendations.

---------

ik CAUTION M.

Any attempt to crank or start the engine before

you have properly serviced it with the recom

mended oil may result in an engine failure.

---------------------

♦ 2.4.5 FUEL SUPPLY_____________________________

The engine must have an adequate supply of prop

er fuel to operate. Before starting it, check that suf

ficient fuel is available.

Generac* Power Systems, Inc.

2.5

STARTING THE GENERATOR

NOTE:

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 gen erator, 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.

Section 2 - Operation

Series QP55-G Recreational Vehicle Generator

OPERATION

(ÿtï

To start the generator from either the generator

control panel or from the optional remote panel, proceed as follows;

1. Turn OFF electrical loads using the means pro vided in your vehicle (such as a main line cir cuit breaker or transfer switch).

NOTE:

If starting from the generator control panel, turn OFF loads by setting the generator’s main circuit breaker to the OFF (or open) position. If starting from a remote panel, turn OFF loads using the means provided in the vehicle (such as a main circuit breaker). Electrical load circuits will be turned ON after the generator has start ed, stabilized and warmed up.

2. If you have not started the engine in more than two weeks, press the Fuel Pump Primer switch and hold it for about five seconds to prime the fuel system. However, if the engine is warm, skip Step 2.

3. Hold the engine Start/Stop switch in the START position to crank the engine. Release the switch when the engine starts.

-------

Mk CAUTION M.

If the engine does not start after it has been

k cranking for 15 seconds, release the Start/Stop

switch and try again. Holding the switch for longer than 15 seconds can damage the starter motor.

Let the engine run at no-load for a few minutes

-------------

to stabilize and warm up.

Turn ON electrical loads using the means

5. provided (such as a main circuit breaker or transfer switch).

2.6 STOPPING THE GENERATOR

1. Turn OFF all electrical loads using the means provided (such as a main circuit breaker or transfer switch).

2. Let generator run at no-load for a few minutes, to stabilize internal engine generator temperatures.

3. Place the Start/Stop switch in its STOP position.

♦ 2.7.1 LEHING THE ENGINE STABILIZE

The generator supplies correct rated voltage only at

the proper governed speed. Some electrical appli ances may be extremely sensitive to voltage. Incorrect voltages can damage such 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 at no-load.

2.8

SUIVIIVIER/WINTER HEAT RISER SYSTEM

Under certain weather conditions, it is possible for

ice to form in the venturi area of the carburetor. This condition can be very dangerous because it

can prevent the governor system from functioning

properly, which results in a “runaway” engine. The most common weather conditions leading to

this problem are temperatures in the range of 25° F

to 35° F (-4° C to 1.7° C), along with high humidity. This ice formation also can 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 Summer/Winter Lever (Figure 2.4) should be in

the WINTER position for ambient temperatures below 40° F (4.4° C) and in the SUMMER position

for ambient temperatures above 40° F (4.4° C). When the heat riser is in the SUMMER (down) posi

tion (Figure 2.4), air is drawn into the air cleaner from the upper intake tube.

Figure 2.4 - Heat Riser System

WINTER POSITION

2.7 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.

When the heat riser is in the WINTER (up) position,

air is drawn from the lower intake tube, which is positioned to draw the heated air near the exhaust manifold.

To prevent carburetor icing, the owner/operator

should physically position the heat riser to the proper position dependent on the temperature.

Generac®

Power Systems, Inc.

OPERATION

(ÿc

Section 2 - Operation Series QP55-G Recreational Vehicle Generator

• 2.8.1 DO NOT OVERLOAD THE GENERATOR

You can read the rated wattage/amperage capacity of your generator on the generator data decal (see Section 1.1 on Page 4).

Applying electrical loads in excess of the unit’s rated capacity will cause the engine/generator to automatically shut down.

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 generator’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.

• If a load does not show its rated wattage, multi ply 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 condi tioner, etc.) need about 2-1/2 time 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.

• Do not apply heavy electrical loads for the first two or three hours of operation.

2.10 PROTECTION SYSTEMS

♦ 2.10.1 LOW OIL PRESSURE SWITCH

This switch (Figure 2.5) has normally closed (N.C.)

contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop below a preset level, switch contacts close, and the engine automatically shuts down. The unit should not be restarted until oil is added.

♦ 2.10.2 HIGH TEMPERATURE SWITCH

This switch (Figure 2.5), which has normally open

(N.O.) contacts, is mounted near the oil filter. The contacts close if the temperature should exceed approximately 293° F (145° C), initiating an engine shutdown.

Figure 2.5 - Low Oil Pressure and

High Temperature Switches

_______________

HIGH

2.9 OPERATING PRECAUTIONS

—A Emm A—

Never operate the recreational vehicle genera

tor set while the vehicle is parked over dry leaves, dry grass or any other combustible sub stance. The generator's exhaust system becomes extremely hot and can cause fire if it is too close to combustible materials.

The generator's exhaust system gives off

DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness and even death.

Never operate the generator set with the vehi cle 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.

'1 O Generac* Power Systems, Inc.

diode and resistor that are not part of the automat ic choke circuit. These two components are part of a "field boost” circuit (Figure 2.6). During engine cranking only, a positive DC (battery) voltage is delivered through the diode, resistor, brushes and slip rings, and the generator rotor. Application of this voltage to the rotor “flashes the field” whenev er it is started. Flashing of the field each time the generator starts makes sure that a sufficiently

strong magnetic field is available to produce “pick

up” voltage in the stator windings.

Section 2 - Operation

Series QP55-G Recreational Vehicle Generator

OPERATION

(jCt

Figure 2.6 - Field Boost Circuit

CLOSEST TO BEARING

GRND

0 F-

£5

FIELD

♦ 2.1 Q.4

A solid-state voltage regulator (Figure 2.7) controls

the generator’s AC output voltage. This regulator supplies an excitation current to the rotor. By reg ulating 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 Hertz, volt age is regulated at 120 volts (voltage-to-frequency ratio is 2-to-l).

OVERVOLTAGE PROTECTION

_______________

Figure 2.7 - Solid State Voltage Regulator

"Tj'ZhSENSlNG

-4(+)n TO ROTOR (DIRECT CURRENT)

r‘ hFROM STATOR

EXCITATION MINDING

(ALTERNATING CURRENT]

2.11 AODITIONAUNFORlVIATiON

• 2.11.1 25-HOUR BREAK-IN PERIOD_________________

The first 25 hours of operation is the break-in peri

od for the generator. Properly breaking in the gen erator is essential to minimize fuel consumption and provide maximum engine performance. During this 25-hour break-in period, follow this procedure:

• Run the unit at varying electrical loads to help seat the engine piston rings properly.

• Check the engine oil level frequently. Add oil if needed. It is normal for the generator engine to consume more oil than is normal until the piston rings have properly seated.

• For the 75-hour operation following the break-in period, avoid light electrical loads. Load the generator at 50 percent (or more) of its rated wattage capacity. Repeated light loads during these 75 hours can cause improper seating of engine piston rings, resulting in blowby and high oil consumption.

• After operating the unit for 25 hours, complete the tasks recommended under Section 2.11.2.

• 2.11.2 25-HOUR CHECK-UP

After the 25-hour break-in period, contact a Generac Authorized Service Dealer for the following maintenance. The vehicle owner is responsible for any charges:

• Change the engine crankcase oil and oil filter.

• Check the oil level.

• Inspect the cooling and ventilation openings.

• Check the engine carburetor adjustments.

• Check the engine ignition system.

• Inspect the entire electrical system.

• Inspect the engine exhaust system.

_______________________

The voltage regulator also incorporates a “voltage

surge protection circuit.” This circuit prevents trou blesome surges in the generator AC output voltage. Voltage surge is a common cause of damage to elec

tronic equipment.

♦ 2.10.5

ENGINE

OVERSPEED

________________________

If engine speed is increased manually or otherwise, the circuit controller board will disable the system

and shut down the engine.

DANCER

Do NOT attempt to physically adjust or control

the engine speed. Equipment damage or per sonal injury may result.

• 2.11.3 ATTENTION REQUIRED AFTER

___________

SUBMERSION

__________________________

If the recreational vehicle generator has been sub merged in water, it MUST NOT be started and oper ated. Following any submersion in water, have a Generac Authorized Service Dealer thoroughly clean and dry the generator.

• 2.11.4 OPERATION IN HIGH GRASS OR

___________

BRUSH

________________________________

Never operate the generator while the vehicle is parked over high grass, weeds, brush, leaves or any other combustible substance. Such materials can ignite and bum from the heat of the exhaust sys tem. The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down.

Generac®

Power Systems, Inc. 1 1

MAINTENANCE

Section 3 - Maintenance Series QP55-G Recreational Vehicle Generator

♦ 2.11.5 EFFEQS OF MOISTURE AND DIRT

Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dirt, corro sive 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 contaet 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 windings. Salt (as from sea air) also will worsen the problem since it tends to absorb moisture from the air. Salt and moisture, when combined, form a good electrical conductor.

3.1 CHECKING THE ENGINE OIL LEVEL

P'or oil capacities and requirements, see “Engine Oil Requirements,” Section 1.5.4 (Page 6). Check the engine crankcase oil level at least every eight hours of operation, or before you use it. To check the engine oil level, proceed as follows (see Figure 3.1):

Be sure the generator is as level as possible.

Remove the dipstick and wipe it dry with a clean, lint-free cloth.

Install and tighten the dipstick cap; then, remove it again. The oil level should be at the dipstick “Full” mark.

If necessary, remove the oil fill cap on the rock er cover and slowly add oil until it reaches the dipstick “Full” mark. DO NOT FILL ABOVE THE “FULL" MARK.

Figure 3.1 - Oil Maintenance Features

---------

Mk CAUTION Mk

Never operate the engine with the oil level

below the "Add" mark on the dipstick. Doing this could damage the engine.

-------------------

5. Install and tighten the oil fill cap and the dip stick before operating the engine.

3.2 CHANGING THE ENGINE OIL

AND/OR OIL FILTER

• Change the engine oil after the first 25 hours of

operation (after the 25-hour break-in period, see Section 2.11.1, Page 11). Thereafter, change the oil every 50 operating hours. Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures.

• Change the engine oil filter after the first 25

hours of operation, and every 100 operating hours thereafter.

To change the oil and/or oil filter, proceed as

follows (see Figure 3.1):

1. Run the engine until it is thoroughly warmed

up (at least five minutes) then shut OFF the engine. Immediately after the engine shuts OFF, pull

the oil drain hose free of its retaining clip. Remove the cap from the hose and drain the oil into a suitable container. Loosening the oil fill cap will allow the crankcase to drain faster.

After the oil has drained, replace the cap onto the

3. end of the oil drain hose. Retain the hose in the clip. GO TO STEP 7 IF CHANGING OIL ONLY.

With the oil drained, remove the old oil filter by

4. turning it counterclockwise.

Apply a light coating of clean engine oil to the

5. gasket of the new filter.

1 S Generac* Power Systems, ino.

Section 3 - Maintenance

Series QP55-C Recreational Vehicle Generator

MAINTENANCE

6. Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter. Then, tighten the filter an additional 3/4 to one turn.

7. Remove the dipstick and wipe it dry with a

clean, lint-free cloth. This will be used later to check the oil level.

8. Remove the oil fill cap on the rocker cover and

slowly add the proper type and amount of rec ommended oil (see Section 1.5.4, Page 6). Periodically use the dipstick to check the oil

level and continue to fill the crankcase until the

oil reaches the dipstick “Full” mark. DO NOT

FILL ABOVE THE “FULL” MARK.

