Generac Power Systems Q-55G Series User manual

Part No. 98773
OWNER’S
Manual
Series Q-55G and Q-70G
AIR-COOLED
RECREATIONAL VEHICLE
GENERATORS
Model Nos. 9592-3 and 9593-3
C O R P ORATION
Revision 1 (06/02/98)
Printed in U.S.A.

GENERAL SAFETY RULES _
THE MANUFACTURER SUGGESTS THAT THESE •'RULES 1 ' FOR SAFE OPERATION BE COPIED AND
POSTED IN POTENTIAL HAZARD AREAS OF THE INDUSTRIAL VEHICLE. SAFETY SHOULD BE STRESSED
TO ALL OPERATORS AND POTENTIAL OPERATORS OF THIS EQUIPMENT.
Study these SAFETY RULES carefully before operating
or servicing applicable equipment. Become familiar
with this Owner’s Manual and with your generator. Safe,
efficient and reliable operation can only be achieved if
generator is properly installed, operated and main¬
tained. Many accidents are caused by failing to follow
simple and fundamental rules or precautions. The man¬
ufacturer suggests that these GENERAL SAFETY
RULES be copied and posted in potential hazard areas
of the industrial vehicle. Safety should be stressed to
all operators and potential operators of equipment.
The manufacturer cannot possibly anticipate every pos¬
sible 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 recommend, you must
satisfy yourself that it is safe for you and others. You
must also make sure the procedure, work method or
operating technique that you chose does not render the
generator to be unsafe.
• For fire safety, the industrial mobile generator must
be properly installed and maintained. Installation
must always remain in compliance with applicable
codes and standards. In addition, the generator
must be installed in conformance to the
manufacturer’s detailed installation instructions.
Following installation, nothing must be done that
might render the generator in noncompliance with
such codes, standards and instructions.
• The RV generator produces extremely high and
dangerous electrical voltages and can cause dan¬
gerous, and possibly fatal, electrical shock. Avoid
contact with bare wires, terminals, etc. while the
unit is running. If you must work around an operat¬
ing generator, stand on an insulated, dry surface to
reduce shock hazard.
• Never work on this equipment or handle any elec¬
trical device while standing in water, while barefoot,
or while hands or feet are wet. Dangerous electri¬
cal shock will result.
• Have the generator properly grounded (bonded)
during installation onto the vehicle, either by solid
mounting to the vehicle frame or chassis or by
means of an approved bonding conductor. DO
NOT disconnect the bonding conductor, if so
equipped. DO NOT reconnect the bonding 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 AWG copper wire
minimum.
• Inspect the generator periodically. Repair or re¬
place all damaged or defective parts immediately.
In case of accident caused by electric shock, shut
down the source of electrical power down at once.
If this cannot be done, free victim from live conduc¬
tor. AVOID DIRECT CONTACT WITH THE VIC¬
TIM. Use a dry board, dry rope, or other non-con¬
ducting implement to free the victim from live con¬
ductor. If victim is unconscious, apply CPR (cardio¬
pulmonary resuscitation) and get medical help.
Inspect fuel system frequently for leaks or damage.
Repair or replace any damaged or leaking compo¬
nent immediately. Never attempt to change, alter
or modify the generator fuel system in any way that
might affect safety or compliance with applicable
codes and standards’.
The generator engine gives off DEADLY carbon
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concentra¬
tions, can cause unconsciousness or even death.
This exhaust system must have been properly in¬
stalled, in strict compliance with applicable codes
and standards. Following installation, you must do
nothing that might render the system unsafe or in
non-compliance with such codes and standards.
The generator compartment must be completely
vapor sealed from vehicle interior. There must be
no possibility of exhaust fumes entering the vehicle
interior. Never operate this equipment with a leak¬
ing or defective exhaust system.
Never use the generator or any of its parts as a step.
Stepping on the unit can stress and break parts and
may result in dangerous operating conditions from
leaking exhaust gases, fuel leakage, oil leakage,
coolant leakage, etc.
