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GE A4021 User's Manual

1. The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For fire safety the recreational vehicle generator A must be properly installed and maintained Installation must A remain in compliance with applicable codes and standards In addition the generator must be installed in comformance to the manufacturer s detailed installation instructions Following installation nothing must be done that might render the generator in noncompliance with such codes standards and instructions The RV generator produces extremely high and A dangerous electrical voltages and can cause dan gerous and possibly 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 bare foot or while hands or feet are wet Dangerous electrical shock will result Have the generator properly grounded bonded during installation onto the vehicle either by solid mounting to the vehicle frame or chassis or Dy means of an approved bonding conductor DO NO disconnect the bonding conductor if so equipped DO NOT reconnect the bonding conductor to any that might be removed or disassem led during r
2. Inspect cooling and ventilation openings on the vehicle Check engine carburetor adjustments Check engine ignitions system nspect entire electrical system Inspect the engine exhaust system OPERATION IN HIGH GRASS OR BRUSH Never operate the generator while the vehicle is parked in high grass weeds brush or leaves Such materials can ignite and burn from the heat of the exhaust system The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down FUEL REQUIREMENTS These generators are equipped with a LP vapour withdrawal fuel system as standard equipment To operate normally the generator requires an inlet pressure of 11 WC 0 39 PSI ENGINE OIL REQUIREMENTS Use a high quality detergent oil classified For Service SF and with an oil viscosity rating of SAE 10W 30 oil Do not pour in any aditives to the recommended oil Engine crankcase capacity is 1 5 U S quarts See MAINTENANCE section for oil level check and filling procedures ENGINE SPECIFICATIONS Type of Engine 1 117 dE GN 480 le HY GN 570 Cooling Air cooled Rated Horsepower s e tata ROT 16 at 3600 Q 7OLP 19 at 3600rpm Displacement Perce er ven b Ee ia 480cc Q Z0LP 0 04 570cc Compression Ratio 8 6 to 1 Cylinder Block Aluminum with cast iron sleeve Type o
3. OWNER S MANUAL AIR COOLED RECREATIONAL VEHICLE GENERATORS Model Nos 9735 3 9736 3 GENERAL SAFETY RULES SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF THE MANUFACTURER SUGGESTS THAT THESE RULES FOR SAFE OPERATION BE COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHICLE THIS EQUIPMENT Study these SAFETY RULES carefully before operat ing or servicing applicable equipment Become familiar with this Owners Manual and with your generator Safe efficient and reliable operation can only be achieved if generator is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer suggests that these GENERAL SAFETY RULES be copied and posted in potential hazard areas of the recreational vehicle Safety should be stressed fo operators and potential operators of equipment The manufacturer cannot possibly anticipate every cir cumstance that might involve a hazard The warnings in this Manual and on tags and decals affixed to the unit are therefore not all inclusive If you use a proce dure work method or operating technique Generac does not specifically recommend you must satisfy yourself that it is sate for you and others You must also make sure the procedure work method or operat ing technique that you chose does not render the gen erator to be unsafe WARNING
4. Drawing No 95955 REPAIR PARTS BASE 8 PULLEYS PART DESCRIPTION 1 OOO 0 11 28 29 30 31 32 33 86318 90141 46911 25017 22237 22129 72391 77603 22259 52858 51730 29459 75215 73146 75209 73174 79678 55173 72383 90859 75224B 73106B 75216 49451 42633 77017 73118 74906 23152 72375 73185 22097 77682 A ND lt DPADD V BASE MOUNTING GROUND CABLE MOUNT RUBBER CAPSCREW HEX HD 3 8 16 1 2 LOCKWASHER 3 8 LOCKWASHER M8 SKID RUBBER MOUNT SAFETY BOLT 5 16 18 x 3 1 2 NUT HEX 5 16 18 NUT FLANGED LOCK M8 1 25 CAPSCR HEX HD 8 1 25 x 60MM SPRING BELT TENSION WASHER SPRING CNTR SLIDE NYLON SUPPORT NYLON SLIDE MANIFOLD EXHAUST GASKET EXHAUST MANIFOLD CAPSCR HEX HD M8 1 25x20MM GRADE 10 9 GASKET COLLECTOR PAN COVER PLATE EXTERNAL PULLEY ENGINE PULLEY ALT BELT POLY V 4L 40 WASHER PULLEY RETAINER CAPSCR HEX HD 3 8 24 x 1 GRADE 5 GUIDE BLOWER HOUSING CAPSCR HD 3 8 24 X 2 1 4 SCREW TAPTITE M6 1 00 X 20 CAPSCR HEX HD 3 8 16 X 3 4 HOUSING BLOWER SPACER BLOWER HOUSING LOCKWASHER M6 CAPSCR HEX HD M5 0 80 X 80MM ITEM PART NO QTY DESCRIPTION 34 35 36 42 43 75242 49813 45757 26925 75710A 74958 67871 75712 75711 73179 70185 60108 74948 74950 74951 73134 38750 749
5. Have engine crankcase properly serviced with recom mended oil before starting Refer to Maintenance and Specifications sections for oil servicing proce dures and recommendations CAUTION Any attempt to crank or start the engine before you have property serviced it with the recommended oil may result in engine failure Lu FIR M FUEL SUPPLY The engine must have adequate supply of proper fuel to operate Before starting check that sufficient fuel is available E COOLING AND VENTILATING AIR Air inlet and outlet openings in the generator compart ment must be open and unobstructed for continued proper operation Without sufficient cooling and venti lating air flow the engine generator quickly overheats which causes it to quickly shutdown Overheating could also damage the unit or your vehicie ENGINE EXHAUST GAS Before starting the generator engine you should be sure there is no way for exhaust gases to enter the vehicle interior and endangering people or animals Close windows doors and other openings in the vehi cle that if open might permit exhaust gases to enter the vehicie DANGER THE GENERATOR ENGINE GIVES OFF DEADLY CARBON MONOXIDE GAS THROUGH ITS EXHAUST SYSTEM THIS DANGEROUS GAS IF BREATHED IN SUFFICIENT CONCENTRATIONS CAUSE UNCONSCIOUSNESS OR EVEN DEATH DO NOT OPERATE THE GENERATOR IF ITS EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE
6. volts x amps watts Some electric motors require more watts of power or amps of current for starting than for continuous operation INSTALLATION This Owner s Manual has been prepared under the assumption that a competent qualified technician installed the generator into a recreational vehicle We also assume the installer complied with all applicable Wu standards and regulations pertaining to instal ation An INSTALLATION MANUAL was shipped with the generator That manual contains manufacturer s instructions and recommendations for installing the unit into a recreational vehicle After installation installers should forward the Installation Manual to Owners Operators for their information Owners Operators have the responsibility to make sure that nothing is done that might render the instal lation unsafe or in non compliance with applicable codes standards and instructions SAFETY Before 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 propery Generac suggests copy ing and posting the GENERAL SAFETY RULES in potential hazard areas of the recreational vehicle Safety should be stressed to all operators of this equipment GENERATOR AC CONNECTION SYSTEM These air cooled Q Series generator sets are equipped with dual stator AC power windings These two stator windings supply electrical power to cus tomer