9. Install and tighten the oil fill cap and the dip stick before operating the engine.

10. Start the engine and check for leaks.

NOTE:

Check the oil level and fill to the “FULL” mark after checking for leaks. The filter will retain some oil.

3.3 MAINTAINING THE ENGINE

AIR CLEANER

♦ 33.1

CLEANING THE FOAM PRECLEANER

Clean and re-oil the foam precleaner every three months or every 25 hours of operation, whichever occurs first. Service the foam precleaner more fre quently if operating the generator in extremely dusty or dirty conditions. Use the following proce dure (Figure 3.2):

Turn the two screws counterclockwise to loosen.

Remove the cover, foam precleaner and paper filter.

Remove the foam precleaner from the cover.

Wash the foam precleaner in liquid detergent

and water.

Wrap the foam precleaner in a clean cloth and

5. gently squeeze it dry.

Saturate the foam precleaner in clean engine

oil. Gently squeeze it in a clean cloth to remove excess oil and to distribute oil (DO NOT TWIST).

Install the foam precleaner into the cover, fol

lowed by the paper filter.

Install the cover, foam precleaner and paper filter.

Tighten the two screws to retain the filter in place.

Figure 3.2 - Engine Air Cleaner

♦ 3.3.2 CLEANING OR REPLACING THE

__________

PAPER FILTER___________________________

Once each year or every 100 hours of operation (whichever comes first), clean or replace the paper filter. The new replacement filter must be flame retardant. Service the paper filter more frequently if operating the generator in extremely dusty or dirty conditions. Use the following procedure (Figure 3.2):

Follow steps 1-3 in Section 3.3.1;

service the foam precleaner if necessary. Remove the paper filter.

Clean the air filter by tapping it gently on a solid

3. surface. If the filter is too dirty, replace it with a new one. Dispose of the old filter properly.

Clean the air cleaner cover then reassemble

4. following steps 7-9 in Section 3.3.1.

3.4 CLEAN AIR INTAKE

Clean all foreign material from the air intake (Figure 3.3) at least 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 3.3 - Cleaning Air Intake

CLEAN THESE AREAS

Generac* Power Systems, Inc. 1 3

MAINTENANCE

3=^

Section 3 - Maintenance Series QP55-C Recreational Vehicle Generator

3.5 CHECKING THE ENGINE

SPARK PLUG

Clean the spark plug and reset the spark plug gap every 100 hours of operation.

1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine. Clean by scraping or washing using a wire brush and commercial solvent. Do not blast the spark plug to clean.

2. Remove the spark plug and check the condi tion. Replace the spark plug if worn or if reuse is questionable.

Check the spark plug gap using a wire feeler

3. gauge. Adjust the gap to 0.030 inch (0.76 mm) by carefully bending the ground electrode (Figure 3.4).

Figure 3.4 - Setting the Spark Plug Gap

SET PLUG GAP AT 0.030 inch

---------ik CAUTION M.

Sparking can occur if the wire terminal does

not fit firmly on the spark plug terminal end. If

necessary, re-form the wire terminal to obtain a tight fit.

---------------------

3.6 FUEL FILTER (gasoline only)

Remove and replace the fuel filter (Figure 3.5) once each year or every 100 hours of operation,

whichever comes first.

Figure 3.5 - Fuel Filter

3.7 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 maintain ing spark arrestor exhaust mufflers, contact your nearest Generac Authorized Service Dealer.

Exhaust mufflers supplied by Generac are spark arrestor types. Generac exhaust mufflers for recre ational vehicle generators do not have a spark arrestor screen, but are of the more efficient “toroid” or “swirl” type. To remove carbon and com bustion deposits from such mufflers, remove the plug from the muffler and run the engine for approximately 15 minutes. Shut down the engine, let the muffler cool and install the plug.

-A WARNING A-

Be sure to reinstall the muffler plug tightly.

Engine vibration could cause a loose plug to fail 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 material. This could result in a fire.

3.8 CLEANING THE GENERATOR

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 windings. Salt (as from sea air) also will worsen the problem since it tends to absorb moisture from the air. Salt and moisture, when combined, form a good electrical conductor.

1 4 Generac* Power Systems, Inc.

---------ik CAUTION ik

Do NOT use a forceful spray of water to clean the generator. Water will enter the generator interior and cause problems, and may also cont aminate the generator fuel system.

----------------------

Section 3 - Maintenance

Series QP55-G Recreational Vehicle Generator

MAINTENANCE

3.9 BATTERY MAINTENANCE

All lead-acid batteries will discharge when not in

use. The generator battery should be inspected as follows:

♦ Î.9.1 WEEKLY

® Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessaiy.

• Check the batteiy fluid level of unsealed batteries and, if necessary, fill with Distilled Water Only. Do not use tap water in batteries.

♦ 5.9.2 EVERY SIX MONTHS

• Have the state of charge and condition checked. This should be done with an automotive-type battery hydrometer.

NOTE:

Servicing of the battery is to be performed or supervised by personnel knowledgeable of bat teries and the required precautions. Keep mnauthorized personnel away from batteries.

Damage will result if the battery connections

are made in reverse.

DANGER

Do not dispose of the battery in a fire. The

battery is capable of exploding. Storage batter ies give off explosive hydrogen gas. This gas can form an explosive mixture around the bat

tery 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. Discharge

static electricity from your body before touch

ing the battery by first touching a grounded

metal surface. A battery presents a risk of electrical shock

and high short circuit current. The following

precautions are to be observed when working on batteries:

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the

battery;

• Disconnect any charging source prior to connecting

or disconnecting battery terminals; and

• Do not use any jumper cables or booster battery to crank and start the generator engine. If any battery has discharged, remove it for recharging.

-A WARNING A-

Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to the skin and eyes, and to be toxic.

The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically conductive and corrosive. The following procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek

medical attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicar bonate of soda solution is to be added until the evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

3.10 MAJOR SERVICE MANUAL

To obtain a service manual for your generator, con

tact Generac or your nearest Generac Authorized Service Dealer. Make sure to identify your MODFIL NUMBER and SERIES.

3.11 DRIVE BELT

The engine drives the generator rotor by means of a pulley and drive belt arrangement. Tire 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 factoiy. If you suspect that drive belt tension is incorrect, contact a Generac Authorized Service Dealer.

3.12 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.

Generac® Power Systems, Inc. I 5

MAINTENANCE

Section 3 - Maintenance

Series QP55-C Recreational Vehicle Generator

3.13 OUT OF SERVICE PROCEDURE

♦ 3.15.1 REMOVAL FROM SERVICE

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:

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply

line and allow the unit to shut down.

3. While the engine is still warm from running,

drain the oil completely. Refill the crankcase with SAE lOW-30 oil having API classification "For Service SF.”

4. Attach a tag to the engine indicating the viscos

ity and classification of the oil in the crankcase.

5. Remove the spark plug and pour two or three

tablespoons of clean, fresh engine oil into the spark plug threaded openings. Reinstall and tighten the spark plug.

6. Remove the battery and store it in a cool, dry

room on a wooden board. Never store the bat tery on any concrete or earthen floor.

7. Clean and wipe the entire generator.

___________________

♦ 3.13.2 RETURN TO SERVICE

To return the unit to service after storage, proceed as follows:

1. Check the tag on the engine for oil viscosity and classification. Verify that the correct recom mended oil is used in the engine (see Section

1.5.4, Page 6). If necessary, drain and refill with

the proper oil.

2. Check the state of the battery. FUl aU cells of unsealed batteries to the proper level with distilled water. DO NOT USE TAP WATER IN THE BAT

TERY. Recharge the battery to 100 percent state of

charge, or, if defective, replace the battery.

3. Clean and wipe the entire generator.

4. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly.

5. Turn OFF all electrical loads. Add fuel if neces sary and then start the engine.

6. Allow the unit to warm up thoroughly.

7. Apply electrical loads to at least 50 percent of the unit’s rated wattage capacity.

8. When the engine is thoroughly warmed up, shut it down.

9. Your generator is now ready for service.

1 B Generac* Power Systems, Inc.

PART II -

INSTALLATION

INSTRUCTIONS

DANGER

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

Safety Rules Series QP55-G Recreational Vehicle Generator

DANGER: Forjire safety, installation of a generator into a recreational vehicle must comply

strictly with article 551, NFPA 70; ANSI Cl-1975; AND, ANSI A119.2-1975/NFPA 501C A.

“Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition,

installation must comply with the manufacturer’s instructions and recommendations.

NOTICE TO INSTALLER

These Installation Instructions have been published by Generac 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 prod ucts that Generac manufactures. Generac also assumes that personnel have been trained in the recommended 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.

Generac cannot possibly know of and advise the recreational vehicle trade of all conceivable meth ods, procedures or techniques by which to perform an installation. Nor can Generac anticipate every

possible hazard that might result from each instal lation method, procedure or technique. Generac has not undertaken any such wide evaluation. Therefore, people who use a method, procedure or technique that Generac does not specifically rec ommend must first completely satisfy themselves that their safety, the safety of the vehicle's occu pants and the product's safety is not endangered by the method, procedure or technique selected.

Information, illustrations, specifications, etc., con tained in these Installation Instructions are based on the latest information available at the time of publication. Every effort has been expended to be sure that such data is both accurate and current. However, the manufacturer reserves the right to change, alter or otherwise improve this product at any time without prior notice.

DANGER

Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

Parts of the generator are rotating and/or hot

during operation. Exercise care near running generators.

Ml GENERAL HAZARDS A

For safety reasons, Generac recommends

that the installation, initial start-up and mainte nance of this equipment is carried out by a Generac Authorized Service Dealer.

The engine exhaust fumes contain carbon

noncompliance with such codes and standards. The generator compartment must be completely vapor sealed from the vehicle interior. There

must be no possibility of exhaust fumes entering

the vehicle interior. Never operate this equipment with a leaking or defective exhaust system.

Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and ven

tilating air is critical to correct generator opera tion and is required to expel toxic fumes and fuel vapors from the generator compartment. Without sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to the generator. Do not alter the installation or permit even partial blockage of ventilation provi sions, as this can seriously affect safe operation of the generator.

When working on this equipment, remain alert at

all times. Never work on the equipment when you are physically or mentally fatigued.

Before performing any maintenance on the gen

erator, disconnect its batteiy cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or H first. Reconnect that cable last.

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 conditions from leaking exhaust gases, fuel leak age, oil leakage, etc.

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.

1 S Generac® Power Systems, Inc.

Safety Rules

Series QP55-G Recreational Vehicle Generator

SAFETY RULES

ELECTRICAL HAZARDS

The generator covered by this manual produces

dangerous electrical voltages and can cause fatal

electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards

and barriers are in place before operating the generator. If you must work around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

During installation onto the vehicle, properly

ground (bond) the generator either by solid mounting to the vehicle frame or chassis, or by means of an approved bonding conductor. DO NOT connect the bonding conductor to any gen erator part that might be removed or disassem bled during roi.itine maintenance. If the ground ing conductor must be replaced, use only a flex ible conductor that is of No. 8 American Wire Gauge (AWG) copper ware minimum.

If the vehicle electrical circuits can be powered by

any other source of electricity (such as a “dockside” power receptacle), there must be no possi

bility of connecting the different power sources to

the vehicle circuits at the same time. The dockside (utility) power source must be positively iso lated from the vehicle circuits whenever the gen erator is operating. Failure to isolate the vehicle circuits from the dockside power supply when

the generator is running may result in damage to the generator or serious injury or death to dock-

side (utility) power workers due to backfeed of

electrical energy. In case of accident caused by electric shock,

Never wear jewelry when working on this equip ment. Jeweliy can conduct electricity resulting In electric shock, or may get caught in moving com ponents causing injury.