Do not smoke around the generator. Wipe up any
fuel, oil and coolant spills immediately. Never leave
oily or fuel soaked rags in the generator compart¬
ment or on the generator itself. Keep the area
around the generator clean and free of debris.
Adequate ventilation is required to expel toxic
fumes and gasoline vapors from the generator com¬
partment. Do not alter the installation of this equip¬
ment in any manner that might obstruct air and
ventilation openings. Such openings must be kept
clear and unobstructed.
Keep hands, feet, clothing, etc., away from drive
belts, fans and other moving parts of this equip¬
ment. Never remove any drive belt or fan guards
while the unit is operating.
Some generators may use LP gas (propane) as a
fuel. LP gas is highly EXPLOSIVE. The gas is
heavier than air and tends to settle in low areas
where even the slightest spark can ignite the gas
and cause an explosion.
Before performing any maintenance on the gener¬
ator set, disconnect its battery cables to prevent
accidental start up. Disconnect the cable from the
battery post indicated by a NEGATIVE, NEG or (-)
first. Reconnect that cable last.

IDENTIFICATION RECORD

TABLE OF CONTENTS
GENERAL SAFETY RULES..inside cover
IDENTIFICATION RECORD. 1
READ THIS MANUAL THOROUGHLY. 3
Operation and Maintenance. 3
How to Obtain Service. 3
GENERATOR FEATURES. 4
GENERATOR FAMILIARIZATION
Generator Applicability. 5
Installation. 5
Safety. 5
Generator AC Connection System. 5
OPERATING INSTRUCTIONS
Generator Panel.
Automatic Choke.
Before Starting the Engine.
Starting.
Stopping the Generator.
Applying Loads to Generator.
Wattage Reference Guide.
ADDITIONAL INFORMATION
Automatic Low Oil Pressure Shutdown
High Temperature Shutdown.
Muffler Kits.
Field Boost.
Over-Voltage Protection.
25-Hour Break in Period.
25-Hour Check Up.
Operation in High Grass or Brush.
6
6
7
7
7
7
8
9
9
9
9
9
10
10
10
SPECIFICATIONS
Generator Specifications.11
Engine Specifications.11
Fuel Requirements.11
Engine Oil Requirements.11
Optional LP Gas Fuel System.11
MAINTENANCE
Checking Engine Oil Level.12
Change Engine Oil.12
Change Oil Filter.12
Engine Air Cleaner.13
Clean Air Intake Screen.13
Engine Spark Plugs.13
Fuel Filter.13
MISCELLANEOUS MAINTENANCE
Spark Arrestor Mufflers.14
Cleaning the Generator.14
Battery.14
Major Service Manual.14
Drive Belts.14
Exercising the Generator.15
Out of Service Protection.15
Return the Unit to Service after Storage.15
TROUBLESHOOTING.16
ELECTRICAL DATA.17
REPAIR PARTS.18 to 29
2-

READ THIS MANUAL THOROUGHLY
!f you don’t understand any portion of this manual,
contact Generac for a demonstration of actual starting,
operating and servicing procedures.
Throughout this publication and on tags and decals
affixed to the generator, DANGER and CAUTION
blocks are used to alert you to special instructions about
a particular operation that may be hazardous if per¬
formed incorrectly or carelessly. Observe them care¬
fully.
These safety warnings cannot eliminate the hazards
that they indicate. Strict compliance with the special
instructions while performing the service plus "common
sense" are major measures to prevent accidents.
The following definitions apply to DANGER, CAUTION
and NOTE blocks found throughout the manual.
DANGER: AFTER THIS HEADING YOU CAN
READ HANDLING, INSTALLING, OPERATING OR
SERVICING INSTRUCTIONS THAT, IF NOT
STRICTLY COMPLIED WITH, MAY RESULT IN
PERSONAL INJURY. __
CAUTION: After this heading you can read instruc¬
tions for handling, installing, operating or servicing
the generator that, if not strictly complied with, may
result in damage to equipment and/or property.
NOTE: After this heading you can read explanatory
statements that require special emphasis.
