Generac Power Systems 00862-2 User Manual
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
A
tion that, if not followed, could endanger personal
safety and/or property of you and others.
This symbol points out potential explosion hazard.
A
This symbol points out potential fire hazard.
A
This symbol points out potential electrical shock
A
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
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.....
Inside Front Cover
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..................................................
IFC
IFC
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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8
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
10
2.10 Protection Systems...........................................................10
2.10.1 Low Oil Pressure Switch..................................10
2.10.2 High Temperature Switch
...............................
10
2.10.3 Field Boost ......................................................10
2.10.4 Overvoltage Protection
....................................
11
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
11
12
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.'
...........................................................
13
3.5 Checking the Engine Spark Plug ............................14
3.6 Fuel Filter ........................................i
...............................
14
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
...................................................
.......................................................
.............................................................
...........................................
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
6
12
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
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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18
...20
22
22
22
22
23
23
24
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
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
......
.....................................
..............................................29
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............................
............................
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27
27
28
28
28
28
28
29
30
30
2.6.4 Conduit.............................................................30
9
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....................
.......................................
............................
32
33
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
36
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.
A
WARNING:
The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
11
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
A
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
A
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.
A
A
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.
A
A
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.
1.
Model Number
3. kW Rating 4.
5.
Phase 6. Hertz
2.
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
A
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
A
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
A
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
..................................................
..........................
.................................................
................................................................................
............................................................................
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
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
A
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
A
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
4.
-------------
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.
3
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
A
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
1^
♦ 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):
1.
Be sure the generator is as level as possible.
2.
Remove the dipstick and wipe it dry with a
clean, lint-free cloth.
3.
Install and tighten the dipstick cap; then,
remove it again. The oil level should be at the
dipstick “Full” mark.
4.
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
A
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
2.
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.
1.
Remove the cover, foam precleaner and paper filter.
2.
Remove the foam precleaner from the cover.
3.
Wash the foam precleaner in liquid detergent
4.
and water.
Wrap the foam precleaner in a clean cloth and
5.
gently squeeze it dry.
Saturate the foam precleaner in clean engine
6.
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
7.
lowed by the paper filter.
Install the cover, foam precleaner and paper filter.
8.
Tighten the two screws to retain the filter in place.
9.
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;
1.
service the
foam precleaner if necessary.
Remove the paper filter.
2.
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
A
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
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 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.
----------------------
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