FIRE HAZARDS

For fire safety, the generator must be installed

and maintained properly. Installation always must comply with applicable codes, standards, laws and regulations. Adhere strictly to local, state and national electrical and building codes. Comply with regulations the Occupational Safety and Health Administration (OSHA) has estab lished. Also, ensure that the generator is installed in accordance with the manufacturer’s instructions and recommendations. Following proper installation, do nothing that miglit alter a safe installation and render the unit in noncom pliance wath the aforeinentioried codes, stan dards, laws and regulations.

Keep a fire extinguisher in the vehicle at all times.

ICxtinguishers rated “ABC” by the National Fire Protection Association arc appropriate for use on tfie recreational vehicle generator electrical sys tem. Keep the extinguisher properly charged and

be familiar with its use. If you have any question

pertaining to fire extinguishers, consult your local fire department.

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any fuel or oil spills immediately. Einsure that no com bustible materials are left in the generator com partment, or on or near the generator, as F'IFíE or EXPLOSION may result. Keep the area surround ing the generator clean and free from debris.

Fuel lines must be properly installed and fastened, and free of leaks. There must be no possibility of gasoline vapors entering the vehicle interior.

You are required to install an approved, flexible,

nonconductive 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.

Generac® Power Systems, Inc. 1

GENERAL

INFORMATION

Section 1 - General Information

Series QP55-G Recreational Vehicle Generator

1.1 PURPOSE AND SCOPE

OF THE MANUAL

These Installation Instructions have been prepared

especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to all information and instructions in the manual, both for safety and for continued reli able 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 for every possible installation.

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

applicable codes, standards and regulations per

taining to the installation and use of this product.

If any portion of this manual appears to be in con flict with such codes, standards or regulations, the applicable codes, standards or regulations must

take precedence over the manual.

1.2 SAFETY

Before handling, installing, operating or servicing

this equipment, carefully read the “Notice to

Installer” and “Safety Rules” on Pages 18 and 19.

Comply with all safety rules to prevent death, per

sonal injury or damage to equipment and/or prop

erty. Stress safety to all installers, operators and

service technicians who work on this equipment.

6. CSA Electrical Bulletin 946, available from the Canadian Standards Association, Housing and Constructions Materials Section, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3.

1.4 EQUIPMENT DESCRIPTION

Instructions and information in this section pertain to Generac air-cooled generators. These generators are designed specifically for installing in rec|eational vehicles. They operate 120-volt, single-phase, 60Hertz, AC electrical loads that require 40.0 amps

(gasoline) or 37.5 amps (LP fuel) at 120 volts.

1.5 GENERATOR ENGINE OPERATING SPEED

The generator’s revolving field (rotor) is driven by a

single-cylinder, four-cycle engine through a pulley and drive belt arrangement. The generator supplies

120 volts AC at 60 Hertz when the rotor is operating at 3,600 rpm.The drive belt arrangement allows the engine to operate at a lower speed than the rotor.

1.6 GENERATOR AC CONNECTION SYSTEM

The generator is equipped with dual stator power windings as shown in Figure 1.1.

Figure 1.1 - 120-volt Single Voltage Connection

1.3 STANDARDS BOOKLETS

Installation, use and servicing of this equipment should comply strictly with published standards, as well as the manufacturer's recommendations.

The following standards booklets (latest revision)

are available 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.” available same 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, avail able from the State of California, Documents Section, P.O. Box 1015, North Highlands, CA 95660.

so Generac* Power Systems, Inc.

• The AC connection system on all air-cooled gen erators uses a GROUNDED neutral.

• A separate green ground wire is connected to the recreational vehicle’s junction box.

• For the.se units, loads connected across T1 (red) to 'T2 (white), MUST NOT exceed 30 amperes or 3,600 watts, and loads connected across T3 (black) and T2 (white) MUST NOT exceed 20 amperes or 2,400 watts each at 120 volts. The combined loading of the two breakers should not exceed 5,500 watts.

NOTE:

Do NOT connect loads in excess of circuit breaker ratings.

Section 1 - General Information

Series QP55-G Recreational Vehicle Generator

Figure 1.2 - Major Features and Dimensions

GENERAL

INFORMATION

Generac* Power Systems, Inc. 21

INSTALLATION

Section 2 - Installation Series QP55-C Recreational Vehicle Generator

2.1 LOCATION AND SUPPORT

• 2.1.1 GENERATOR LOCATION

The most desirable location for the generator set is between the vehicle's main frame members.

However, this is seldom possible. Most units must

be installed on the side of the vehicle and are diffi

cult to reinforce.

Many recreational vehicles have been factory equipped with an area for the generator set. Some vehicles may even have a generator compartment provided by the vehicle manufacturer.

Plan the generator location based on the following:

• The generator set must be installed on a frame work that is part of the recreational vehicle, as

outlined in Section 2.1.2.

• The location must provide an access opening that

is large enough to permit generator removal (unless the generator is to be removed from underneath the supporting framework).

• The location must provide easy access to fre

quently serviced components, such as filters, oil drains, spark plugs and other common mainte

nance parts.

• The location must provide sufficient room to

allow minimum clearances as outlined in Section

2.2. If sound insulation is to be used on the com partment walls and ceiling, the minimum recom

mended applies to the space between the gener

ator and such insulation.

• The location must provide adequate cooling and ventilating airflow for the generator without a

great deal of work and expense.

• 2.1.2 GENERATOR SUPPORT

The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding. The metal

framework on which the generator will rest and

which will restrain the generator set should consist

of at least two horizontal beams. These beams should consist of (a) 1-1 /2-inch square, 11-gauge steel tubing OR (b) 1-1/2-inch, 11-gauge angle iron, A typical supporting frame with horizontal support tubing, is shown in Figure 2.1.

The generator can be installed so that it sits on top

of the horizontal support tubing if the vehicle design permits. Another method is to suspend the generator below the horizontal support tubing by means of suitable, structurally sound metal frame work. The following general rules apply:

• Vehicle construction MUST be capable of sup porting the weight of the generator.

_____________________

Whether the generator is mounted above the hor

izontal support tubing or suspended below the tubing, the supporting frame used must be

structurally sound.

If the generator cannot be bolted directly to

the supporting frame or support tubing, consid er using additional tubing, angle brackets or other supports to give the supporting frame

sufficient strength.

Figure 2.1 - Typical Horizontal Support Frame

♦ 2.1.5 GENERATOR RESTRAINT

Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the

support tubing. These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compartment is used) and (c) the support ing framework (Figure 2.3). All bolts must be long

enough so that when tight, at least three threads are visible past the retaining lock nuts. Refer to Section

2.2 for the location of the generator mounting holes.

Figure 2.3 - Typical Generator Restraint

1/2 INCH THICK

___

HID

PLYWOOD —

fur

METAL UNED

BonoM

A-

..t;

--------

VEHICU CHASSIS

METAL U«ED

ID!

BT”

BASE

TUBUUR METAL SUPPORT FRAME

22 Generac® Power Systems, Inc.

Section 2 - Installation

Series QP55-C Recreational Vehicle Generator

INSTALLATION

2.2 GENERATOR COMPARTIVIENTS

Whether the generator set is being installed inside a

compartment specifically manufactured to house a generator or inside a compartment that the installer constructs, the compartment MUST meet certain specifications as outlined in the following sections:

♦ 2.2.1 COMPARTMENT SIZE

Plan the compartment size carefully. Provide a min imum clearance of 1/2 inch (13 mm) on the front and top, 1 inch (25 mm) on the sides, and 1/2 inch (13 mm) from the back for air circulation AFTER the compartment has been lined with metal and sound insulation (Figure 2.4).

Refer to “Figure 1.2 Dimensions” on Page 21.

Figure 2.4 - Clearances

♦ 2.2.2 COMPARTMENT CONSTRUaiON

• The generator compartment should be either constructed of, or lined with, 26-gauge galva nized steel.

Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum’s low melting point.

• If the compartment is lined with galvanized steel, it may be constructed of any material. Generac recommends that the compartment be construct

ed of 1/2-inch thick plywood (not strandboard), with the floor made of a double thickness of 1/2inch pl}nvood with the grain of the wood at cross

section for added strength (Figure 2.5).

____________________

NOTE:

Major Features and

* •

NOTE:

Figure 2.5 - Typical Compartment Construction

CROSS-SECTION VIEW LINING

• If constructing a compartment, line the exterior (underside) of the compartment floor with 26gauge galvanized steel.

• All seams, splices and joints of the compartment walls (unless vapor tight by design) should be caulked to prevent poisonous, flammable or explosive vapors from entering the vehicle interior.

NOTE:

Caulking must be done so that the caulking mate rial will stay in place permanently. Pressing such materials as putty tape onto joints and seams is NOT acceptable. A high quality silicone rubber base sealant is recommended.

• Holes and openings made in the compartment walls to allow for the passage of electrical con duit, conductors, hoses, cables, etc., into the vehicle living area must be sealed vapor tight with silicone rubber base sealant.

• If flexible metal conduit is used, it must be sealed internally at the end where it terminates inside the compartment’s electrical junction box.

NOTE:

Flexible metal conduit, due to its unique con struction, is NOT vapor tight along its entire

length.

• Seams and joints of the galvanized steel (whether used as a liner or for the compartment itself) must be lapped and mechanically secured. Such seams may be manufactured, welded, bolted, riv eted or screwed. Manufactured lock seams are shown in Figure 2.6. Installer constructed com partments typically utilize a standard lap joint.

Generac* Power Systems, Inc. S3

INSTALLATION

Section 2 - Installation Series QP55-G Recreational Vehicle Generator

Figure 2.6 - Types of Lock Seams

jflL W Ijl'

FOLD LOCKED STANDING

GORDON SEAM

After the compartment has been metal lined and

vapor sealed, line the compartment interior walls

and ceiling with an approved, nonflammable sound insulating material. See Section 2.2.3.

Do not install any flammable material directly

above or around the compartment. Heat, transferred through the compartment structure,

may be sufficient to ignite, char or discolor

seat cushions, fiberboard and other flammable

materials. You may need to use approved nonflammable insulating materials in high

temperature areas.

♦ 2.2.3 SOUND INSULATING MATERIALS

Once installers have determined that a compart ment is properly constructed and metal lined, they can add acoustical material. This may include addi tional sealant or insulating material, to reflect noise away from the vehicle interior.

Sound insulating materials should be of a nonflam mable type. One excellent insulating material is a

1-inch (25 mm) thick fiberglass having a 2-pound

density. When fiberglass is used, its coated side

should face toward the compartment interior.

I I

* ■ OFFSET

DOUBLE LOCK DOUBLE SEAM

STANDARI UP JOINT

DANGER

ACME LOCK

LOCK

SUM

^ 2.2.4 ACOUSTICS

For additional noise abatement, the installer may wish to consider the following:

• Using special sound insulating materials.

• Construction of a special noise abatement compartment.

NOTE:

Any method used to reduce noise must not

adversely affect the flow of cooling and ventilat ing air into or out of the compartment.

In addition to the effective use of sound insulating materials, construction of a special noise abate ment compartment might be considered to reduce noise levels. Such a compartment might be con structed as follows (Figure 2.7);

• Use 5/8-inch thick or 3/4-inch thick plywood in the compartment.

• Construct the compartment floor of a double thickness of 5/8-inch or 3/4-inch plywood.