The operator (driver) is responsible for proper and safe
use of the vehicle, equipment on the vehicle, and the
safety of all vehicle occupants. We strongly recom¬
mend that the operator read this Owner’s Manual and
thoroughly understand all instructions before using this
equipment. We also strongly recommend instructing
other occupants in the vehicle to properly start and
operate the generator. This prepares them if they need
to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
It is the operator’s responsibility to perform ail safety
checks; to make sure that all maintenance for safe
operation is performed promptly; and to have the equip¬
ment checked by an Authorized Dealer periodcially.
Normal maintenance service and replacement of parts
are the responsibility of the Owner/Operator and, as
such, are not considered defects in materials or work¬
manship within the terms of the warranty. Individual
operating habits and usage contribute to the need for
maintenance service.
Proper maintenance and care of your industrial mobile
generator assures a minimum number of problems and
keeps your operating expenses at a minimum. See
your authorized Dealer/Distributor for service aids and
accessories.
HOW TO OBTAIN SERVICE
When your industrial mobile generator set requires ser¬
vicing or repairs, simply contact an Authorized Service
Station for assistance. Service technicians are factory-
trained and are capable of handling all of your service
needs.
When contacting an Authorized Service Facility or the
factory about parts and service, always supply the com¬
plete model number and serial number of your unit as
given on its data plate.
The warranty on your generator is included in this
Owner’s Manual, as well as listings for repair parts.
3 -

GENERATOR FEATURES
i
REFERENCE NUMBER IDENTIFICATION !
i
1. Generator Air Intake Screen
8.
Starter Contactor
2. Engine Start/Stop Switch
9. Fuel Inlet
3. 15 amp Fuse
10 . Fuel Pump Primer Switch
4. 20 or 30 amp Circuit Breaker
11.
Fuel Pump
5. Optional Remote Panel Receptacle
12 . Oil Filter
6. Generator AC Output Leads
13. Oil Drain Plug
7. 30 amp Circuit Breaker
14.
Oil Dipstick and Filler Tube
4 -

GENERATOR FAMILIARIZATION
GENERATOR APPLICABILITY
Q-55G and Q-70G generators have been designed and
manufactured for supplying electrical power for recrea¬
tional vehicles. You should not modify the generator or
use it for any application other than for what it was
designed. If there are any questions pertaining to its
application, write or call the factory. Do not use the unit
until you have been advised by competent authority.
DANGER: FOR FIRE SAFETY, THE GENERATOR
MUST HAVE BEEN PROPERLY INSTALLED IN
COMPLIANCE WITH (1) ANSI 119.2-1975/NFPA
501C-1974 "STANDARD FOR RECREATIONAL
VEHICLES", PART III, "INSTALLATION OF ELEC¬
TRICAL SYSTEMS." THE GENERATOR ALSO
MUST HAVE BEEN INSTALLED IN STRICT COM¬
PLIANCE WITH THE MANUFACTURER’S DE¬
TAILED INSTALLATION INSTRUCTIONS. AFTER
INSTALLATION, DO NOTHING THAT MIGHT
RENDER THE UNIT IN NON-COMPLIANCE WITH
SUCH CODES, STANDARDS AND INSTRUC¬
TIONS. _
You can use your generator set to supply electrical
power for operating one of the following electrical loads:
• Q-55G: 120 and/or 240 volts, single phase, 60 Hz
electrical loads. These loads can require up to 5500
watts (5.5 kW) of power, but cannot exceed 45.8 AC
amperes of current at 120 volts or exceed 22.9 AC
amperes at 240 volts.
• Q-70G: 120 and/or 240 volts, single phase, 60 Hz
electrical loads. These loads can require up to 7000
watts (7.0 kW) of power, but cannot exceed 58.3 AC
amperes of current at 120 volts or exceed 29.1 AC
amperes at 240 volts.
CAUTION: Do not overload the generator. Some
installations may require that electrical loads be
alternated to avoid overloading. Applying exces¬
sively high electrical loads may damage the gener¬
ator and may shorten its life. Add up the rated watts
of all electrical lighting, appliance, tool and motor
loads the generator will power at one time. This
total should not be greater than the wattage capac¬
ity of the generator. If an electrical device nameplate
gives only volts and amps, multiply volts times
amps to obtain watts (volts x amps = watts). Some
electric motors require more watts of power (or
amps of current) for starting than for continuous
operation.