7. 1 BAFFLE BREATHER 62 72366 1 COTTER PIN 63 172367 1 GOVERNOR FORK 64 172365 1 WASHER GOVERNOR 65 68555 2 DOWEL CRANKCASE 66 67806 4 DOWEL CYLINDER HEAD 67 175262 1 SEAL BREATHER SCREW 68 75263 1 SEAL BREATHER SCREW 69 75264 1 STARTER GEAR 70 75265 1 STARTER END ASSEMBLY 71 75266 1 COMMUTATOR CAP ASSEMBLY 72 75267 1 STARTER HOUSING ASSEM 73 68572 2 SCREW OIL PUMP 74 75272 2 TERMINAL SPARK PLUG 75 170122 2 VALVE STEM 76 67910 2 SEAT INTAKE VALVE 77 67911 2 SEAT EXHAUST VALVE 78 67813 4 VALVE GUIDE 79 75268 1 RETAINER AND PIN 80 75270 1 ROLL PIN 81 70592 1 AIR CLEANER BASE 82 73123 1 AIR FILTER FLAME RETARDENT 83 170593 1 COVER AIR CLEANER 84 172300 1 SCREW AIR CLEANER COVER 85 67156 2 SCREW AIR CLEANER BASE 86 69341 1 PRE FILTER 87 80011 1 SPRING BRUSH SET 88 170597 1 TUBE AIR INLET 89 69358 1 DEFLECTOR BREATHER 90 67920 2 GASKET VALVE COVER 91 69328 1 ROCKER ARM COVER 92 70547 1 OIL PUMP ASSEMBLY 93 70536 1 GOVERNOR SLIDER 94 70577 4 PUSH ROD 95 70599 4 ROCKER ARM ASSEMBLY 96 70567 2 SHAFT ROCKER ARM 97 70566 4 SUPPORT ROCKER ARM 98 75271 1 KIT VALVE OVERHAUL 99 67897 2 GASKET EXHAUST 100 91481 1 GASKET amp CAP ASSEMBLY 101 91480 1 ROCKER ARM COVER REPAIR PARTS ENGINE SHEET METAL Drawing No 89403 2 99258 3 67198 4 67890 5 87865 7 86313 8 56893 10 87750 11 74916 12 74908 13 73190 14 178858 15 178859 16 174902 17 66476
8. 16 REPAIR 8 2 17 26 Oa a A 27 CALIFORNIA EMISSIONS WARRANTY 28 29 back FOCUS READ THIS MANUAL THOROUGHLY If you don t understand any portion of this manual contact Generac for a demonstration of actual start ing operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER and CAUTION blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly Observe them carefully These safety warnings cannot eliminate the hazards that they indicate Strict compliance with the special instructions while performing the service plus com mon sense are major measures to prevent acci dents The following definitions apply to DANGER CAU TION and NOTE blocks found throughout the manual DANGER AFTER THIS HEADING YOU CAN READ HANDLING INSTALLING OPERATING OR SERVIC ING INSTRUCTIONS THAT IF NOT STRICTLY COM PLIED WITH MAY RESULT IN PERSONAL INJURY CAUTION After this heading you can read instruc tions for handling 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 These symbols indicate the fol
9. 19 73191 21 DESCRIPTION ENGINE EXPLODED VIEW OF ENGINE KEY WOODRUFF 6 x 22MM WASHER BELLEVILLE NUT HEX M20 1 50 PLUG FLYWHEEL ACCESS HOUSING ENGINE TOP SCREW CRIMPTITE NO 10 24 x 1 2 SCROLL FLYWHEEL COVER BASE 2 SCREW TAPTITE M5 x 10MM WRAPPER NO 2 CYLINDER COVER VALLEY WRAPPER NO 1 CYLINDER WRAPPER BARREL CAPSCREW HEX HEAD M6 1 00 x 12MM W LOCKWASHER COVER BASE 1 CYLINDER PART NO 42907 22129 75246 10 74260 74900 73186 81108 22717 B 22717 A 67866 77001 73132 87858A 29289 87858B 50277 QTY NO k b m m E DESCRIPTION CAPSCREW HEX HEAD M8 1 25 x 16MM LOCKWASHER M8 SCREW TAPTITE 3 8 16 x 1 1 4 WIRE ASSEMBLY NO 16 COVER STARTER WRAPPER CRANKCASE BUSHING SNAP GROMMET RUBBER GROMMET RUBBER O RING PLUG OIL FILL BOOT SPARK PLUG GROUND WIRE ASSEMBLY CYL 1 FOAM TAPE GROUND WIRE ASSEMBLY CYL 2 DECAL OIL DRAIN 5s NOTES CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and Generac Corporation are pleased to explain the Emission Control Systen Warranty on your new recreational vehicle generator engine In California new utility and lawn and garden equipment engines must be designed built and equipped to meet the State s stringent anti smog standards Generac Corporati
10. Reset and replace if necessary Set to GENERATOR position Take generator to an Authorized Generac facility ELECTRICAL DATA Drawing No 92116 AR a ve A PR REPAIR PARTS CARBURETOR Drawing No A4029 ITEM PARTNO QTY DESCRIPTION ITEM PARTNO QTY DESCRIPTION 1 1662 1 CARB V TWIN UP 19 81378 T AR CLEANER DECAL 2 57822 2 HOSE CLAMP IM 72 3 74994 1 1 2 1 0 x 10 LONG HOSE 91351 AIR GLEANER DECAL 4 26307 3 STREET ELBOWS 91352 1 AIR CLEANER DECAL Q 55 5 26915 1 3 4 PIPE NIPPLE 91352 A 1 AIR CLEANER DECAL Q 70 6 75211 1 GASEOUS FUEL REGULATOR 20 75944 1 GOV SPRING BRACKET 7 A2666 1 GASEOUS FUEL SOLENOID 21 73130 1 FLYWHEEL ASSEMBLY 8 78864 1 REG MOUNTING BRACKET 22 70155 1 GOVERNOR LEVER 9 49813 4 6 NUT 23 76242 2 1 8 LD x 1 8 RIVET 10 22097 4 M6 LOCK WASHER 24 70125 1 ANTI LASH SPRING 11 47411 2 64 00 16MM HEX HD 25 70108 1 GOV TO CARB ROD 12 38750 2 1 00 x 30MM HEX HD dips T 2 URE 55162 PIPE SEALANT 13 37398 1 HEX LOCK NUT NYLON 26 81190 1 LP HOOK UP FITTING 14 74961 1 GOV ADJUSTER BRACKET 27 70103 1 AIB G NER SUPPORT 15 56893 5 10 24 x 1 2 SCREW MN 16 47227 1 GOV ADJUSTER SCREW 28 61695 1 BARBED 90 DEG 3 8 x 1 17 174962 1 GOVERNOR SPRING 18 66476 2 M6 1 0 x 12MM HEX SCREW NOT SHOWN W LOCKWASHER 47 EXPLODED VIEW BASE amp PULLEYS Drawing No 95955 18
11. electrical loads by means of a dual 2 wire con nection system The generator may have been installed so that units only power 120 volts AC loads Figure 1 or you can wire them to connect both 120 and or 240 volts AC electrical loads Be sure to remove the jumper between the circuit breakers when connecting for 120 240 volts Figure 1 Connection for 120 Volts Only WINDINGS 5 lt GROUNDED NEUTRAL OPERATING INSTRUCTIONS GENERATOR CONTROL PANEL Mounted on the generator control panel Figure 2 are the following features START STOP SWITCH To crank and start the engine hold this switch at its START position Release the switch when the engine starts To stop an operating engine press and hold the switch in its STOP position until the engine shuts off The switch center position is the RUN position M FUSE Protects the engine DC control circuit against electri cal overload If the fuse element has melted open due to overloading the engine cannot be cranked If you must replace it use only an identical replacement fuse MAIN BREAKER Protects generators AC output circuit against overload i e prevents unit from exceeding wattage amperage capacity NOTE if the Series Q 55LP or Q 70LP has been recon nected for dual voltage AC output 120 240 volts you can install line breakers having an amperage rating that is different than stated previously The replacement main breaker