• Line the compartment interior walls and floor, as

well as the underside of the floor, with 26-gauge

galvanized steel.

• Vapor seal all compartment seams and joints.

• Over the galvanized steel lining, install a combi nation of acoustical materials as mentioned in Section 2.2.3.

DANGER

To prevent fire or explosion, do not install any

insulation or other absorbent materials on the interior or underside of the compartment floor.

Seal all compartment door edges to prevent noise

leakage around the door perimeter.

Line the compartment door interior (except for air

openings) with suitable, fireproof sound insula tion (such as 1-inch (25 mm) thick fiberglass with a 2-pound density).

Figure 2.7 - Typical Noise Abatement

DANGER

A Do not install sound insulation or any

fflSa absorbent material on the compartment floor

interior. Such materials will become soaked with combustible or explosive vapors and liquids and will become a fire hazard.

Using a combination of sound insulating materials can often reduce noise more effectively than a sin gle material. For example, a sheet of lead or visco elastic material, along with a layer of other acousti cal material, is more effective than when a single

material is used.

24 Benerac* Power Systems, Inc.

Section 2 - Installation

Series QP55-G Recreational Vehicle Generator

INSTALLATION

• 2.2.5 COMPARTMENT FLOOR CUTOUTS

You must provide openings in the generator com

partment for the following items (Figure 2.8):

• Engine exhaust and cooling air outlets

• Generator cooling air inlet

• Four holes for passage of generator mounting bolts. See Section 2.1.4 (Page 23).

DANGER

Fuel lines and exhaust piping must not pene

trate into the vehicle living area.

Figure 2.8 - Compartment Floor Cutout

23 COOLING AND VENTILATING AIR

It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. Without sufficient airflow, the engine/generator quickly overheats. Such overheating can cause serious operating diffi culties and also may cause fire and personal injury.

The installer must make sure that sufficient air is

available to the generator for cooling, ventilating and combustion. The installer also must provide for a path for exhausting the cooling air to the exterior of a compartment, if so equipped.

Generac* Power Systems, Inc. 35

INSTALLATION

Section 2 - Installation Series QP55-G Recreational Vehicle Generator

DANGER

Never use discharged cooling air for heating or permit

such air to enter the vehicle interior.This air contains deadly carbon monoxide gas and other poisonous, flam

mable or explosive gases.

♦ 2.3.1 GENERATOR AIRFLOW

_______________________

Engine operation drives cooling fans for the two-stage cooling air system. A pressure fan draws cooling air into the top of the generator (Figure 2.9). This airflow cools the engtne/generator and electronic compo nents. The second part of the cooling system, a suc tion fan, draws air that is heated from a hot engine into a collector pan at the base of the unit. This heat ed air (although cooler than exhaust muffler) is then deflected out the bottom toward the ground.

Figure 2.9 - Airflow Through Engine/Generator

Figure 2.10 - Air Inlet in Compartment Door

100 SQUARE INCHES UNRESTRICTED MINIMUM OPENINGS

NOTE:

Be sure to meet the minimum clearances illus trated in Figure 2.4 (Page 23).

When the unit is installed on a suspended mount ing system, one of several different methods of sup plying airflow may be used as follows:

• Provide a door in the vehicle skirt having an air inlet opening (Figure 2.11).

♦ 2.5.2 COOLING AIR INLET OPENINGS

The minimum size of the air inlet opening, whether

the generator is housed in a conventional compart ment or not, is at least 100 square inches (see Figure 2.10). This rule applies whether inlet air is brought in through an opening in the compartment door, an opening in the vehicle skirt, through duct

work, or by any other means.

NOTE:

Screening, louvers or expanded metal that cover air openings restrict airflow. You must compen sate for this by making the actual air opening pro portionately larger. See Section 2.3.3 (Page 27).

Figure 2.11 - Suspended Mount: Inlet Door

Using ductwork (Figure 2.12, Page 27). The

installer must be sure air is available to the top of the generator since air inlets are located at the top.

By providing an opening in the vehicle skirt and

space behind the generator for cooling airflow (Figure 2.13 Page 27). Recommended clearance behind the back of the generator is at least

1/2 inch (13 mm).

SB Generac* Power Systems, Inc.

Section 2 - Installation

Series QP55-G Recreational Vehicle Generator

INSTALLATION

Figure 2.12 - Air Inlet Using Ductwork

ANTI-SPLASH

Figure 2.13 - Air Inlet in Vehicle Skirt

♦ 2.3.4 TESTING THE INSTALLATION

Generac recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, you will need to enlarge the air openings. Never place a unit into service until absolutely certain that cooling and ventilation is adequate.

NOTE:

You must test the installation, especially if you bring in air from below the generator set.

2.4 GASOLINE FUEL SYSTEH

The installation of a gasoline fuel system (Figure

2.14) for a recreational vehicle generator set must comply with applicable codes, standards and regu lations. The entire fuel system must be completely free of leaks. There must be no possibility of gaso line vapors entering the vehicle interior.

Figure 2.14 - Generator Fuel System

♦ 2.5.3 COMPENSATING FOR RESTRICTIONS

Such materials as screening, louvers or expanded metal can restrict the free flow of air. Compensate for this restriction by making the actual air opening proportionately larger.

Some materials may offer only a 60 percent “free air inlet area.” Other more efficient materials may pro vide up to a 90 percent free air inlet area. The per centage of free air inlet opening is usually available from the material supplier or manufacturer.

To determine the actual air inlet opening size required, divide 100 square inches by the per centage of free air inlet area for the material you will use.

For example: If you plan to use screening with an 80

percent free air inlet area, divide 100 by 0.8, which results in 125 square inches. Minimum actual size of air inlet opening in this case is 125 square inches.

DANGER

Gasoline is highly flammable, and its vapors are explosive. Comply with all codes, standards and

regulations pertaining to gasoline fuel systems used in recreational vehicle generators. Properly install and maintain the fuel system and keep it entirely free of leaks. Gasoline

vapors must not enter the vehicle interior.

Factory installed generator fuel system components include (a) fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and (d) interconnecting lines and fittings. Connect a fuel supply line to the fuel filter inlet. Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines.

Generac* Power Systems, Inc. 27

INSTALLATION

Section 2 - Installation

Series QP55-G Recreational Vehicle Generator

4- 2.4.1 FUEL TANK

Either the generator must share the vehicle engine's fuel tank, or you must install a separate fuel tank for the generator set. All fuel tanks installed on the vehicle must be constructed, installed and restrained so they comply with applic able codes, standards and regulations.

If the generator is to share the vehicle engine's tank, separate fuel pickup tubes are required for the engine and the generator. Generac recommends that you make the fuel pickup tube 2 to 3 inches

(51 to 76 mm) shorter than the vehicle engine's pickup tube. This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods.

-A CAUTION A~

Do not tee the generator fuel supply line into

the vehicle engine fuel supply line. If this is

done, the generator will be starved of fuel

when both engines are operating at the same

time. Also, while the vehicle engine is not run

ning, generator operation may drain the vehi cle engine supply line, making it difficult to start the vehicle engine.

♦ 2.4.2 GENERATOR FUEL SUPPLY LINE

2.4.2.1 Rigid Fuel Lines

Those lines used to supply fuel from a tank to the

generator must comply with applicable codes, stan dards and regulations. The following general rules apply to rigid fuel lines:

• Rigid lines should be of annealed, seamless,

drawn aluminum or steel.

• Lines and fittings must comply with SAE J512F,

“Standard Automotive Fittings,” or with ANSI

B 126.26 (latest edition).

• Route the fuel line so that at least 2 inches (51

mm) of clearance is maintained between the line and any exhaust system parts.

® Do not attach electrical wiring to fuel lines. Route

the wiring so it cannot come into contact with any fuel line.

• Route fuel lines so if they leak, fuel does not drip onto any electrical or exhaust system parts.

• Use nonferrous metal straps without sharp edges to secure fuel lines.

2.4.2.2 Flexible Fuel Line

Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines. This prevents breaking of the line caused by vibration, shifting, settling or movement.

The following rules apply:

• The flexible hose must comply with SAE J30B, “Standard for Fuel and Oil Hose.” It must be

approved for use with gasoline.

• The hose should be at least 6 inches (152 mm)

longer than is needed to prevent the hose from rupturing if the generator shifts or settles.

2.5 EXHAUST SYSTEIVI

The generator exhaust system must be safely and

properly installed. Only approved mufflers and other exhaust system parts must be used. A prop erly installed exhaust system must be vapor tight, quiet and completely safe.

DANGER

The generator engine gives off DEADLY carbon

monoxide gas through its exhaust system. This

dangerous gas, if breathed in sufficient concen trations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT OPERATE THE GENERATOR IF THE

EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED. SYMPTOMS OF CARBON MONOX

IDE POISONING ARE (a) inability to think coher ently; (b) vomiting; (c) twitching muscles; (d) throbbing temples; (e) dizziness; (f) headaches; (g) weakness; and (h) sleepiness. IF YOU FEEL ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST. GET

MEDICAL HELP. Do not operate the generator until its exhaust system has been inspected and properly repaired.

-------

M CAUTION M.

Never tee the generator engine exhaust pipe

into the vehicle engine exhaust piping. This causes excessive back pressure on the genera tor engine. Also, water from one engine can damage the other engine.

---------------

as Generac® Power Systems, Inc.

Section 2 - installation

Series QP55-G Recreational Vehicle Generator

INSTALLATION

♦ 2.5.1 MUFFLERS AND SPARK ARRESTORS

This muffler meets code and standard require

ments of the U.S. Forest Service. Use only mufflers and parts approved by Generac. Any person(s) installing an unapproved muffler, or an unap

proved exhaust system part, or modifying an

exhaust system in any way that might cause a haz ard, is liable for any damage, injury or warranty expense that might be caused by such unapproved

installation or modification. Failure to provide and maintain a spark arrestor

may be in violation of the law. If this generator is used on any forest covered, brush covered or grass covered unimproved land, you must provide a

spark arrestor. The vehicle owner or operator must maintain this device in good condition. In the state of California, the preceding is required by law

(Section 4442 of the California Public Resources

Code). Other states may have similar laws. Federal laws apply on federal lands.

♦ 2.5.2 TYPE OF EXHAUST SYSTEM

_______________

This generator has a configuration for a side out exhaust system and is equipped with such

exhaust muffler (Figure 2.15).

Figure 2.15 — Exhaust System

• Extend the exhaust system at least 1 inch (25 mm) past the outer edge of the vehicle. Do not terminate the exhaust system under the vehicle.

• Terminate the exhaust tailpipe such that exhaust gases will not be drawn back into the generator compartment and recirculated.

• If there is any possibility of the tailpipe or muffler being damaged, protect these damage-prone areas by means of a protective device (such as a skid bar).

• Install the generator exhaust system according to safe automotive practices.

• Use enough exhaust system hangers to prevent any part of the system from being dislocated.

• Use exhaust system parts recommended by Generac. Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person(s) installing such unauthorized parts.

• Do not terminate the exhaust system under any opening, window or vent that can be opened or is not permanently sealed from the vehicle Interior.

• Exhaust piping must be large enough to prevent excessive back pressure on the generator engine.

• Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping. This causes excessive back pressure on the generator engine. Also, water from one engine can damage the other engine.

• Plan exhaust system installation carefully. Comply with all applicable codes, standards and regulations.

♦ 2.5.5 EXHAUST SYSTEM SAFETY

•

• Maintain a clearance of at least 3 inches (76 mm) between exhaust system parts and any com

bustible material (such as wood, felt, cotton, organic fibers or other like material). If you can not maintain the 3-inch (76 mm) clearance, locate, insulate or shield the exhaust part(s) so that the temperature of any combustible materi al is not raised more than 117° F (65° C) above the ambient air temperature.