INSTALLATION
This Owner’s Manual has been prepared under the
assumption that a competent, qualified technician in¬
stalled the generator into an industrial vehicle. We also
assume the installer complied with all applicable codes,
standards and regulations pertaining to installation.
An INSTALLATION MANUAL was shipped with the
generator. That Manual contains manufacturer’s in¬
structions and recommendations for installing the unit
into an industrial vehicle. After installation, installers
should forward the Installation Manual to Owners/Oper¬
ators for their information.
Owners/Operators have the responsibility to make sure
that nothing is done that might render the installation
unsafe or in non-compliance with applicable codes,
standards and instructions.
SAFETY
Before using the generator set, carefully read GEN¬
ERAL SAFETY RULES inside the cover. Comply with
these RULES to prevent accidents and damage to
equipment and/or property. Generac suggests copying
and posting the GENERAL SAFETY RULES to potential
operators of this equipment.
GENERATOR AC CONNECTION SYSTEM
These air-cooled Q Series generator sets are equipped
with dual stator AC power windings. These two stator
windings supply electrical power to customer electrical
loads by means of a dual 2-wire connection system.
The generator may have been installed so that units
only power 120 volts AC loads (Figure 1); or you can
wire them to connect both 120 and/or 240 volts AC
electrical loads. Be sure to remove the jumper between
the circuit breakers when connecting for 120/240 volts.
QROUNOED
NEUTRAL
Figure 1 — Connection for 120 Volts Only
-5-

OPERATING INSTRUCTIONS
GENERATOR CONTROL PANEL
Mounted on the generator control panel (Figure 2) are
the following features:
• Fuel Pump Primer: Before starting a cold engine
(it has not been started in more than two weeks),
you must press this switch to bring fuel from the tank
to the fuel pump. This rocker type switch springs
back into its original position when you release it.
• Start/Stop Switch: To crank and start the engine,
hold this switch at its START position. Release the
switch when the engine starts. To stop an operating
engine, place the switch in its STOP position. The
switch center position is the RUN position.
• 15 amp Fuse: Protects the engine DC control
circuit against electrical overload. If the fuse ele¬
ment has melted open due to overloading, the en¬
gine cannot be cranked. If you must replace it, use
only an identical 15 amp replacement fuse.
• Line Breakers: Protects generator’s AC output
circuit against overload, i.e., prevents unit from
exceeding wattage/amperage capacity. NP-50G
has one 20 amp breaker and one 30 amp breaker.
NOTE: If your "Q" Series generator has been recon¬
nected for dual voltage AC output (120/240 volts), you
can install line breakers having an amperage rating that
is different than stated above. The replacement line
breakers consist of two separate breakers with a con¬
necting piece between the breaker handles (so that both
breakers will operate at the same time). If the unit is
reconnected for dual voltage, it is no longer RVIA listed.
OPTIONAL REMOTE START/STOP PANEL
Optional remote mounted panels are available which
permit you to crank and start the generator from any
convenient location in the industrial vehicle. Figure 3
shows the Model 9042 remote panel which includes (a)
start/stop switch and (b) a generator run lamp.
You can also order Model 9043, a remote panel which
includes the (a) start/stop switch, (b) the generator run
lamp and (c) an hourmeter. The hourmeter provides a
continuous indication of engine-generator operating
time. Use the hourmeter for checking off periodic main¬
tenance requirements on the unit.
(
©
GENERAC
R.V.
GENERATOR
GEN. (Q) RUN
Figure 3 — Optional Remote Panel (Model 9042)
AUTOMATIC CHOKE
The engine is equipped with an automatic choke that
consists of two main components—choke solenoid and
prechoke.