12. use Inspect the generator battery as follows ONCE WEEKLY Inspect battery posts and cables for tightness corro sion Clean and or tighten as necessary Also check battery fluid level and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERY EVERY SIX MONTHS Have the battery state of charge and condition checked by an automotive service facility This should be done with an automotive type battery hydrometer DANGER STORAGE BATTERIES GIVE OFF EXPLOSIVE HYDROGEN GAS THIS GAS CAN FORM AN EXPLOSIVE MIXTURE AROUND THE BATTERY FOR SEVERAL HOURS AFTER CHARG ING THE SLIGHTEST SPARK CAN IGNITE THE GAS AND CAUSE AN EXPLOSION SUCH AN EXPLOSION CAN SHATTER THE BATTERY AND CAUSE BLINDNESS OR OTHER INJURY ANY AREA THAT HOUSES A STORAGE BATTERY MUST BE PROPERLY VENTILATED DO NOT ALLOW SMOKING OPEN FLAME SPARKS OR ANY SPARK PRODUCING TOOLS OR EQUIPMENT NEAR THE BATTERY DANGER BATTERY ELECTROLYTE FLUID IS AN EXTREMELY CAUSTIC SULFURIC ACID SOLUTION THAT CAN CAUSE SEVERE BURNS DO NOT PER MIT FLUID TO CONTACT EYES SKIN CLOTHING PAINTED SURFACES ETC WEAR PROTECTIVE GOGGLES PROTECTIVE CLOTHING AND GLOVES WHEN HANDLING A BATTERY IF YOU SPILL THE FLUID FLUSH THE AFFECTED AREA IMMEDIATE LY WITH CLEAR WATER DANGER DO NOT USE ANY JUMPER CABLES OR BOOSTER BATTERY TO CRANK AND START THE GENERATOR ENGINE IF ANY BATTERY HAS DISCHARGED REMOVE IT FROM THE VEHICLE FOR RECHARGING MAJO
13. 2 PLUG OIL DRAIN 3 8 NPT 72334 1 CRANK SHAFT ASSEMBLY 75247 1 OIL SUMP ASSEMBLY 67924 1 OIL SEAL 35 DIAMETER 67878 9 BOLT OIL SUMP 75248 2 PISTON ASSEMBLY STANDARD 75249 2 RING SET PISTON STANDARD 69327 4 LOCKING RING PISTON 75250 2 PISTON PIN STANDARD 75251 2 CONNECTING ROD ASSEMBLY 72346 4 BOLT CONNECTING ROD 69316 2 EXHAUST VALVE 69317 2 INTAKE VALVE 67816 4 VALVE SPRING 69320 4 RETAINER VALVE SPRING 70513 4 KEEPER VALVE 70584 4 TAPPET VALVE 70530 1 CAMSHAFT ASSEMBLY 72358 1 INTAKE MANIFOLD 69379 2 GASKET CARBURETOR MNTG 67895 2 GASKET INTAKE MANIFOLD 70594 2 CARBURETOR MNTG 67158 4 BOLT INTAKE MANIFOLD MNT 68574 1 PIPE PLUG 1 8 NPT 68554 1 SEAL GOVERNOR SHAFT 68573 1 O RING OIL PUMP 70506 1 O RING OIL GALLEY 70554 1 SPACER CARBURETOR 70568 4 STUD ROCKER ARM 75253 4 SEAL WASHER VALVE COVER 67885 4 NYLOK M6 75254 4 SCREW VALVE ADJUST 70535 1 SCREEN OIL 75255 1 STARTER MOTOR 75256 2 BOLT STARTER MOTOR 75257 4 BRUSH ASSEMBLY 67891 1 IGNITION ARMATURE ASSEM 72356 2 SCREW IGNITION ARMATURE REPAIR PARTS ENGINE ITEM PART QTY DESCRIPTION 52 72347 2 SPARK PLUG CHAMPION R12YC 53 75258 1 GASKET KIT ENGINE 54 75259 1 WASHER BREATHER SCREW 55 75260 1 STARTER DRIVE ASSEMBLY 56 75261 1 CLUTCH ASSEMBLY 57 66480 1 AIR CLEANER 58 75269 1 ARMATURE ASSEMBLY 59 72361 1 BUSHING GOVERNOR SHAFT eo 72362 1 BUSHING GOVERNOR 61 70199
14. 22 22129 2 5 16 LOCK WASHER 58 51715 1 M4 0 7 HEX NUT 23 22259 2 5 16 18 HEX NUT 59 90157 1 DECAL CB RATING 30A 24 86316 1 PANEL SHEET METAL 60 90156 1 DECAL CB RATING 20A 25 53650 1 4 PIN CONNECTOR 61 89438A 1 DECAL CUSTOMER 26 20575 1 CONNECTOR CONNECTION 50 52 amp 55 27 765244 1 REMOTE HARNESS 89438B 1 DECAL CUSTOMER 28 66476 2 6 1 0 x 12MM CAPSCREW 66 70 amp 72 W LOCKWASHER 62 31791 1 CLAMP HOSE 29 86729 1 STARTER CONTACTOR 63 23897 2 M5FLAT WASHER 30 75476 3 M4 07 x16 LG CAPSCREW 64 74908 1 10 LONG TAPTITE 31 22264 4 M4LOCK WASHER 65 234845 1 BUSHING 32 65795 1 BATTERY CHARGE RECTIFIER 66 75763 A 1 BOOT BATTERY CABLE 33 90987 2 3 0 5 x 12 LG CAPSCREW EXPLODED VIEW ENGINE Drawing No 79216 EXPLODED VIEW ENGINE Drawing No 79216 EXPLODED VIEW ENGINE Drawing No 79216 R gt Uw NE N 5 24 Drawing No 79216 SCO ON OO RO O 0 ROP O 31 32 PART NO QTY DESCRIPTION 69331 m CYLINDER ASSEMBLY 69333 1 SLEEVE BEARING 30 DIA 67805 1 OIL SEAL 30 DIAMETER 79234 1 CYLINDER HEAD ASSEM NO 1 79235 1 CYLINDER HEAD ASSEM NO 2 70169 4 SEALING WASHER 69332 2 GASKET CYLINDER HEAD 72301 1 BREATHER ASSEMBLY 72315 1 GASKET BREATHER 70190 1 SCREW BREATHER 70596 1 TUBE BREATHER 69336 1 GASKET OIL SUMP 69325 8 BOLT CYLINDER HEAD 67888
15. 49 68548 62684 29289 75281 74027 43182 75237 77681 75474 90800 94670 75226 56893 75229 75227 79246 22473 72384C 4 2 2 Q Q o l c l c cA ADNa h A ua SPRING GEN SET MT NUT HEX M6 X 1 0 CAPSCR HEX HD M6 1 0 X 25 LONG 3 8 OIL DRAIN TUBE OIL FILL AND DRAIN CAP 8 DIPSTICK ASSEM O RING CAP O RING DRAIN PIPE OIL DRAIN ADAPTOR OIL FILTER SUPPORT FILTER OIL FRAM PH3614 10 PSI SWITCH OIL PRES FITTING 5 16 TUBE OUTER OIL TUBE INNER OIL ADAPTOR OIL PAD CAPSCREW HEX HEAD M6 1 00 x 30MM FITTING BARBED 90 5 16 GASKET OIL PAD LUG GROUNDING TAPE FOAM 1 16 x 1 2 SWITCH HIGH TEMP SCREW HEAD M3 0 50 LOCKWASHER M3 WASHER SPRING RETAINER CAP VINYL LOS 2 WIRE CAP VINYL 17D x 42L x 2H ELBOW EXHAUST CLAMP EXHAUST 1 1 8 COVER AIR SCREW CRIMPTITE 10 24 x 1 2 LONG SLIDE PAN GASKET SLIDE PAN CAPSCREW HEX HEAD M6 1 00 x 16MM W LOCK WASHER FLATWASHER M6 COVER EXHAUS EXPLODED VIEW ALTERNATOR Drawing No 92118 TO ENGINE GROUND REPAIR PARTS ALTERNATOR Drawing No 92118 QTY DESCRIPTION QTY DESCRIPTION 24 1 75995 1 LOWER BEARING CARRIER 34 86317 1 PANEL SUPPORT BRACKET 2 926056 1 ROTOR ASSEM 50 35 75235 4 5 0 8 x 30 LG CAPSCREW 77005G 1 ROTOR ASSEM 52 36 82737 4 VI
16. A INABILITY TO THINK COHER ENTLY VOMITING TWITCHING MUSCLES 0 THROBBING TEMPLES DIZZINESS F HEADACHE WEAKNESS AND SLEEPINESS IF YOU FEEL ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP STARTING IMPORTANT Read the vehicle manufacturer s instructions The owner operator should become familiar with the vehicle in which this generator is installed Differences exist between vehicles For example some vehicles may use a transfer switch to isolate dockside power from the generator while other vehicles may use an isolating receptacle Some vehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads To crank and start the generator engine proceed as follows 1 Turn OFF electrical loads using whatever means provid ed in your vehicle such as a main line circuit breaker or transfer switch NOTE you start the engine with the start stop switch on the generator control panel turn OFF loads by setting the panel s main breakers to their OFF or OPEN positions Electrical load circuits will be turned ON after the generator has started stabilized and warmed up 2 To crank and start the engine hold the start stop switch at START Release the switch when the engine starts CAUTION If the engine does not start after it has A been cranking for 15 seconds release the start stop switch and t
17. ALTERNATING CURRENT The voltage regulator also incorporates a voltage surge protection circuit This circuit prevents trouble some surges in the generator AC output voltage Voltage surge is a common cause of damage to elect tronic equipment 25 HOUR BREAK IN PERIOD The first 25 hours of operation are for breaking in the new generator Correctly breaking the genera tor is essential to minumize fuel consumption and pro vide maximum engine performance During this 25 hour break in period comply with the following Run the unit at varying electrical loads to help seat the engine piston rings properly For the 75 hours of operation after the break in period avoid light electrical loads Load the generator at 50 or more of its rated wattage capacity Repeated light loads during the break in period can cause improper seating of engine p ston rings which could cause blowby and high oil consumption During the break in period check engine oil level fre quently It is normal for oil consumption to be high during the breaking in period After the 25 hour break in period complete the tasks rec ommended under 25 Hour Check Up SPECIFICATIONS 25 HOUR CHECK UP After the 25 hour break in period contact an autho rized service facility for the following maintenance The vehicle owner is responsible for any charges Change engine cranckcase oil and oil filter Check all fluid levels