2.6 ELECTRICAL CONNECTIONS

Be sure to read Section 1.6 on Page 20. The following general rules apply to electrical con

nections in a recreational vehicle:

• Qualified electricians who are familiar with applicable codes, standards and regulations should install electrical wiring.

• The wiring should comply with codes, standards and regulations. The National Electrical Code

(NFPA 70), and state and local codes apply.

• Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent dam age from road shock.

• Wiring must be of adequate size, have approved insulative qualities and be properly supported.

• Conduit and wire openings into the generator compartment (if used) must be vapor-sealed to prevent entry of flammable, explosive or poiso

nous gases into the vehicle.

Generac* Power Systems, Inc. 23

INSTALLATION

Section 2 - Installation Series QP55-G Recreational Vehicle Generator

• 2.6.1 ELEgRICAL JUNCTION BOX__________________

Install an approved, square electrical junction box

with a blank cover on the interior or exterior wall of

the area you plan to install the generator (NOT on the generator). Route the generator’s AC output leads into this junction box through approved flex ible conduit. This is the point of first termination for generator AC output leads.

• 2.6.2 WIRING

• Wiring should be of stranded copper to reduce the chance that vibration may cause breakage.

® Wire gauge size should be large enough to handle

at least 1 15 percent of the installed generator's rated maximum current.

• If neutral conductors are used, they must be the same size as other leg wires.

• Route power supply conductors from generator AC output leads T1 (red). T2 (white), T3 (black) and the green ground wire through approved flexible conduit to the electrical junction box on the compartment wall.

If flexible metal conduit is used between the gener

ator and the compartment junction box, the con duit end that teniiinates the compartment junc tion box must be vapor-sealed. Flexible metal con duit is NOT vapor tight along its entire length.

• From the junction box, route power supply wares through approved conduit to either (a) double-pole, double-throw transfer switch, or (b) approved iso

lation receptacle. Connecting to a transfer switch or isolation receptacle must prevent vehicle electri cal circuits from being connected to two different power supplies at the same time (such as genera tor and dockside power).

• Conductors must be rated 221° F (105° C) or must be of a larger conductor size.

• 2.6.3 GENERATOR AC CONNECTIONS

Generator AC output leads T1 (red), T2 (white) and

T3 (black) come out of the generator as shown in

Figure 2.16. Leads T1 (red) and T3 (black) are “hot,”

while T2 (white) is the grounded neutral lead. There

is also a green lead that connects to ground in the

junction box of the recreational vehicle.

Figure 2.16 - Generator AC Output Leads

Line T1 (red) to T2 (white) is protected against over load by a 30-amp circuit breaker (CBl). Use this line-to-neutral connection separately to operate

120-volt, single-phase, 60 Hertz, AC loads requiring

up to 3,600 watts (3.6 kW) of power. Line T3 (black)

to T2 (white) also is protected against overload by a 20-amp circuit breaker (CB2). IJse this line-to-neu-

tral connection separately to operate similar loads.

However, be sure the total unit load does not

exceed the maximum rating of the generator. The neutral line (T2, white) on all units is a grounded neutral.

------

Jk CAUTION Ü

Do NOT connect electrical loads in excess of any

circuit breaker rating or you will develop prob lems with circuit breaker tripping, which causes a

loss of AC output. Also, do NOT exceed the gen erator's rated wattage capacity. Add the watts or amperes of all lighting, appliance, tool and motor

loads the generator will operate at one time. This total should be less than the unit's rated wattage/amperage capacity.

• 2.6.4 CONDUIT__________________________________

-----------

Route the connections between the generator and the junction box through approved, flexible con duit. The following general rules apply:

• Cut wiring to the required length and allow extra wire for junction box connections.

® Carefully prepare conduit ends to prevent sharp

edges from cutting through wiring insulation.

• Route conduit so it does not interfere with gener ator movement.

• If you use metallic conduit, vapor seal the end of the conduit where it enters the junction box. Do this because flexible metallic conduit is not vaporproof along its entire length.

30 Generac* Power Systems, Inc.

Section 2 - Installation

Series QP55-G Recreational Vehicle Generator

INSTALLATION

4 2.6.5 ISOLATING DIFFERENT POWER

__________

SOURCES

______________________

________

Connections from the junction box must terminate

in a double-pole, double-throw transfer switch

(Figure 2.17). An alternate method for isolating dif ferent power sources is by using an isolating recep tacle (Figure 2.18). Whichever method you use, you must be certain that both power sources are NOT

connected at the same time.

Figure 2.17 - Transfer Switch Isolation Method

♦ 2.6.6 POWER SUPPLY CORD

The power supply cord must comply with all applic

able codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected.

♦ 2.6.7 GROUND FAULT CIRCUIT INTERRUPTERS

The National Electrical Code (NFPA 70. 551-7) requires that you install ground fault circuit inter rupters (GFCIs) on all external and some internal electrical receptacles. Contact your manufacturer or dealer for recommendations.

2ND AIR

Figure 2.18 - Installation With Isolation Receptacle

Ge пегас* Power Systems, Inc. 31

DOCKSIDE POWER RECEPTACLE

POWER SUPPLY

CORD

INSTALLATION

—

z ?

Section 2 - Installation Series QP55-G Recreational Vehicle Generator

2.7 BATTERY INSTALLATION

• 2.7.1 RECOMMENDED BATTERY___________________

Install a battery that meets the following requirements:

• The battery must be a 12-volt, automotive type storage battery.

• For prevailing ambient temperatures above 32° F (0° C), use a batteiy rated 70 amp-hours and capable of delivering 400 cold-cranking amperes.

• For prevailing ambient temperatures below 32° F (0° C), use a battery rated 95 amp-hours and

capable of delivering 400 cold-cranking amperes.

NOTE:

If the battery is to be used to power other vehi cle accessories, as well as start the generator, you may need a battery with a larger capacity.

• 2.7.2 BATTERY CABLES

Using batteiy cables that are too long or too small in diameter may cause a drop in voltage, which causes starting problems. For the best cold weather starting, the voltage drop between batteiy terminals and the generator connection point should not exceed 0.12 volts per 100 amperes of cranking current.

These generators are rated at about 100 DC amperes of cranking current.

Select battery cables based on (a) cable length and (b) prevailing ambient temperatures. Generally, the longer the cable and the colder the weather, the larg er the cable size must be, as shown in the chart.

CABLE LENGTH in Feet (meters)

0 to 10 (0 to 3) 2*

11 to 15 (3.4 to 4.5) 0

16 to 20 (4.5 to 6)

CABLE SIZE

000

♦ For warm weather, use No. 2 cable up to 20 feet.

♦ 2.7.3 BATTERY CABLE CONNECTIONS

1. Connect the battery cable from the battery post or terminal indicated by a POSITIVE, POS or (+) to the lug on the starter contactor (Figure 2.19).

NOTE:

Check to be sure the battery cable hoot for the starter cable has been

Connect the battery cable from the battery post indicated by a NEGATIVE, NEG or (-) to the frame ground connection (Figure 2.19).

Connect cables so the connectors are clean and tight.

Figure 2.19 - Connecting Battery Cables

- ♦ 2.7.4 BATTERY COMPARTMENT

Install the generator battery in its own, vented com

partment. Place the batteiy compartment away from any source of heat, sparks or flame.

Provide ventilation openings in the batteiy com

partment. The minimum size of openings should be

2 square inches at the top of the compartment. Mount the battery on a strong, rigid supporting structure, where leaks and spills of battery fluid

will not cause damage.

installed.

SIDE VIEW OF GENERATOR

____________________

32 Generac® Power Systems, Inc.

Section 5 - Post-installation Start-up Adjustments

Series QP55-G Recreational Vehicle Generator

POST-1

INSTALLATION START-UP ADJUSTMENTS

3J POST INSTALLATION TESTS

The air-cooled generator set was factoiy tested and

adjusted. You should not be required to adjust the unit any further except under special circum stances.

--------

-ik WARNING Mk

Do not make any unnecessary adjustments.

Factory settings are correct for most applica

tions. When making adjustments, however, be

careful to avoid overspeeding the engine.

----------------

3.2 BEFORE INITIAL START-UP

Before starting, complete the following;

1. Check the engine crankcase oil level and, if nec essary, fill to the dipstick “FULL” mark (crosshatched area) with the recommended oil. Do not fill above the FULL mark.

Check the fuel supply. Gas fuel lines must have

been properly purged and leak tested in accor dance with applicable fuel codes. All fuel shut off valves in the fuel supply lines must be open.

DANCER

-A

If a liquid propane (LP) gas fuel system has

been installed, it must be properly tested for leaks before operating the system in compli ance with ANSI A119.2/NFPA 501C. No leakage is permitted. You must be sure no gasoline fuel

vapors enter the vehicle interior.

3.3 INITIAL START

When you are absolutely certain that the unit has

been properly Installed and prepared for use, start the engine as follows;

1. Turn off all electrical loads. Do this by setting the generator’s main circuit breakers to their

“OFF” (or open) position.

2. Refer to Part I, Section 2.5, “Starting the Generator” (Page 8), for cranking and starting instructions. The engine may require more cranking for initial starting since the fuel lines have to be primed (use of the primer switch will shorten this time).

3. Let the engine warm up for about five minutes to allow internal temperatures to stabilize.

4. Carefully inspect the engine/generator for fuel, oil

and exhaust system leaks. Before proceeding to

the next step, correct any leakage immediately.

5. When all tests and adjustments at no-load are completed, apply electrical loads and check for proper operation under load. See Section 3.4. Run the unit at least 30 minutes with loads applied.

6. Turn off all electrical loads by setting the gener ator’s main circuit breakers to their “OFF” (or open) position.

7. Let the unit run at no-load for a few minutes to stabilize internal engine/ -generator tempera tures. Then, shut down the engine.

NOTE:

The generator set was thoroughly tested and

adjusted at the factory before shipping. No addi tional adjustment should be necessary. Only qualified service technicians who have been trained should perform adjustments outlined in this manual.

3.4 TESTING UNDER LOAD

Apply electrical loads equal to about 75 to 100 per

cent of the unit's rated wattage/amperage capacity. Let the unit run at least 30 minutes with load

applied. During this part of the test, check that the unit is not running excessively hot and that adequate cooling airflow is available. You must not allow the unit to overheat during prolonged operation.

NOTE:

The generator engine is equipped with a high temperature switch. The switch has normally closed (N.C.) contacts. When the engine temper ature is too high, switch contacts close, and the engine shuts down automatically.

GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLING.

Generac* Power Systems, Inc. 33

TROUBLESHOOTING

Section 4 - Troubleshooting Series QP55-G Recreational Vehicle Generator

4.1 INSTALLATION CHECKLIST

♦ LOCATION AND SUPPORT

□ Generator is properly located. □ Generator is properly supported. □ Generator is properly restrained.

♦ GENERATOR COMPARTMENT

□ Compartment construction is proper. □ Holes/Openings are vapor-sealed. □ Compartment size is correct. □ Compartment is vapor-sealed. □ Sound insulation is correct. □ Floor cutouts are properly completed.

♦ COOLING AND VENTILATING AIR

□ Airflow is adequate.

□ Air inlet opening is correct. □ Compensate for restrictions. □ Check that installation has been tested.

♦ GASOLINE FUEL SYSTEM

□ Fuel tank complies with all applicable codes. □ Fuel system is properly installed and checked

for leaks.