Choke Solenoid: During engine cranking (start/stop
switch at START), a solid state choke module signals
the choke solenoid to actuate and cycle (choke
on/choke off) until engine starts. The choke solenoid
thus opens and closes the carburetor choke valve only
when the engine is cranking. When the engine starts,
the choke cycling stops.
Prechoke: The choke system also has a temperature
sensjtive metal strip that adjusts the choke valve angle
according to ambient temperatures (i.e. in cold ambient
temperatures the choke valve closes more). Once the
engine starts, an element heats the temperature-sensi¬
tive strip to a normal operating condition, opening the
choke valve. This may take about 3 minutes in cooler
weather.
BEFORE STARTING THE ENGINE
IMPORTANT: INSTRUCTIONS AND INFORMATION
IN THIS MANUAL ASSUME THE GENERATOR HAS
BEEN PROPERLY INSTALLED, CONNECTED, SER¬
VICED, TESTED AND ADJUSTED BY A QUALIFIED
INSTALLATION TECHNICIAN OR INSTALLATION
CONTRACTOR.
• Installation: Generator installation must have
been properly completed so it complies with all
applicable codes, standards and regulations and
with the manufacturer’s recommendations.
• Engine Lubrication: Have engine crankcase
properly serviced with recommended oil before
starting. Refer to "Maintenance'' and "Specifica¬
tions” sections for oil servicing procedures and rec¬
ommendations.
CAUTION: Any attempt to crank or start the engine
before you have properly serviced it with the recom¬
mended oil will result in an engine failure.
FUSE MAIN
START ISA BREAKER
(r %
% »
STOP FUEL
_ PRIMER _
Figure 2 — Typical Control Panel
6

• Fuel Supply: The engine must have adequate
supply of proper fuel to operate. Before starting,
check that sufficient fuel is available.
• NOTE: On some installations, the generator en¬
gine may "share" the vehicle’s gasoline fuel tank
with vehicle engine. Some installations may pro¬
vide separate fuel tanks for generator and vehicle
engine.
• Cooling and Ventilating Air: Air inlet and outlet
openings in the generator compartment must be
open and unobstructed for continued proper oper¬
ation. Without sufficient cooling and ventilating air
flow, the engine-generator quickly overheats which
causes it to quickly shutdown. Overheating could
also damage the unit or your vehicle.
• Engine Exhaust Gases: Before starting the gen¬
erator engine, you should be sure there is no way
for exhaust gases to enter the vehicle interior and
endangering people or animals. Close windows,
doors and other openings in the 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 DAN¬
GEROUS GAS, IF BREATHED IN SUFFICIENT
CONCENTRATIONS, CAN CAUSE UNCON¬
SCIOUSNESS OR EVEN DEATH. DO NOT OPER¬
ATE THE GENERATOR IF ITS EXHAUST SYSTEM
IS LEAKING OR HAS BEEN DAMAGED. SYMP¬
TOMS OF CARBON MONOXIDE POISONING ARE
(A) INABILITY TO THINK COHERENTLY, (B)
VOMITTING, (C) TWITCHING MUSCLES, (D)
THROBBING TEMPLES, (E) DIZZINESS, (F)
HEADACHE, (G) WEAKNESS AND SLEEPINESS.
IF YOU FEEL ANY OF THESE SYMPTOMS, MOVE
INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS
PERSIST, GET MEDICAL HELP. _
STARTING
IMPORTANT: Read the vehicle manufacturer's instruc¬
tions. The owner/operator should become familiar with
the vehicle in which this generator is installed. Differ¬
ences exist between vehicles. For example, some ve¬
hicles may use a transfer switch to isolate dockside
power from the generator, while other vehicles may use
an isolating receptacle. Some vehicles may be
equipped with a DC converter which allows the gener¬
ator to power certain DC lighting and other DC loads.
To crank and start the generator engine, proceed as
follows:
1. T urn OFF electrical loads, using whatever means
provided in your vehicle (such as a main line circuit
breaker or transfer switch.
NOTE: If you start the engine with start/stop switch on
the generator control panel, turn OFF loads by setting
the panel's main breakers to their "OFF" or “OPEN"
positions. Electrical load circuits will be turned ON after
the generator has started, 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 30 seconds to activate the automatic
shut-off function. However, if the engine is warm,
skip Step 2.
3. To crank and start the engine, hold the start/stop
switch at START. Release the switch when the
engine starts.
CAUTION: If the engine does not start after it has
been cranking for 15 seconds, release the start/stop
switch and try again. Holding the switch for longer
than 15 seconds can damage the starter motor.
4. Let the engine run at no-load for a few minutes to
stabilize and warm up the engine.
5. Turn ON electrical loads, using whatever means
provided (such as a main circuit breaker or transfer
switch).
STOPPING THE GENERATOR
1. Turn OFF all electrical loads, using whatever
means provided (such a main circuit breaker or
transfer switch).
2. Let the generator run at no-load for a few minutes,
to stabilize internal engine-generator tempera¬
tures.
3. Press STOP on the start/stop switch. The engine
will come to complete stop.
APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator, ob¬
serve these guidelines:
• Before applying electrical loads, let the generator
stabilize and warm up for a minute or two.
• DO NOT overload the generator.
Letting Engine Stabilize: The generator supplies cor¬
rect rated frequency and voltage only at the proper
governed speed. Some electrical appliances may be
extremely sensitive to voltage and frequency. Incorrect
frequencies and/or voltages can damage those appli¬
ances.
If electrical loads are applied at reduced operating
speeds, such loads imposed on the engine when suffi¬
cient power is not available may shorten engine life.
Never turn ON electrical loads until after the generator
engine has started and stabilized ON-speed.
7-

Do Not Overload the Generator: You can read the
rated wattage/amperage capacity of your generator on
the generator data plate (see 'Identification Record" on
Page 1).
Applying electrical loads in excess of the unit’s rated
capacity can bum out the unit and anything connected
to it. Also, overloading trips main circuit breakers.
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 indi¬
cate 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, multiply
that load’s rated VOLTS times AMPS to obtain
WATTS.
• Induction type motors (such as those that run the
vehicle’s furnace fan, refrigerator, air conditioner,
etc.) need about 2-1/2 times more watts of power
for starting than for running (for a few seconds
during motor starting). Be sure to allow for this
when connecting electrical loads to the generator.
First, figure the watts needed to start 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.
WATTAGE REFERENCE GUIDE
RUNNING
WATTS
'Air Conditioner (12,000 Btu).1700
Battery Charger (20 amp). 500
Belt Sander (3‘).1000
Chain Saw.1200
Circular Saw (6-12/").800 to 1000
Coffee Maker.1000
'Compressor (1 HP).2000
'Compressor (3/4 HP).1800
‘Compressor (1/2 HP)..’.1400
Curling Iron.700
'Deep Freeze.500
Disc Sander (9*).1200
Edge Trimmer.500
Electric Nail Gun.1200
Electric Range (one element).1500
Electric Skillet.:.1250
'Furnace Fan (1/3 HP).1200
Hair Dryer.1200
Hand Drill (I").1100
Hand Drill (1/2').750 to 1000
Hand Drill (3/8").500
Hand Drill (1/4'). 2 50
Hedge Trimmer.450
Impact Wrench.500
'Jet Pump.800
RUNNING
WATTS
Lawn Mower. 1200
Light Bulb.100
Microwave Oven.,.700
'Milk Cooler.1100
Oil Burner on Furnace.300
Oil Fired Space Heater (140,000 Btu).400
Oil Fired Space Heater (85,000 Btu).225
Oil Fired Space Heater (30,000 Btu).150
'Paint Sprayer, Airless (1/3 HP).600
Paint Sprayer, Airless (handheld).150
Radio...50 to 200
'Refrigerator.;.600
Slow Cooker.200
'Submersible Pump (1-1/2 HP).2800
'Submersible Pump (1 HP)..2000
'Submersible Pump (1/2 HP).1500
Sump Pump.600
'Table Saw (10").:.1750 to 2000
Television.200 to 500
Weed Trimmer.500
* Allow 2-1/2 times the listed watts for starting these
devices.
8