18. AMAGES EVEN IF SUCH DAMAGES ARE A RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential dam ages so the above limitation may not apply to you Buyer agrees to make no claims against Generac based on neg ligence This warranty gives you specific legal rights and you may also have other rights which vary from state to state generac corporation p o Box 8 hwy 59 and hillside road Waukesha WI 53187
19. BRATION MOUNT 77005G 1 ROTOR ASSEM 55 37 49813 4 M6 1 0 HEX NUT 770040 1 ROTOR ASSEM 66 38 49815 1 M5 08x 16 LG HEX 800950 1 ROTOR ASSEM 72 amp 70 CAPSCR 3 92604 1 STATOR ASSEM 50 39 43182 2 M3 LOCK WASHER 87844G 1 STATOR ASSEM 52 41 53623 1 C BREAKER 2 5A ON 50 52 878440 1 STATOR ASSEM 55 2 68 54502 1 C BREAKER 3 0A ON 66 70 878460 1 STATOR ASSEM 72 amp 70 42 67444 2 M5 SHAKEPROOF WASHER 4 73159 1 BALL BEARING 43 83049 1 REGULATOR VOLTAGE 5 31971 1 BALL BEARING 49226 6 M5 LOCK WASHER 6 72379 1 UPPER BEARING CARRIER 51716 4 M5 0 8 HEX NUT 7 77006 4 5 5 90144 1 C BREAKER 20A 50 52 8 55 8 52858 8 M8 1 25 FLANGE LOCK NUT 90145 1 C BREAKER 30A 66 70 8 72 9 66386 1 BRUSH HOLDER 47 90145 1 C BREAKER 30A ALL UNITS 10 66849 2 5 0 8 16 LG 48 25105 4 65 32 WILOCK WASHER SCREW 11 27756 4 NYLON WASHER 49 86315 1 PANEL COVER 12 86314 1 GENERATOR HOUSING 50 90734 4 M40 7 x 16 LG GAPSCR 1 75234 1 RESISTOR 3 M6 FLAT WASHER PATATE 51 22985 1 M4 FLAT WASHER 15 22097 5 M6 LOCK WASHER 16 74095 1 M6 1 0 x 60LG CAPSCREW 72 b Eh 17 90141 2 GROUND CABLE 2616 1r 18 22447 1 SHAKEPROOFLOCKWASHER 54 87798 19 74906 4 gt 1 0 x 20 LG TAPTITE 55 92113 1 SWITCH S P D T FUEL PUMP 20 92234 1 CONTROLLER P C B 56 75210A 1 TERMINAL BLOCK 21 10 74260 1 STARTER CABLE 57 23365 1 M4SHAKEPROOF WASHER
20. Corporation Warranty may provide a longer warran ty period Both the ECS Warranty and the Generac Corporation Warranty describe important rights and obligations with respect to your new engine Warranty service can only be performed by a Generac Corporation Authorized Service Outlet At the time of requesting warranty service evidence must be presented of the date of the sale to the original purchaser The purchaser shall pay any charges for making service calls and or for transporting the products to and from the place where the inspection and or war ranty work is performed The purchaser shall be responsible for any damage or loss incurred in connection with the trans portation of any engine or any part s thereof submitted for inspection and or warranty work IF YOU HAVE ANY QUESTIONS REGARDING YOUR WARRANTY RIGHTS AND RESPONSIBILITIES YOU SHOULD CONTACT GENERAC CORPORATION AT 1 800 222 3136 P EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1995 and Later Model Year Utility and Lawn and Garden Equipment ngines Applicability This warranty shall apply to 1995 and later model year utility and lawn and garden equipment engines The 5 Period ECS Warranty Period shall begin on the date the new engine or equipment is delivered to its origi nal end use purchaser and shall continue for 24 consecutive months thereafter B General Emissions Warranty Coverage Generac C
21. R SERVICE MANUAL To obtain a service manual for your generator order it from your dealer distributor or contact the factory Be sure to identify your units MODEL NUMBER and SERIAL NUMBER DRIVE BELTS The engine drives the generaor rotor by means of a pulley and drive belt arrangement The drive train drive belt and pulleys are warranted for the life of the generator Drive belt tension was properly adjusted before the unit was shipped from the factory If you suspect that drive belt tension is incorrect contact an authorized service facility 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 13 OUT OF SERVICE PROTECTION If you cannot exercise the generator every seven days and it is to be out of service longer than 30 days prepare the generator for storage as follows Start the engine and let it warm up While the engine is still warm from running drain the oil completely Refill crankcase with recommended oil See Specifications Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase Remove spark plug s and add about two or three table spoons of clean fresh engine oil into spark plug s threaded opening s Crank engine several times to dis tribute oil then install and tighten spark plug s Remove the battery an
22. SES 15 amp fuse is blown Loose corroded or defective battery cables Defective engine Start Stop switch Defective starter contactor Defective starter motor Low Battery Voltage Out of fuel Fuel pump is defective Open Wire 14 from Eng Control Bd Engine is flooded Spark plug defective Air cleaner plugged or damaged Defective spark plug Engine oil is low Engine is overheated Defective Low Oil Pressure System Defective Engine Control Board Defective Computer Control Board Defective Start Stop switch Open disconnected wire 18 between Start Stop switch and Engine Control Open disconnected wire 0 between Start Stop switch 8 Engine Control Bd Defective Engine Control Board Check circuit breaker Check vehicle circuit breaker amp fuses Transfer sw set to NORMAL position Generator internal failure REMEDY Replace 15 amp fuse Tighten or replace as necessary Replace Start Stop switch Replace contactor Replace starter motor Charge or replace battery Replenish fuel Replace fuel pump Reconnect wire Wait 5 10 min before trying Clean regap or replace plug Clean or replace as needed Clean regap or replace plug Check oil add as needed Check adequate ventilation Have serviced replaced Have board serviced replaced Have board serviced replaced Replace switch Reconnect or close wire Reconnect or close wire Replace board Reset to ON or CLOSED
23. Serial Number 3 kW Rating 4 Rated Voltage 5 Phase 6 Hertz MODEL NO F SERIAL NO J GENERATOR RPM FOR SERVICE CENTER LOCATION CALL 800 333 1322 24 HOURS A DAY GENERAC CORPORATION WAUKESHA WISC TABLE OF CONTENTS GENERAL SAFETY RULES inside cover IDENTIFICATION 1 READ THIS MANUAL THOROUGHLY Operation and Maintenance 3 How to Obtain Service 3 GENERATOR 4 GENERATOR FAMILIARIZATION Generator Applicability 5 Installation 3 cerent A 5 Safety coerente bra 5 Generator AC Connection System 5 OPERATING INSTRUCTIONS Generator Control 6 Optional Remote 5 6 Before Starting the Engine 6 eene rene 7 Stopping the Generator een 7 Applying Loads to 7 Don t Overload the 8 Wattage Reference 8 Automatic Low Oil Pressure Shutdown 9 Hig
24. Y INSTALLED IN COMPLIANCE WITH 1 ANSI 119 2 1975 NFPA 501C 1974 STANDARD FOR RECREATIONAL VEHICLES PART Ill INSTALLATION OF ELEC TRICAL SYSTEMS THE GENERATOR ALSO MUST HAVE BEEN INSTALLED IN STRICT COM PLIANCE WITH THE MANUFACTURER S DETAILED INSTALLATION INSTRUCTIONS AFTER INSTALLA TION DO NOTHING THAT MIGHT RENDER THE UNIT IN NON COMPLIANCE WITH SUCH CODES STANDARDS AND INSTRUCTIONS You can use your generator set to supply the follow ing electrical loads Q 55LP 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 5500 watts 5 5 kW of power but cannot exceed 45 8 AC amperes of current at 120 volts or exceed 22 9 AC amperes at 240 volts Q 70LP 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 7000 watts 7 0 kW of power but cannot exceed 58 3 AC amperes of current at 120 volts or exceed 29 1 AC amperes at 240 volts CAUTION Do not overload the generator Some installations may require that electrical loads be alternated to avoid overloading Applying exces sively high electrical loads may damage the gener ator and may shorten its life Add up the rated watts of all electrical lighting appliance too 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
25. aired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period Any warranted emissions related part which is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac Corporation according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions 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 Corporation Authorized Service Outlet 5 The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective provided that such diagnostic work is performed at a Generac Corporation Authorized Service Outlet 6 Generac Corporation shall be liable for damages to other original engine components or approved modifications proxi mately 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
26. and 500 Weed Trimmer M 500 Hand Drill 1 47 250 Hedge 450 Allow 2 1 2 times listed watts for starting these Impact Wrench 500 If a load does not show its rated wattage multiply that load s rated VOLTS times AMPS to obtain WATTS Induction type motors such as those that run the vehi cle s furnace fan refrigerator air conditioner etc need about 2 1 2 times more watts of power for starting than for running for a few seconds during motor starting Be sure to allow for this when connecting electrical loads to the generator First figure the watts needed to start elec tric motors in the system To that figure add the running wattages of other items that will be operated by the gen erator On a new generator do not apply heavy electrical loads for the first two or three hours of operation devices Zas AUTOMATIC LOW OIL PRESSURE SHUTDOWN The engine is equipped with a normally open N O oil pressure switch Figure 4 Engine oil pressure holds the switch open during cranking and operation Should oil pressure drop below about 8 10 PSI the switch contacts close and the engine automatically shuts down Figure 4 Switches for Engine Safety Shutdown HIGH TEMPERATURE SWITCH PRESSURE SWITCH HIGH TEMPERATURE SHUTDOWN An oil temperature switch Figure 4 with normally op
27. cient to meet the expected demand for such emission related parts 8 Any Generac Corporation 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 owner Such use shall not reduce Generac Corporation ECS warranty obligations 9 Unapproved add on modified parts may not be used to modify or repair a Generac Corporation engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac Corporation shall not be liable hereunder for failures of any warranted parts of a Generac Corporation engine caused by the use of such an unapproved add on or modified part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Carburetor assembly and its internal components 4 Catalytic muffler if so equipped a Fuel filter a Muffler gasket if so equipped b Carburetor gaskets b Exhaust manifold if so equipped c Fuel pump if so equipped 5 Crankcase breather assembly and its components 2 Air cleaner assembly a Breather connection tube a Air filter element b Intake pipe manifold 3 Ignition system including a Spark plug b ignition module GENERAC S THREE YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS Generac warrants to the original purchaser that its generators will be free from defects in materials or workman ship for the period set forth b
28. d store in a cool dry room on a wooden board Never store the battery on any concrete or dirt floor Clean and wipe the entire generator Shut off fuel supply RETURN UNIT TO SERVICE AFTER STORAGE To return the unit to service after storage proceed as follows Check tag on engine for oil viscosity and classification Verify that the correct recommended oil is used in engine If necessary drain and refill with proper oil Check battery Fill all cells to the proper level with distilled water DO NOT USE TAP WATER IN THE BATTERY Recharge battery to 100 state of charge or if defective replace the battery Turn OFF all electrical loads turn on fuel supply then start the engine Let engine warm up Apply electrical loads to at least 50 of the units rated wattage capacity When engine is thoroughly warmed up turn off electrical loads and shut it down THE GENERATOR IS NOW READY FOR SERVICE SERVICE DEALER LOCATION TO LOCATE THE NEAREST GENERAC SERVICING DEALER PLEASE CALL OUR 800 NUMBER ONLY DEALER LOCATIONINFORMATION CA BE OBTAINED AT THIS NUMBER 1 800 333 1322 14 TROUBLESHOOTING PROBLEM Engine won t crank Engine cranks but won t start Engine starts hard runs rough Engine starts shuts down when Start Stop switch is released Start Stop switch at Stop engine continues to run No AC output from generator POSSIBLE CAU
29. elow from date of original purchase During said warranty period Generac will at its option repair or replace any part which upon examination by Generac or Generac Authorized Distributors and or Dealers is found to be defective under normal use and service THREE YEAR WARRANTY SCHEDULE 1 All Q Series generators used in a recreational vehicle shall be warranted for a period of three 3 years or 2 000 hours of operation whichever occurs first All parts labor removal and reinstallation shall be covered for the first two years Parts and labor on selected generator and engine parts shall be covered during the third year or 2 000 hours whichever occurs first These selected parts are limited to the main Rotor and Stator with regard to the generator the Cylinder Block Cylinder Head Crankshaft Piston Valve Valve Lifter and Manifolds with regard to the engine The drive train belt and pulleys if so equipped on Q Series air cooled generators used in recreational vehicles shall be warranted against failure due to defective materials or normal usage for the life of the generator For the original owner this drive train warranty shall include parts an labor plus 50 00 payment upon return of the failed belt or pulley by the original owner For succeeding owners this power train warranty shall cover belt or pulley parts only Rental units demonstrators prime power or commercial applications such as construction utility are warra
30. emove carbon and combustion deposits from such mufflers remove the PLUG from the muffler and run the engine for about 15 minutes Shut engine down let the muf fler cool and install the plug WARNING BE SURE TO RE INSTALL THE PLUG A FROM THE MUFFLER TIGHTLY ENGINE VIBRATION COULD CAUSE A LOOSE PLUG TO FALL OUT WITHOUT THE PLUG IN PLACE HOT ENGINE EXHAUST IS DIRECTED OUT THE OPENING THIS HOT EXHAUST DEPENDING ON THE INSTALLA TION COULD BE DIRECTED TO AREAS NOT ABLE TO WITHSTAND THE EXTREME HEAT SUCH AS WOODEN FLOOR BOARDS OR OTHER FLAMMA BLE MATERIALS THIS COULD RESULT IN A FIRE CLEANING THE GENERATOR Keep your generator set as clean and dry as possible Dirt and moisture that are permitted to accumulate on electrical windings have an adverse affect on the insulation resistance of those windings Moisture that is allowed to remain in contact with windings will be retained in voids and cracks of the windings Dirt makes the problem worse since it tends to hold the moisture into contact with the wind ings Salt as from sea air worsens the problem since it tends to absorb moisture from the air The combina tion of salt and moisture makes a good electrical con ductor CAUTION Do NOT use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also conta minate the generator fuel system BATTERY All lead acid storage batteries will discharge when not in
31. en N O contacts is mounted near the oil filter oil temperature were to exceed a preset temperature the switch contacts close and the engine shuts down FIELD BOOST The Controller Circuit Board Houses a field boost diode and resistor which are not part of the automatic choke circuit These two components are part of a field Boost circuit Figure 5 During engine crank ing only a positive DC battery voltage is delivered through the diode resistor brushes and slip rings and to the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce the required pick up voltage in the stator windings Figure 5 Field Boost Circuit CLOSEST TO BEARING OVER VOLTAGE PROTECTION A solid state voltage regulator Figure 6 controls the generator s AC output voltage This regulator sup plies an excitation current to the rotor By regulating the rotor s excitation current the strength of its mag netic field is regulated and in turn the voltage deliv ered to connected electrcal loads is controlled When the AC frequency is 60 Hz voltage is regulated at 120 volts voltage to frequency ratio is 2 to1 Figure 6 Solid State Voltage Regulator E 22 SENSING 10 ROTOA CURRENT E 2 zen FROM STATOR EXCITATION WINDING
32. f Governor Mechanical fixed speed Engine Governed Speed 2500 rpm Air Paper element Starter iens 12 volts DC electric Ignition Solid state Recommended Spark Plugs Champion iP A RC12YC Dior R45S Fram A utolite 2 65 Spark Plug Gap 0 030 inch 0 8mm GENERATOR SPECIFICATIONS SERIES Rotor RPM Rotor Poles Engine RPM Rated Max Continuous AC Output Voltage Rated Max Continuous Current Phase Frequenc Weight Length Width Height Q 55LP 2 250 Q 70LP 3600 3600 2500 2500 120 7000 watts 7 0 kW 58 3 AC amps 1 60 Hertz 222 pounds 25 inches 18 5 inches 15 75 inches All units are reconnectable to 120 and or 240 volts dual voltage output Units are not listed per RVIA ANSI when reconnected for dual voltage output Rated maximum continuous current at 240 volts is 22 9 amps Rated maximum continuous current at 240 volts is 29 1 amps 10 m This section includes information about simple main tenance which includes the following tasks Checking engine oil level Changing engine oil Changing filter Changing the air cleaner Cleaning the air intake screen Cleaning spark plugs CHECKING ENGINE OIL LEVEL Check engine crankcase oil level at least every eight h
33. f all scheduled maintenance As the recreational vehicle generator engine owner you should however be aware that Generac Corporation may deny you warranty coverage if your recreational vehicle generator engine or a part thereof has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your recreational vehicle generator engine to a Generac Corporation Authorized Servic Outlet as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceea 30 days Warranty service can be arranged by contacting either a Generac Corporation Authorized Service Outlet or by contacting Generac Corporation at GENERAC CORPORATION PH 414 544 4811 P O BOX 8 414 544 0179 WAUKESHA WI 53187 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 Corporation pursuant to California law See also the Generac Corporation Limited Warranties for Generac Corporation which is enclosed herewith on a separate sheet and also is provided to you by Generac Corporation The ECS Warranty applies only to the emission control system of your new engine To the extent that there is any conflict in terms between the ECS Warranty and the Generac Corporation Warranty the ECS Warranty shall apply except in any circumstances in which the Generac
34. first 25 hours of operation every 100 operating hours thereafter Turn oil filter counterclockwise to remove Figure 9 Figure 9 Replacing Engine Oil Filter TO LOOSEN Coat gasket of new filter with engine oil Turn new filter clockwise until its gasket contacts tightly with the filter adapter Then tighten with an additional 3 4 to one turn by hand Run engine and check for leaks NOTE Check oil level and fill to full mark after checking for leaks Filter will retain some oil ee CLEAN AIR INTAKE SCREEN Clean all foreign material from the air intake screen Figure 10 at lease 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 10 Areas to Clean on Air Intake Screen CLEAN AREA ENGINE AIR CLEANER Clean and re oil the foam pre cleaner every three months or every 25 hours of operation whichever occurs first Service the foam pre cleaner more fre quently if you operate the generator in extremely dusty or dirty conditions Figure 11 Turn KNOB counterclockwise to loosen Remove COVER FOAM PRE CLEANER AND PAPER FILTER Remove foam pre cleaner from cover Wash foam pre cleaner in liquid detergent and water PAPER FILTER Wrap foam pre cleaner in a cloth and squeeze dry Saturate foam pre cleaner in e
35. h Temperature 9 Over Voltage Protection 9 25 Hour Break 9 SPECIFICATIONS 25 Hour Check 10 Operation in High Grass or 10 Fuel Requirements eee 10 Engine Oil 5 10 Engine Specifications seen 10 Generator Specifications 10 MAINTENANCE Checking Engine Level 11 Change Engine 2 2 2 2 11 Change oil filter seen 11 Clean Air Intake 5 12 Engine Air Cleaner esee 12 Engine Spark Plugs eee 12 Spark Arrestor Muffler 13 Cleaning the 13 BAI Yi ge UOTE tes rente AJ 13 Major Service 13 o Z AO 13 Exercising the 13 Out of Service Protection Lise vats 14 Return the Unit to Service after Storage 14 TROUBLESHOOTING eee 15 ELECTRICAL DATA
36. lowing Points out important safety information and if not followed could endanger personal safety and or property of yourself and others 4 Potential explosion hazard A fire hazard Potential electrical snock hazard P The operator driver is responsible for proper and safe use of the vehicle equipment on the vehicle and the safety of all vehicle occupants We strongly rec ommend that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked by an Authorized Dealer periodi cally Normal maintenance service and replacement of parts are the responsibility of the Owner Operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your industrial mobile generator assures a minimum number of prob lems and keeps your operating expenses at a mini mum See your authorized Dealer Distributor for ser vice aids and accessorie
37. ngine oil Squeeze to remove excess oil and to distrubute Install foam pre cleaner into cover followed by paper filter Tabs at edges of paper filter must lock into slots on cover Insert bottom locking tab of cover into slot Install cover foam pre cleaner and paper filter ENGINE SPARK PLUG Clean engine spark plug and set gap to 0 030 inch 0 76mm every 100 hours of operation Figure 12 Clean by scraping or wire brushing and washing with solvent DO BLAST CLEAN SPARK PLUG CAUTION Sparking can occur if wire terminal does not fit firmly over spark plug terminal end If necessary reform wire terminal to obtain a tight fit Figure 12 Setting Spark Plug Gap SET PLUG GAP AT 0 030 inch GOVER 12 4 SPARK ARRESTOR MUFFLER 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 maintaining spark arrestor exhaust mufflers contact your nearest authorized service facility Exhaust mufflers supplied by Generac are spark arrestor types Generac exhaust mufflers for RV gen erators do not have a spark arrestor screen but are the more efficient toroid or swirl type To r
38. nt ed for 1 one year or 2 000 hour whichever comes first warranty expense allowances are subject to the conditions defined in the published GENERAC POLICIES AND PROCEDURES manual THIS WARRANTY DOES NOT COVER Costs of maintenance installation and startup Failures due to a normal wear and tear from GN engine or b accident misuse abuse negligence or improper installation e Products which are modified or altered in a manner not authorized by Generac in writing incidental consequential indirect damages caused by defects in materials workmanship or any delay in repair or replacement of defective parts Failure due to misapplication Telephone telegraph teletype or other communication expenses Living or travel expenses of persons performing service Any and all transportation travel expenses Rental equipment used while warranty repairs are being performed Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO 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 PARTS AS STATED ABOVE IN NO EVENT SHALL GEN ERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL D
39. on will warrant the emission control system on your recreational vehicle generator for the periods of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your recreational vehicle genera tor engine Your emission control system may include parts such as the carburetor ignition system and exhaust system Also included may be the compression release system and other emission related assemblies Where a warrantable condition exists Generac Corporation will repair your recreational vehicle generator engine at no cost to you for diagnosis parts and labor MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1995 and later model year utility and lawn and garden equipment engines are warranted for two years as hereinafter noted If during such warranty period any emission related part on your engine is defective in materials or workmanship the part will be repaired or replaced by Generac Corporation OWNER S WARRANTY RESPONSIBILITIES As the recreational vehicle generator engine owner you are responsible for the performance of the required maintenance listed in your owners manual Generac Corporation recommends that you retain all receipts covering maintenance on your recreational vehicle generator engine but Generac Corporation will not deny warranty solely due to the lack of receipts or for your failure to provide written evidence of the performance o
40. orporation warrants to the original end use purchaser of the new engine or equipment and to each subsequent purchaser that each of its utility and lawn and garden equipment engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pur suant to its authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period will cause a warrant ed emissions related part to fail to be identical in all material respects to the part as described in the engine manufac turer s application for certification C The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts which 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 Corporation according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period Any warranted emissions related part which 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 rep
41. ours of operation or before each use Figure 7 Figure 7 Oil Dipstick and Fill Tube Be sure the generator is as level as possible Remove oil dipstick and wipe dry with clean lint free cloth Install and tighten oil dipstick then remove again Oil should be at dipstick FULL mark necessary add the recommended oil to the FULL mark only DO NOT FILL ABOVE FULL MARK Install and tighten oil dipstick cap before operating the engine NOTE See Engine Oil Requirements on Page 10 for recommended oils CHANGE ENGINE OIL Change engine oil after the first 25 hours of operation after the 25 hour break in period rage 9 Thereafter oil every 50 operating hours Change oil more frequently if operating consistently under heavy load or at high ambient temperatures Warm up engine for at least five minutes then shut down MAINTENANCE With engine still warm from running clean area around oil drain plug and remove oil drain plug Figure 8 Drain oil completely into a suitable container Figure 8 Location of Drain Plug When oil has drained install and tighten drain plug Remove oil dipstick and fill crankcase with the recom mended oil See Page 10 The engine crankcase can hold about 1 quart 950ml DO NOT FILL ABOVE FULL MARK Install and tighten dipstick cap before operating engine CHANGE OIL FILTER Replace the engine oil filter after the
42. outine maintenance If the grounding conductor must be replaced use only a flexible con ductor that is of No 8 AWG copper wire minimum In case of accident caused by electric shock shut down the source of electrical power down at once If this can not be done free victim from live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a dry board dry rope or other n n conducting implement to free the victim from live conductor Inspect fuel system frequently for leaks or dam age Repair or replace any damaged or leaking component immediately Never attempt to change alter or modify the generator fuel system in an way that might affect safety or compliance wit applicable codes and standards The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentra tions can cause unconsciousness or even death This exhaust system must have been properly installed in strict compliance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in non compliance with such codes and standards The generator compartment must be completely vapor sealed from vehicle interior There must be no possibility of exhaust fumes entering the vehi cle interior Never operate this equipment with a leaking or defective exhaust system Never use the generator or any of its parts as a step Stepping on the unit can s
43. r arret it terere 1100 Coffee Maker essen 1000 Oil Bumer on 300 Compressor 1 HP 2000 Oil Fired Space Heater 140 000 Btu 400 Compressor 3 4 HP 1800 Oil Fired Space Heater 85 000 Btu 225 Compressor 1 2 1400 Oil Fired Space Heater 30 000 Btu 150 Curling noi 700 Paint Sprayer Airless 1 3 HP 600 Deep Freeze 500 Paint Sprayer Airless handheld 150 Disc Sander 97 essen 1200 Eda 50 to 200 Edge Trimmer eese 500 Refrigerator 600 Electric Nail Gun 1200 9 69 09 200 Electric Range one element 1500 Submersible Pump 1 1 2 HP 2800 Electric Skillet 1250 Submersible Pump 1 2000 Furnace Fan 1 3 HP 1200 Submersible Pump 1 2 HP 1500 Hair asik 1200 SUMP E 600 Hand Drill 4 1100 Table Saw 107 REA 1750 to 2000 Hand Drill 1 2 750 to 1000 TEIEVISION swa adi 200 to 500 H
44. ry again Holding the switch for longer than 15 seconds may damage the starter motor 3 Let the engine run at no load for a few minutes to stabi lize and warm up the engine 4 Turn ON electrical loads using whatever means provided such as a main circuit breaker or transfer switch NOTE If you start a warm generator engine you may press the start switch slightly to engage the gomon system However you should press and hold the starter switch for a minimum of two 2 seconds to energize the field boost system If you start the engine without AA the field boost system the generator produces no AC output STOPPING THE GENERATOR 1 Turn OFF all electrical loads using whatever means pro vided such a main circuit breaker or transfer switch 2 Let the generator run at no load for a few minutes to sta bilize internal engine generator temperatures 3 Place Start Stop switch in its STOP position APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Before applying electrical loads let the generator stabilize and warm up for a minute or two DO NOT overload the generator M LETTING ENGINE STABILIZE The generator supplies correct rated Paa and voltage only at the proper governed speed Some electrical appliances may be extremely sensitive to voltage and frequency Incorrect frequencies and or voltages can damage those appliances If electrical load
45. s HOW TO OBTAIN SERVICE When your industrial mobile generator set requires servicing or repairs simply contact an Authorized Service Facility for assistance Service technicians are 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 complete model number and serial number of your unit as given on its data plate The warranty on your generator is included in this Owner s Manual as well as listings for repair parts GENERATOR FEATURES REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake Screen 2 Engine Start Stop Switch 3 15 amp Fuse 4 20 or 30 amp Circuit Breaker 5 Optional Remote Panel Receptacle 6 Generator AC Output Leads T 8 9 10 11 12 30 amp Circuit Breaker Starter Contactor Fuel Pump Primer Switch Oil Filter Oil Drain Plug Oil dipstick and filler Tube GENERATOR FAMILIARIZATION GENERATOR APPLICABILITY These generators have been designed and manufac tured for supplying electrical power for recreational vehicles You should not modify the generator or use it for any application other than for what it was designed 1f there are questions pertaining to its application write or call the factory Do not use the unit until you have been advised by a competent authority DANGER FOR FIRE SAFETY THE GENERATOR MUST HAVE BEEN PROPERL
46. s are applied at reduced speeds such loads imposed the engine when suf ficient power is not available may shorten engine life Never turn ON electrical loads until after the genera tor engine has started and stabilized ON speed T 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 1 Applying electrical loads in excess of the unit s rated capacity will cause the engine generator to automati cally shutdown To avoid overloading add up the wattage of ali con nected electrical lighting appliance tool and motor loads This total should not be greater than the gener ator s rated wattage capacity Most lighting appliance tool and motor loads indicate their required watts on their nameplate or data plate For light bulbs simply note the wattage rating of the bulb WATTAGE REFERENCE GUIDE RUNNING RUNNING WATTS WATTS Air Conditioner 12 000 1700 Jet PUMP nee aee rete eh d 800 Battery Charger 20 500 Lawn 1200 Belt Sander 9 neces 1000 Light Bulb za entero nre t eere 100 ueterem Fn 1200 Microwave Oven 2 4 00400 700 Circular Saw 6 12 800 to 1000 Milk Coole
47. s consist of two separate breakers with a con necting piece between the breaker handles so that both breakers will operated at the same time If the unit is reconnected for dual voltage it is no longer RVIA listed Figure 2 Typical Control Panel FUSE MAIN STOP FUEL PRIMER OPTIONAL REMOTE START STOP PANEL Optional remote mounted panels are available which permit you to crank and start the generator from any convenient location in the recreational vehicle Figure 3 shows the model 9042 remote panel which includes a start stop switch and b a generator run lamp Figure 3 Optional Remote Panel Model 9042 GENERATOR GEN RUN STOP START You can also order Model 9043 a remote panel which includes the a start stop switch b the gener ator run lamp and c an hourmeter The hourmeter provides a continuous indication of engine generator operating time Use the hourmeter for checking of periodic maintenance requirements on the unit BEFORE STARTING THE ENGINE IMPORTANT INSTRUCTIONS AND INFORMATION IN THIS MANUAL ASSUME THE GENERATOR HAS BEEN PROPERLY INSTALLED CONNECTED SERVICED TESTED AND ADJUSTED BY A QUALI FIED INSTALLATION TECHNICIAN OF INSTALLA TION CONTRACTOR INSTALLATION Generator installation must have been properly pleted so it complies with all applicable codes stan dards and regulations and with the manufacturer s recommendations ENGINE LUBRICATION
48. tress and break parts and may result in dangerous fuel leakage oil leakage etc Do not smoke around the generator Wipe up any fuel and oil immediately Never leave oily or fuel soaked rags in the generator compartment or on the generator itself Keep the area around the generator Clean and free of debris Adequate ventillation is required to expel toxic fumes and fuel vapors from the generator com partment Do not alter the installation of this equip ment in any manner that might obstruct air and ventillation openings Such openings must be kept clear and unobstructed Keep hands feet clothing etc away from drive belts fans and other moving parts of this equip ment Never remove any drive belt or fan guards while the unit is operating Inspect the pln periodically Repair or replace all damaged or defective parts immediately These generators use LP gas propane as a fuel Liquid Propane gas is AA XPLOSIVE 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 paton post indicated by a NEGATIVE or first Reconnect that cable last IDENTIFICATION RECORD Please record the following information from the generator DATA PLATE or information decal 1 Model Number 2

GE A4021 User's Manual

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