♦ OPTIONAL LP GAS FUEL SYSTEM

□ Fuel system is properly installed and checked

for leaks. □ Pressure at regulator inlet is correct. □ Rated flow of primary regulator is correct. □ All parts are properly installed. □ Fuel system is properly tested/adjusted.

_______________________

____________________

_______________________

♦ EXHAUST SYSTEM

□ Exhaust system complies with all applicable

codes.

□ Exhaust system is properly and safely installed.

♦ ELECTRICAL CONNECTIONS

□ Connections comply with local code require

ments and all National Electrical Codes. □ Junction box is properly installed. □ Wiring meets all standards. □ All connections are correct. □ Conduit is properly Installed and sealed. □ Generator is properly bonded to the vehicle.

♦ BATTERY INSTALLATION

□ Recommended battery is installed. □ Recommended cables are installed. □ Cables are clean and tight. □ Cables are connected properly. □ Proper ventilation is provided. □ Terminals are coated with anti-corrosion grease,

and terminal covers are positioned.

♦ OPTIONAL ACCESSORIES

□ Check that remote start/stop panels (if used) are

installed properly. □ Check that hourmeter kit (if used) is installed

properly. □ Check that any other options and accessories (if

used) are installed properly.

♦ POST INSTALLATION TESTS

□ Check that all tests are completed properly.

DATE OF INSTALLATION

NAME OF INSTALLER

SIGNATURE OF INSTALLER

3^1 Generac* Power Systems, Inc.

4.2 TROUBLESHOOTING GUIDE

Section 4 - Troubleshooting

Series QP55-G Recreational Vehicle Generator

TROUBLESHOOTING

PROBLEM CAUSE

The engine will not crank. 1. Fuse blown

2. Loose, corroded or defective battery cables

3. Defective engine Start/Stop

switch

4. Defective starter contactor

5. Defective starter motor

6. Low or defective battery

The engine cranks but will not start.

1. Out of fuel

2. Defective fuel pump

3. Open #14 wire from

engine control board

4. Flooded engine

5. Defective spark plug(s)

6. Fuel line shut-off closed

7. Plugged fuel filter

The engine starts hard

and runs rough.

1. Air cleaner

plugged or damaged

2. Defective spark plug(s)

The engine starts, but shuts

down when the Start/Stop switch is released.

1. Engine oil level low

2. Defective low oil

pressure switch

3. Defective high temperature

switch

4. Defective engine control board

5. Overheated engine

CORRECTION

1. Replace fuse.

2. Tighten, clean or replace

as necessary.

3. Replace Start/Stop switch.

4. Replace contactor.

5. Replace starter motor.

6. Charge or replace battery.

1. Replenish fuel.

2. Replace fuel pump.

3. Check connections and.

insulation of #14 wires.

4. Wait 5-10 minutes before trying.

5. Clean, re-gap or replace plug(s).

6. Open fuel line shut-off.

7. Clean or replace fuel filter.

1. Check, clean or replace air cleaner.

2. Clean, re-gap or replace plug(s).

1. Check oil and add oil as needed.

2. Replace pressure switch.

3. Replace temperature switch.

4. Replace control board.

5. Check that the airflow

openings are adequate.

The Start/Stop switch is

set to Stop, but the engine continues to run.

There is no AC output from

the generator.

1. Defective Start/Stop switch

2. Open/Disconnected #18 wire

between Start/Stop switch and engine control board

3. Open/Disconnected #0 wire

between Start/Stop switch and engine control board

4. Defective engine control board

1. Main line circuit breaker open

2. Fault with vehicle circuit

breaker and/or fuses

3. Transfer switch set to NORMAL

4. Start switch not held long

enough to flash the field

5. Generator internal failure

1. Replace switch.

2. Reconnect or close wire.

3. Reconnect or close wire.

4. Replace control board.

1. Reset circuit breaker to ON (or closed).

2. Reset and replace if necessary.

3. Set switch to GENERATOR.

4. Stop, then restart the engine (Hold Start switch for at least

2 seconds).

5. Contact a Generac Authorized

Service Dealer.

Generao* Power Systems, Inc. 3S

ELECTRICAL

DATA

Section 5 — Electrical Data Series QP55-G Recreational Vehicle Generator

Electrical Schematic and Wiring Diagram - Drawing No. A6692-A

3S Generac* Power Systems, Inc.

Section 6 — Exploded Views and Parts Lists

Series QP55-G Recreational Vehicle Generator

Outer Sheet Metal - Drawing No. C1862-A

.PARTS

LISTS

TEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION

Cl 781

ASSEMBLY, ENCLOSURE 16 79246 10

HHCS W/LOCK WASHER,

TOP & BACK M6-1.0 X 16mm

A8011 1 SUPPORT, SOUND PAD 17 3 Cl 774 4

Cl 775 5

A9130 6 C5401 7 Cl 462 1

PANEL, ENGINE SIDE

PANEL, ALTERNATOR SIDE 19 C4006 1 ENCLOSURE, DOOR 1 GASKET, MUFFLER 1/4"

MUFFLER, ENCLOSURE

22473

18 22985 5 20 A1658 21 52857 1

11 FLAT WASHER, 1/4"-M6

FLAT WASHER #6

CABLE, BATTERY 30" LG.

2 LOCK WASHER, SPECIAL

FLANGE NUT-M6-1.00

ASSEMBLY 22 49721 1 HHCS, M6-1.0 X 35mm

8 C2331

DECAL, UNIT QPACT 55

23 A7215

21 SWAGE FASTENER WITH

9 A6917 2 LATCH, LIFT & TURN NYLON WASHER, 10 11 12

A7163 C5107 1

A6859 13 A6760 6.5 FT. SEAL, EXTRUSION 14

29451 6 FT. RUBBER TAPE 1/8" 15 C8281

1 HEAT SHIELD, MUFFLER

ASSEMBLY, WIRE HARNESS

2 GROMMET

x 72"

1 CONDUIT ASSEMBLY

A7835 3 25 A7836 5 26 27

C5400 1 BRACKET, ANGLE

58443

Generac* Power Systems, Inc. 37

1/4"-20 X 5/8" PAD, SOUND DAMPENING RIVET, 1/8" DIM.

2 CRIMPTITE, 74-20 X 5/8"

PARTS

LISTS

Section 6 — Exploded Views and Parts Lists Series QP55-G Recreational Vehicle Generator

Base and Pulleys - Drawing No. C5198-A

3B Generac® Power Systems, Inc.

Section 6 — Exploded Views and Parts Lists

Series QP55-G Recreational Vehicle Generator

Base and Pulleys - Drawing No. C5198-A

^PARTS

LISTS

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO.

C2368 2 53407 1 GROUND CABLE 3 46911 4

1 BASE, MOUNTING 34 75242

35 46526

MOUNT, (RUBBER)

36 A4456

4 25017 7 CAPSCREW, HEX HD.- 37 90475

3/8"-16 X 1/2" 38 87769

22237

5 6 22129 7

A6479 8 77603 2 9 22259

10 52858 6 11 51730

12 13 14

29459

75215 2

73146

15 75209 16 A6138 1 17

90239

18 40976

LOCK WASHER, 3/8"

39 A7695

7 LOCK WASHER, 5/16" - M8

1 SKID, RUBBER MOUNT

SAFETY BOLT 5/16"-18 X 3 1/2" 41

2 NUT, HEX-5/16"-18

40 42

A6922 1 96289 22145

NUT, FLANGED LOCK-M8-1.25 43 38150 3

CAPSCR. HEX HD.-

M8-1.25 X 60MM 45

SPRING, BELT TENSION

WASHER, SPRING CNTR. 47

4 SLIDE (NYLON) 48

SUPPORT, NYLON SLIDE

MANIFOLD, EXHAUST 50

GASKET EXHAUST MANIFOLD

2 SOCKET HD. CAPSCR.,-

44 A8010A 1 GASKET, BLOWER HSNG

52859

75237 4 75763-A 1 BOOT, BATTERY CABLE A8692 1 PLATE, BLOWER HOUSING

49 30340

A8594 1 PAN, SLIDE 51 A8475 52 23152 1

M8-1.25 X 20 LG.

19 A6858

A8614 1 SKID, RUBBER MOUNT

21 75224-G

1 GASKET, EXHAUST 53

1 PULLEY, ENGINE M6-1.0 X 10 LG.

22471 2

45756

22 73106-B 1 PULLEY, ALT. 55 22131 23 75216 24 25

49451 42633 1

1 BELT (POLY V 4L)-40"

1 WASHER, PULLEY RETAINER 57 81105

CAPSCR., SOCKET HD.

48031-C

3/8"-24 X 1" (GRADE 5) 58 66849 5

42907

3 CAPSCR., HEX HD.-

M8-1.25 X 16 59 86729

A8250 28 56893 18 29 A8615 30 Cl 320 31 A8043 32

A8406

33 51756

1 CAPSCR., HEX HD.-3/8"-24 X 2" 60 A8010

CRIMPTITE-#10-24 X 1/2" 61 A8693 1 BRACKET-FUEL PUMP 62 10-74260 1

HOUSING, BLOWER 63

MUFFLER SUPPORT BRACKET 64 22097 2 LOCK WASHER, 1/4" - M6

1 1 MUFFLER

CAPSCR. HEX HD.-

65 66 A1658

22127 2 22264 2 LOCK WASHER, #8 - M4

M10-1.5 X 20 LG.

QTY. DESCRIPTION

4 SPRING, GENERATOR SET MT 2 LOCK WASHER-MI0

3/8" SPECIAL LOCK WASHER

1 FUEL PUMP 1 FUEL FILTER 1 FITTING-1/8" PIPE TO 1/4"

TUBE

FUEL TUBE, METAL

CLAMP, EXH. PIPE-1-1/4" DIA.

4 FLAT WASHER-M8-5/16"

FLAT WASHER, #8 - M4

FLANGE NUT-MI0-1.50 WASHER, SPRING RETAINER

6 IN.

HOSE, FUEL 1/4" I.D. SPECIAL LOCK WASHER, M5

CAPSCR., HEX HD.3/8"-16 X 3/4" HEX NUT-#8-32

2 SCREW, TAPTITE1 FLAT WASHER, 3/8" - M10

2 CLAMP, HOSE %" 2 NUT, FLANGE-5/16--18

(SPECIAL) SCREW, TAPTITE M5-0.8 X 16 LG.

STARTER CONTACTOR 1 GASKET, BLOWER HSNG 1 GASKET, BLOWER HOUSING 1 STARTER CABLE - RED

HEX NUT-1/4"-20

1 SPECIAL LOCK WASHER, Va"

Generac® Power Systems, Inc. 33

^PARTS

LISTS

Section 6 — Exploded Views and Parts Lists

Series QP55-G Recreational Vehicle Generator Engine Sheet Metal - Drawing No. A7233-D

40 Generac® Power Systems, Inc.

Section 6 — Exploded Views and Parts Lists

Series QP55-G Recreational Vehicle Generator

Engine Sheet Metal - Drawing No. A7233-D

.PARTS

LISTS

ITEM PART NO. QTY.

A4323

2 45756 8

29289 2.5 FT.

SRV 91222-■D1 FLYWHEEL

67198-N 1

67890

6 7 A4456

56893

A6358

10 91646 11

92572 1

12 92079 13

22717A 1 14 73132 15 16 17 18 19

20 21

A1658

89685

22129

22127 1 57821 2

59637 2 21544 1

1 1 3/8" SPECIAL LOCK WASHER

1 COVER,TOP FLYWHEEL 1 DEFLECTOR, EXHAUST 35

1 2 6

22 40976 2 23

SRV A6370 24 A8875 25

A7299

A9539

1 ASSY.-ELECTRONIC GOV. 1 1 1

DESCRIPTION ITEM PART NO.

SCROLL, FLYWHEEL 27 31580 SCREW, TAPTITE 28 M6-1.0 X 10MM

29 22473

FOAM TAPE 30

38593 A6357

WASHER, BELLVILLE M20 31 A6360 NUT, M20 X 1.5

SCREW, CRIMPTITE #10-24 X .5"

32 A6489 33

A6359

34 10-74260

90892 1 PORT 36 ASSEMBLY, IGNITION COIL

SCREW, TAPTITE 38

91159

91160

91161 M6-1.0 X 25MM GROMMET, RUBBER

49821 BOOT, SPARK PLUG

SPECIAL LOCK WASHER, 'A"

40 86999

GROMMET, RUBBER LOCK WASHER-M8

41 60108 HEX NUT-1/4"-20 CAPSCR., HEX HD.M8-1.25 X 40MM

42 75281

Cl 085 SCREW, TAPTITE 3/8"-16 X .75"

44 MOTOR, STARTER-12VOLT 45 SOCKET HD. CAPSCR.,

43182 2 70185 A7629

M8-1.25 X20MM

47 ASSEMBLY, DIPSTICK & CAP 48

82774 1

90388 OIL DRAIN/DIPSTICKTUBE OIL DRAIN HOSE ASSEMBLY

QTY.

DESCRIPTION

1 PIPE NIPPLE, 3/8" X 8.5" LG. 1 BRASS STREET ELBOW, 3/8"

FLAT WASHER, 1/4"-M6

WRAPPER, ENGINE SPARK

PLUG WRAPPER, STARTER SIDE

WRAPPER, REAR GEAR

CASE WRAPPER, CARB. SIDE

ASSEMBLY, WIRE-STARTER

(#16) SUPPORT, OIL FILTER

1 BUSHING, RUBBER

WASHER, RUBBER

BOLT, SHOULDER-

M6-1.0 X 15MM BOLT, SOCKET HD. CAPSCR.

-M8-1.25 X 30MM GASKET, OIL FILTER

SUPPORT SWITCH, OIL PRESSURE-

10 PSI

SWITCH, OIL TEMPERATURE

SCREW, PHILIPS PAN HD.

MACH.-M3-.5 X 8MM LOCK WASHER-M3

1 FILTER, OIL

ENGINE, LONG BLOCK-

GN410VSRV KEY, WOODRUFF 4X19 DIA.

TAPTITE, M6-1.00 X 12MM

Generac® Power Systems, Inc. 41

PARTS

LISTS

Section 6 — Exploded Views and Parts Lists Series QP55-G Recreational Vehicle Generator

Engine Accessories - Drawing No. A7235-C

o> m <o

42 Generac'* Power Systems, Inc.

Section 6 — Exploded Views and Parts Lists

Series QP55-G Recreational Vehicle Generator

Engine Accessories - Drawing No. A7235-C

j>ms

LISTS

ITEM PART NO. QTY.

1 A6532 1

91039

3 51753

4 72347 1 5 89228

A6562

6 7

90970

A6564 1

56893

A6566 1

1 1 CARBURETOR 1

3 11 A6780 1 12 96290 2

13 73111 14

81646 A6563 1

15 16 C3633

1 1

2 17 A7095 2

C2332 1

A6269 1

66482 1

20 21 23897 1 22

A7173 A6270 1

23 24

49813

A6365 1

83512

26 27

A6239

A6584 1 LINKAGE, CHOKE

36544

89473 1

1 2 NUT, M6-1.0 2

DESCRIPTION

MANIFOLD, INTAKE 31

ITEM PART NO. QTY. DESCRIPTION

A7094

SCREW, PHILIPS PAN HD. GASKET, MANIFOLD/HEAD MACH. #4-40 X .25" HHCS M6-1.0X40MM 32 20753 SPARK PLUG, CHAMP 33

#RC12YC

GASKET, CARB./MANIFOLD 35

A6754

34 A6583

A6582

36 A6503

GASKET, CARB./AIR FILTER

A6569

BASE, AIR FILTER

CRIMPTITE #10-24 X 1/2" 38 A6565

DETENT 39 A6568 SPRING, A/L BELLCRANKCARB. 40 BOLT, CARB. MOUNT 90 LONG FILTER, AIR

A6567

41 90968

42 83532

PRE-CLEANER, AIR FILTER

COVER, AIR FILTER 43 86681

KNOB, AIR CLEANER RHMS #4-40 X .312" 45

A7325

A6753 DECAL, AIRBOX QP55 46 92586 BELLCRANK, ELEC. GOV.

91161 HHCS/LW M5-0.8 X 10MM FLATWASHER, #10-M5 48 A6913 BUSHING, GOV. ADJ. BRACKET BRACKET, PIVOT 49

A6785

1 HHCS M6-1.0 X 60MM 1 GROMMET, SUMMER AIR 1 TUBE, SUMMER INLET 1 TUBE, WINTER INLET 1 GROMMET 1/16"-1-1/2" 1 GROMMET, WINTER/SUMMER

VALVE 1 VALVE, WINTER/SUMMER 1 GROMMET, WINTER/SUMMER

VALVE 1

SPRING, DETENT 1 LEVER, GOVERNOR ARM 1 BOLT, HEX HD. WASHER/LOCK

WSHER M6-1.0X30MM 1 NUT, M6-1.0 SPECIAL 1

SPRING, GOVERNOR 1 BELLCRANK, GOV. RODS 2 WASHER, FELT 1 BOLT, SHOULDER

M6-1.0 X 15MM ROD, LINKAGE GOV. LEVER-

BELLCRANK ROD, LINKAGE BELLCRANK-

CARB.

SPRING, A/L GOV. LEVER-

ROD, GUIDE 50

A6778 TAPTITE M8-1.25 X 16MM ASSEMBLY, CHOKE SOLENOID 51 A6581

52 22473

PIN, COTTER 53

22097

BELLCRANK BREATHER TUBE

FLATWASHER, M6

2 4 LOCKWASHER, M6

ASSEMBLY, CHOKE HEATER

Cenerac* Power Systems, Inc. 43

PARTS

LISTS

Section 6 — Exploded Views and Parts Lists

Series QP55-G Recreational Vehicle Generator 410VS - Drawing No. A7894-D

-11

-14

■54

44 Generac* Power Systems, Inc.

Section 6 — Exploded Views and Parts Lists

Series QP55-G Recreational Vehicle Generator

410VS - Drawing No. A7894-D

^PARTS

LISTS

TEM

PART NO. QTY. DESCRIPTION ITEM

21533

3 71978

71980

5 71983

21713B

A1442

21742 4 M10 1.5 X 105MM HHFL

9 96699 10 76701 11 45756

80308 80309

13 14 80338

15 26925

83897

72694 2 PIVOT BALL STUD 50 86002

17 18 72696

78672

78694 1 PUSH ROD GUIDE PLATE

83907

21 22 21714

86514

23 24 86515

86516

86517

26 27 89673

91308

A9877

PART NO.

PISTON RING SET

CONNECTING ROD WITH CAP & BOLT 32

PISTON PIN 33

2 PISTON PIN RETAINER 34

CYLINDER HEAD GASKET FLANGED HEX HD,

30 72655

76361 1

A5776 A7308 78645

78691 1

CAPSCREW M8-1.25 X 42

36 74908

PISTON

1 CRANKCASE GASKET

2 M6-1.0 X 10TAPTITE (THD.

FORMING) 40

BREATHER GASKET 1 BREATHER COVER 1

OIL BREATHER SEPARATOR 46 A7628

PIPE PLUG-3/8" 48 C3396C

TAPPET, SOLID 49 84430

JAM NUT (ROCKER ARM) 51 86026

SEAL, VALVE STEM

ROCKER ARM

CYLINDER HEAD W/VALVE 55 C3150 SEATS AND GUIDES

VALVE SPRING RETAINER

VALVE SPRING KEEPER

38 39

A8930 A5771

B2104 1 SPRING WASHER

89280D 1

78658

43 78659

52 88396B 2

90416A

53 54 90747 1

92362 79246

1 EXHAUST VALVE 59 83921 1

INTAKE VALVE 60 77158

WASHER, VALVE SPRING

VALVE SPRING

CAMSHAFT ASSEMBLY 65

63 76329 64 86254 1

93064

QTY. DESCRIPTION

CRANKSHAFT 35 I.D. SEAL

THRUST WASHER

PRESSURE RELIEF BALL

1 1 GOVERNOR SPOOL 1 GOVERNOR RETAINER

(C-RING) COVER, OIL PRESSURE RELIEF M5-0.8 X 10MMTAPTITE

1 1 GOVERNOR GEAR ASSEMBLY

OIL PRESSURE SPRING

OIL SUMP ASSEMBLY

1 GOVERNOR ARM "R" PIN

THRUST WASHER

2 1 GOVERNOR ARM RC45

CRANKCASE SUB ASSEMBLY

1 1 BALANCER 1 OUTER GEROTOR 1

INNER GEROTOR PUSH ROD

1 CRANKSHAFT ASSEMBLY

BREATHER VALVE ASSEMBLY ROCKER COVER GASKET

ROCKER COVER W/FILL

1 4 M6-1.0 X 16MM HEX HEAD.

SCREW. AND LOCKWASHER

1 BEARING TUBE SHAFT 1 OIL SCREEN PICKUP ASSY.

1 OIL FILL PLUG

"0" RING 17.8 I.D. X 2,4 THICK

1 OIL FILL CAP ASSEMBLY

Generac* Power Systems, Inc. 45

PARTS

LISTS

Section 6 — Exploded Views and Parts Lists Series QP55-C Recreational Vehicle Generator

Alternator & Control Panel - Drawing No. A9649-B

Generaci Power Systems, Inc.

Section 6 — Exploded Views and Parts Lists

Series QP55-G Recreational Vehicle Generator

Alternator & Control Panel - Drawing No. A9649-B

^PARTS

LISTS

ITEM

PART NO.

75995

A5649H 1 3 A5646H 4

73159 5 31971 1 BALL BEARING 6 72379-B 1 UPPER BEARING CARRIER 7

A6529 8 52858 9

66386

10 12

66849

C3818

13 75234 14

22473

QTY.

DESCRIPTION

LOWER BEARING CARRIER ROTOR ASSEM.

STATOR ASSEM.

BALL BEARING

ITEM

39 40 41 53623 43 44 45

STUD-STATOR

M8-1.25 FLANGE LOCK NUT 47

BRUSH HOLDER

M5-0.8 X 16 LG.TAPTITE WASHER

GENERATOR TOP HOUSING

RESISTOR1R 5% 25 W/ LUG

%"/ M6-FLAT WASHER

46 48 49

PART NO.

43182 45771 4

83049 22152 5 M5-LOCK WASHER 51716 90144 1 C/BREAKER 20A. 90145 25105

86315 90734 4

QTY.

DESCRIPTION

2 M3-LOCK WASHER

HEX NUT, M8

1 C/BREAKER 2.5A.-ON 1

REGULATOR VOLTAGE 3 M5-0.8 HEX NUT 1 C/BREAKER 30A.

#6-32 SCREW W/LOCK

1 PANEL COVER

M4-0.7 X 12 LG.

CAPSCR.W/LOCK-WASHER & 15 22097 5 1/47 M6-LOCK WASHER FLAT WASHER 16 A2053 17 90141 2 18 A1658 19

74906

20 94039 21

22129

86316 25 53650 26

C4258 27 75244 1 ASSEMBLY, REMOTE CABLE 30 31 32 33 34

75476

22264

65795

90987 2

86317A

1 M6-1.0 X 65 LG. CAPSCREW

51 22985

GROUND CABLE 52 32300

SPECIAL LOCK WASHER, M6

M6-1.0 X 20 LG. TAPTITE 54 87798

CONTROLLER P.C.B. (START-STOP)

4 5/16" -M8 LOCK WASHER

1 PANEL SHEET METAL 1

4-PIN CONNECTOR 57

1 CONDUIT ASSEMBLY

55 56

59 3 M4-0.7 X 16 LG. CAPSCREW 4

#8/ M4-LOCK WASHER

BATTERY CHARGE RECTIFIER

62 31791

M3-0.5 X 12 LG. PPHMS 64

1 PANEL SUPPORT BRACKET

35 75235 3 M5-0.8 X 30 LG. CAPSCREW 67 36 82737 37 38

49813 55440

VIBRATION MOUNT

M6-1.0 HEX NUT

2 M5-08 X 25 LG. HEX HD.

22676

92113 75210-A 1 TERMINAL BLOCK A8475A 51715 90157 90156

23897 74908 23484-S 94070 94071 27756 A8475 3

#6-FLAT WASHER

1 FUSE HOLDER 1 FUSE AGC-15A.

1 SWITCH S.P.D.T. 6A.- 1 SWITCH S.P.D.T.-(FUEL PUMP) 1 SPECIAL LOCK WASHER, M4

1 M4-0.7 HEX NUT

DECAL, CB RATING 30A.

1 DECAL, CB RATING 20A.

CLAMP, HOSE

#10/ M5-FLAT WASHER

M5-0.8 X 10 LONG TAPTITE

BUSHING

1 SPACER-PLASTIC

M5-.08 X 110 LG. PPHMS

NYLON WASHER

SPECIAL LOCK WASHER, M5

CAPSCR.

Generac* Power Systems, Inc. 47

Section 7 - Warranty Series QP55-G Recreational Vehicle Generator

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT .

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.* New utility, and lawn and garden equipment engines must be designed, built and equipped to meet stringent anti-smog standards for the state of California and the federal government. Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved mod ification or improper maintenance of your engine.

Your emission control system may Include parts such as the carburetor, Ignition and exhaust systems. Generac will repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted. If, during such warranty period, any emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factoiy supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.

As the engine purchaser/owmer, you should, however, be aware that Generac may deny any and/or all warranty cov erage or responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect, improper mainte nance or unapproved modifications, or the use of counterfeit and/or ‘grey market’ parts not made, supplied or approved by Generac.

You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Seiwice Facility. To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

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 pursuant to California and federal law. See also the

"Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where the Generac W'arranty may provide a longer warranty period. Both the ECS Warranty and the

Generac Warranty describe important rights and obligations with respect to your new engine. Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty

service, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner shall be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at

the following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, Wl 53190

Part 1

4S Generac* Power Systems, Inc.

Section 7 - Warranty

Series QP55-G Recreational Vehicle Generator

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines;

(a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin

on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.

(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine

or equipment, and to each subsequent purchaser/owner, that each of its engines is ...

(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARS pur

suant to their respective authority, and

(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a

warranted emlsslons-related part to fail to be identical in all material respects to the part as described in the engine

manufacturer’s application for certification.

(1) Any warranted, emissions-related parts that 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 according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.

(2) Any warranted, emissions-related part that 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 the remainder of the ECS Warranty Period.

(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s

Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part falls prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be war ranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emis sions-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 Authorized Warranty Service Facility.

(5) "When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held respon

sible for diagnostic costs if the repair is deemed warrantable.

(6) Generac 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 suffi

cient to meet the expected demand for such emission-related parts.

(8) Any Generac 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 purchaser/owner. Such use shall not reduce Generac’s ECS Warranty obligations.

(9) Unapproved, add-on, modified, counterfeit and/or ‘grey market’ parts may not be used to modify or repair a Generac

engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or ‘grey market’ part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

1.1) Gasoline carburetor assembly and its internal components (if so equipped).

a) Fuel filter (if so equipped)

b) Carburetor gaskets

c) Fuel pump (if so equipped)

1.2) LPG carburetion assembly and its

internal components (if so equipped). a) Fuel controller (if so equipped) b) Mixer and its gaskets (if so equipped) c) Carburetor and its gaskets (if so equipped) d) Primary gas regulator (if so equipped)

2) Air Induction System including: a) Intake pipe/mantfold b) Air cleaner

3) ignition System including: a) Spark plug b) Ignition module

4) Catalytic Muffler Assembly (if so equipped) including: a) Muffler gasket b) Exhaust manifold

5) Crankcase Breather Assembly including: a) Breather connection tube

e) LP liquid vaporizer (if so equipped)

*Generac engine types covered by this warranty statement include the following:

1) Utility

2) Lawn and Garden Equipment

3) Recreational Vehicle (RV) Generator

4) Industrial Mobile (IM) Generator

Part 2

Generac* Power Systems, Inc. 43

Section 7 - Warranty Series QP55-G Recreational Vehicle Generator

GENERAC POWER SYSTEMS' THREE--YEAR LIMITED WARRANTY

FOR, RECREATIONAL ¥EHiCLE GENERATORS

NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE EACILITIES. For a period of 3 (three) years or 2,000 (two thousand) hours of operation from the date of original sale, whichever occurs first, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Auüiorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac generators sold and rated for “Recreational Vehicle” (RV) appli cations. as Generac has defined Recreational Vehicle generator applications. This warranty is effective only upon Generac's receipt, from the original purchaser/owner, of a completed Warranty Registration Card. This card is tlie only valid registration identification and must be presented at time of request for warranty service. Claims will not be accepted without presentation of the Warranty Registration Card. The factory recommends exercising the unit one half-hour every season.

WARRANTY SCHEDULE - COMMERCIAL APPLICATIONS

YEAR ONE - 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:

• Engine - All components

• Alternator - All components

• Transfer System - All components

WARRANTY SCHEDULE - CONSUMER/PERSONAL APPLICATIONS

YEARS ONE AND TWO - 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:

» Engine - All components

• Alternator - All components

• Transfer System - All components YEAR Three - 100% (one hundred percent) only on selected part(s) and labor listed (Any labor and part(s) not listed, and removal and rein

stallation are the owner’s responsibility):

• Rotor, Stator, Computer Control Board, (if applicable with regard to the generator! Cylinder Block, Cylinder Head, Crankshaft, Pistoii(s), Valve,

Valve Lifter(s), Intake and Exhaust Manifolds

FOR THE LIFE OF THE RECREATIONAL VEHICLE GENERATOR (IF SO EQUIPPED)

The drive train belt and pulleys (if so equipped) on generators used in recreational vehicles shall be warranted against failure due to defec tive materials or normal usage for the life of the generator. For the original purchaser/owner, this drive train warranty shall Include part(s) and labor (removal and reinstallation are not included) plus $50 (fifty dollars - U.S.) payment upon return of the failed belt or pulley by the original purchaser/owner. For subsequent purchaser/owner, this drive train warranty shall cover belt and pulley part(s) ONLY (labor not included). Labor, removal and réinstallation is the responsibility of the subsequent purchaser/owner.

Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators manu factured after January 1, 1998, have a transferable warranty to the second owner ONLY for the remainder of the three-year limited war ranty, Proof-of-purchase Is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any warranty service.

All warranty expense allowances are subject to the conditions defined in Generac’s super seWice information manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Costs of normal maintenance, adjustments, installation and start-up.

• Failures caused by any contaminated fuels or oils.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all

mechanical devices, the GN-Series engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing,

lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Products that 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 replace ment of the defective part(s).

■ Failure due to misapplication.

• Telephone, telegraph, teletype or other communication expenses.

■ Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.

• Rental equipment used while warranty repairs are being performed,

• Overnight freight costs for replacement part(s),

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE 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 PiART(S) AS STATED ABOVE. IN NO EVENT SHALL GEN ERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GEN ERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limita tion may not apply to you. Purchaser/owner agrees to make no claims against Generac based on ne¿igence.

This warranty gives you specific legal rights. You also may have other rights that vary from state to state.

GENERAC« POWER SYSTEMS, INC.

P.O. BOX

Part No. CT BSD

■ WAUKESHA, W1 531 B7

Revision О (06/1 5/00)

Printed in U.S.A,

Generac Power Systems 00862-2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Reference Number Identification

DANGER

#1.5.1 FUEL REQUIREMENTS

# 1.5.2 FUEL CONSUMPTION

♦ 2.1.1 FUEL PRIMER

♦ 2.1.2 START/STOP SWITCH

♦ 2.2.1 REMOTE PANEL PLUG-IN RECEPTACLE

♦ 2.2.2 MODELS 4057-0 AND 4184-0

♦ 2.1.3 FUSE

4 2.1.4 MAIN BREAKER

(jti

OPERATION

(ÿtï

♦ 2.7.1 LEHING THE ENGINE STABILIZE

OPERATION

• 2.8.1 DO NOT OVERLOAD THE GENERATOR

♦ 2.10.1 LOW OIL PRESSURE SWITCH

♦ 2.10.2 HIGH TEMPERATURE SWITCH

♦ 2.11.5 EFFEQS OF MOISTURE AND DIRT

♦ 3.15.1 REMOVAL FROM SERVICE

♦ 3.13.2 RETURN TO SERVICE

• 2.1.1 GENERATOR LOCATION

• 2.1.2 GENERATOR SUPPORT

♦ 2.1.5 GENERATOR RESTRAINT

♦ 2.2.3 SOUND INSULATING MATERIALS

^ 2.2.4 ACOUSTICS

• 2.2.5 COMPARTMENT FLOOR CUTOUTS

DANGER

DANGER

♦ 2.3.1 GENERATOR AIRFLOW

♦ 2.5.2 COOLING AIR INLET OPENINGS

♦ 2.3.4 TESTING THE INSTALLATION

♦ 2.5.3 COMPENSATING FOR RESTRICTIONS

DANGER

4- 2.4.1 FUEL TANK

♦ 2.4.2 GENERATOR FUEL SUPPLY LINE

2.4.2.1 Rigid Fuel Lines

2.4.2.2 Flexible Fuel Line

♦ 2.5.1 MUFFLERS AND SPARK ARRESTORS

♦ 2.5.2 TYPE OF EXHAUST SYSTEM

♦ 2.6.6 POWER SUPPLY CORD

♦ 2.6.7 GROUND FAULT CIRCUIT INTERRUPTERS

-ik WARNING Mk

♦ LOCATION AND SUPPORT

♦ GENERATOR COMPARTMENT

♦ COOLING AND VENTILATING AIR

♦ GASOLINE FUEL SYSTEM

♦ OPTIONAL LP GAS FUEL SYSTEM

♦ EXHAUST SYSTEM

♦ ELECTRICAL CONNECTIONS

♦ BATTERY INSTALLATION

♦ OPTIONAL ACCESSORIES

♦ POST INSTALLATION TESTS

DATE OF INSTALLATION

NAME OF INSTALLER

SIGNATURE OF INSTALLER

YOUR WARRANTY RIGHTS AND OBLIGATIONS

MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

PURCHASER'S/OWNER'S WARRANTY RESPONSIBILITIES:

EMISSION CONTROL SYSTEM WARRANTY

EMISSION RELATED PARTS INCLUDE THE FOLLOWING: