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1. BH1 NOTE ALL WIRES 18 AWG 16 1 16 300V UL LISTED UNLESS au eel mw SHOWN OTHERWISE SP4 17 17 WS SIZE SP2 18 18 SP9 14 REL 14 17 1 Sw1 r 18 r 14 HM 11A 22 33A amp 44 TO TS 10 SP7 150 56 150 ARE 600V UL LISTED PHC 13 KE 13 18 io sae ko 14 poe 33 SP8 1 11 BH2 12 mo 16 5 16 12 WIRE LEGEND 15A za X COLOR FUNCTION WIRE 5 855 WHITE NEUTRAL 0 1 22 44 SW2 RED NON FUSED DC 4 15 6 45 ORANGE FUSED DC 1415 150 BROWN CONTROL 17 18 157 18 BLUE SIGNAL SENSING 11 56 85 150 162 BLACK AC MISC 13 157 10 33 11 o COMPONENTS LOCATED IN Bb 10l 114 VOLTAGE REGULATOR COMPARTMENT W 22 se 10 44 1 120 S a 19 O0 TS 72 72 T3 xo o _ 44 GND 61 GND1 10 334 12 10 12 22 1 22 44 44 2 N 77 16 1 18 5 120
2. EP THEO TER RCM COMPONENTS LOCATED IN CUSTOMER REMOTE ENGINE CONTROL CONNECTOR 4 Ean lt 17 D gt 18 18 1 5 cm lt 150 SP7 i lt 6 15 5 1 REAR 14 T m mS 7 75 27 257 o 7 915 ECU x ino SP1 18 p 18 1 16 2 16 BH1 1 15 15 53 15 T BCR 2 15 14 lt 14 85 65 85 19 157 amp 1g 157 56 4 amp 56 127 145 17 CB1 44 44 lt 44 COMPONENTS LOCATED ON ENGINE 0 1 BLK HWT SP5 r 14 85 T LOS 85 85 Q 0 0 4 SP6 14 ENS 0 14 R2 SP9 14 BH1 6 120 240 C u DUAL VOLTAGE ve PAGES 3 amp 4 13 16 13 4 157 15 7 3 13 gt 10 9o HEE 8 T GP GP GP 150 BH1 10 150 4 BH1 11 41 16 4i SM 16 m WRE LOCATING no e SLE x LK ON GROUND BAR GND BATTERY AVR F 1 ALT 1 CUSTOMER PROVIDED RI 0 GND1 5 4 BHI 2 0
3. METAL LINED Y2 INCH THICK BASE 1 TUBULAR METAL E SUPPORT FRAME E gt 4 GRADE 5 BOLTS METAL LINED VEHICLE BOTTOM CHASSIS 2 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compartment that the installer constructs the compartment must meet certain spec ifications as outlined in the following sections 2 2 1 COMPARTMENT CONSTRUCTION The generator compartment should be either con structed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum s low melting point If the compartment is lined with galvanized steel it may be constructed of any material The manu facturer recommends that the compartment be constructed of 1 2 inch thick plywood not strand board with the floor made of a double thickness of 1 2 inch plywood having the grain of the wood at cross section for added strength Figure 2 3 INSTALLATION Section 2 Installation Recreational Vehicle Generator Figure 2 3 Typical Compartment Construction CROSS SECTION VIEW METAL LINING Epis di FIREPROOF dn j SOUND INSULATION Be METAL LINING
4. ag lt 391 53 INUSJ 2E T3NVd 30935 AVIA L2 S281 L 0S 221 1456 eee f T 8 I 137110 15 lt lt Lette 1 2 o L 00 223 6 EES S S 8SS i 225 A 9 9 L8E TU o 9 682 91112 o i w S LI9YT 58 5 _ 974 v1 E Nivad 1491005 S410H ONILNNOW 91 8 821 5 581229 InDUNVv312 1 061 t9 5 SA3NOS 20153449 66 lt gt JAILYDIN gt 5 7 8 SAJNIS N3AD NOLLOANNOD 1198 L201 LAG 9E 626 92 a 57 521 0566 JALLISUd LLL m c L2T9 NOILIANNOD AXILLYE E 9 o S Ole 55322 1991819373 4 1 1 1 9 5 E b LOTT lt 682 45 53825 ASAT 5 4 168121 L28 2 09 d 1 123 02 310W38 865 aava 1112412 9 193 35 1 5 dWv ISNA 4 i f Ct 5 0 201 HOLIMS 14915 4 18 A ddns 313043 Nanl3a8 7304 TESK CLINGNOD LHOLL CINOIT 2115410 ID THa LNW 1009 SS3NNVH YaMOd OV Tu 710 8313 28 11 l S
5. HOURMETER START STOP SWITCH START STOP EN 5 5 LINE BREAKER LINE pl FUSE BREAKERJL ION ON 15 PREHEAT 30 SEC NOTE PANEL SHOWN WITHOUT WEATHER SEAL BOOTS Section 2 Operation OPERATION Recreational Vehicle Generator ix 2 1 1 HOURMETER This indicates the length of time the engine generator has operated in hours and tenths of hours Use the hourmeter to ensure that the periodic maintenance tasks for the generator are completed on a timely basis 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 s center position is the RUN position 2 1 5 FUSE 15 amp fuse protects the engine s DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine can not be cranked If the fuse must be replaced use only an identical replacement i e AGC 15 caution If a fuse element melts find the cause of the overload before replacing the fuse 2 1 4 LINE BREAKER The line i e main breaker protects the generator s AC output circuit against overload and provides a method of turning OFF the generator s 120 240 volt AC output to the
6. 44 Section 6 Exploded Views and Parts Lists CG urs Recreational Vehicle Generator Engine Alternator Drive and Starter Assembly Drawing No 0G7350 B 0 0 5598 0 9674 0 6055 0 6054 031971 073159 066386 066849 0 6862 063168 0G67720ST03 0G69990ST03 0C8646 0C5298A 020692 0C4841 073106G 0C6363 051730 071956 022129 045771 040250 0C7933 068485 051769 0C4537 022304 023316 049451 042633 046526 052212 069673J 051756 049813 043107 0C2417A 039253 0A1658 067989 0C1069 0G2321 049808 055934D 0A7043 0C8644 024426 048705 022145 0F4354 022097 042568 022237 Sk K NS NS 6 O0 lx u Sy M Eo lx c ro BEARING CARRIER FRONT BEARING CARRIER UPPER ROTOR ASSEMBLY STATOR ASSEMBLY BEARING 6205 2NSE C3 E SRI2 5 BALL BEARING BRUSH HOLDER SCREW HHTT M5 0 8 X 16 SCREW HHC 8 1 25 X 324 G8 8 WASHER LOCK SPECIAL 5 16 LUG LIFT RV DIESEL RAIL RH ENGINE PULLEY 4 5 FLAT BELT V RIB POLYESTER STARTER MOTOR SPACER STARTER PULLEY ALTERNATOR FLYWHEEL ASSEMBLY SCREW HHC 8 1 25 X 60 G8 8 WASHER VIBRATION ISOLATOR WASHER SPLIT LK M8 NUT HEX M8 1 25 G8 CLEAR ZINC SCREW SHC 5 16 18 X 1 5 98 8 Z GUARD FLYWHEEL SCREW HHC M12 1 25 X 20 08 8 WASHER LOCK M12 ENGINE BRACKET WASHER FLAT 1
7. 4 o Bl ep S 17 40 yi 18 18 BH1 5 330 eS 150 5 7 D 6 i ua Y REAR 6 14 EX DOWNIE uds SUP pi D ME bbs Ten o __ 17 BH1 01 z 17 BH1 4 ECU lt s 0 B BH2 D SP lt lt 18 18 _ 16 2 16 BH1 1 15 a 15 53 15 dressa BCR 2 15 14 2 14 85 85 1 157 14 157 6 56 11 56 17 62 17 CBI 11 11 11 COMPONENTS LOCATED ON ENGINE 1 BLK HWT SP5 14 8 85 85 85 Se Los 0 0 14 Se 14 0 SP9 14 BH1 6 120 VAC ee 4 ONLY E PAGES 1 amp 2 _ 13 d E 6 13 157 F o 1 13 ERAS 13 Pos 157 10 9 Mz HRE 8 HOO GP GP GP SP7 150 BH1 10 150 CON 4 BH1 11 41 16 SM 16 WIRE LOCATIONS MAY CHANGE rayo ii yg ow ON GROUND BAR GND UT AVR F 1 TEES ALT 1 CUSTOMER PROVIDED RI 0 GND1 NM ELLE ME MS PAGE 1 OF 4 BH1 2 0 CON 1 0 Section 5 Electrical Data Recreational Vehicle Generator ELECTRICAL Wiring Diagram 120 VAC Drawing No 0G7333 D Page 2 of 4 4 COMPONENTS LOCATED CONTROL PANEL
8. STARTER GRD CABLE 17 ITEM PART NO QTY _ DESCRIPTION ITEM PART NO QTY _ DESCRIPTION 1 0D2126 1 Base Frame Weldment 13 022097 3 Washer Split Lk 1 4 M6 2 0D2131 1 Door Service Rear 14 043146 2 HHCS 6 1 00 x 10 3 0C5088 1 Door Service Front 15 0C7561 1 Carriage Bolt 3 8 16 x 55mm 4 0C5644 4 Slide Latch Flush 16 044456 1 3 8 Special Lock Washer 5 056326 2 Vinyl Trim Black 180mm 17 0C7968 3 Hex Nut 3 8 16 Brass 6 029451 1 Rubber Tape 1 8 x 12 26 6 LG 18 047411 2 HHCS M6 1 00 x 16 0 7857 4 Grommet 1 8 x 13 32 19 049813 2 Nut Hex M6 0 1 0 8 070936E 4 Vibration Mount 20 005443 1 Block Terminal Battery Post 9 006721 1 Gasket Cleanout 21 007423 1 STUD 3 8 16 X 2 1 4 BRASS 10 006722 1 Plate Cleanout 22 022131 1 WASHER FLAT 3 8 M10 ZINC 11 042907 8 HHCS 8 1 25 x 16 23 022237 1 WASHER LOCK 3 8 12 022129 8 Washer Split Lk M8 24 022473 2 WASHER FLAT 1 4 M6 ZINC 5a ITEM PART NO QTY DESCRIPTION gt WELDMENT CONTROLLER BOX BLOCK MARATHON 4 POS 600V ASSY PCB POTTED REG W FIN RES WW 20R 5 15W QK CONN ASSY MARINE CNTL BRD RECTIFIER BATT CHARG BRK 5 1 ETA 46 500 TAPE UL PERMACEL P247 1 0 SCREW 5 0 8 X 30 BP SCREW HHTT 5 0 8 X 16 WASHER LOCK 8 4 NUT HEX 4 0 7 G8 YEL CHR PCB SUPPORT SNAP IN 1 4 SCREW 3 0 5 12 BP ek cO 0G71570ST03 071914 0830490SRV 0 5752
9. LI VAPOR SEALED PLYWOOD ATALLTIMES METAL LINING e 2 If constructing compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel All seams splices and joints of the compart ment walls unless vapor tight by design should be caulked to prevent poisonous flammable or explosive vapors from entering the vehicle interior NOTE Caulking must be done so that the caulking mate rial will stay in place permanently Pressing mate rials such as putty tape onto joints and seams is NOT acceptable A high quality silicone rubber base sealant is recommended Holes and openings made in the compartment walls to allow for the passage of electrical conduit conductors hoses cables etc into the vehicle liv ing area must be sealed vapor tight with silicone rubber base sealant Ifa flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartments electrical junction box NOTE Flexible metal conduit due to its unique construc tion is NOT vapor tight along its entire length INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator Seams and joints of the galvanized steel whether used as a liner or for the compartment itself must be lapped and mechanically secured Such seams may be manufactured welded bolted riv
10. 26 2 4 Diesel Fuel SySteti 2 ettet 27 2 5 Exhaust SyStem aa ohh ete entere noa ena 29 2 6 Electrical Connections eese 30 2 7 Battery nstallati ni tette 2 8 Optional Accessories Section 3 Post installation Startup Checks 35 3 1 Post Installation Tests 2 35 3 2 Before Initial Startup 3 9 Initial SUE ee Der eoe epit 3 4 Testing Under 3 5 Installation Checklist Section 4 Troubleshooting 37 4 1 Troubleshooting Guide 37 Section 5 Electrical 38 Section 6 Exploded Views and Parts Lists 44 Section 7 68 SAFETY RULES Safety Rules Recreational Vehicle Generator SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe N operation be copied and posted in potential hazard areas of the recreational vehicle Safety should be stressed to all operators and potential operators of this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state o
11. ONLY DOR o i D E DPE SEN AGES 1 amp 2 BCR UAN L 02 1 GND SP3 14 34 R2 6 4 200 SP10 4 6 INJINI 22 11 ALTERNATOR CONNECTIONS LEGEND ALT ALTERNATOR GP GLOW PLUG AVR AUTOMATIC VOLTAGE REGULATOR HM HOUR METER BCR BATTERY CHARGE RECTIFIER HWT HIGH WATER TEMP SWITCH BH_ BULKHEAD CONNECTOR LOS LOW OIL PRESSURE SWITCH MAIN CIRCUIT BREAKER PRE HEAT CONTACTOR CB2 FIELD CIRCUIT BREAKER R_ RESISTOR CON CUSTOMER REMOTE CONNECTOR SC STARTER CONTACTOR 0_ DIODE SM STARTER MOTOR ECU ENGINE CONTROL UNIT SP_ SPLICE F1 FUSE SWI AUTO MANUAL SWITCH FP FUEL PUMP SW2 PRE HEAT SWITCH FS FUEL SOLENOID TS TERMINAL STRIP GND GROUND o GND PAGE 2 OF 4 41 Section 5 Electrical Data Recreational Vehicle Generator ELECTRICAL _ s Wiring Diagram 120 240 Dual Voltage Drawing 0G7333 D Page 3 of 4
12. 0709390305 1 SNAP RING 0F28730194 1 O RING 0709390307 1 SPRING 0709390308 1 WASHER 0G23210149 2 NUT 0709390310 1 STOP LEVER 0F28730195 5 BOLT 0F28730180 3 BOLT 0F28730150 2 BOLT 022129 4 WASHER LOCK 8 5 16 0709390314 2 COVER 0G23210151 1 GASKET 045771 4 NUT 0709390660 1 O RING 0709390313 1 SPRING 0F28730199 1 SPRING 0 488805703 1 BRACKET FUEL FILTER BLACK 051730 3 SCREW HHC 8 1 25 X 60 G8 8 052265 1 SCREW HHC M8 1 25 X 65 G8 8 65 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 1 0 Liter Diesel Injector Pump Drawing No 0G7507 A 0G23210133 0F28730201 0 28730173 0F28730202 0F28730203 0G23210134 0F28730205 0G23210135 0G23210136 0G23210137 0G23210138 0G23210139 N INJECTION PUMP ASSEMBLY ADJUSTING SHIM SET NUT BOLT GASKET INJECTOR ASSEMBLY COMPLETE RETURN PIPE COMPLETE INJECTION PIPE COMPLETE INJECTION PIPE COMPLETE INJECTION PIPE COMPLETE CLAMP BOLT 0F28730173 0F28730209 0F28730210 0G23210140 0F28730214 0709390264 0709390343 0F28730212 0F28730176 0F28730213 0C4736 NUT GLOW PLUG NUT CONNECTOR GASKET BOLT SEAL WASHER SCREW SEAL WASHER FOR THERMO SWITCH SOLENOID COVER Section 6 Exploded Views and Parts Lists CG urs Recreational Vehicle Generator 1 0 Liter Diesel Fuel Supply Drawing No 0G7508 A 14 To Fuel 19 Model 0
13. For safety reasons the manufacturer recommends that the installation initial startup and main tenance of this equipment be performed by an Authorized Service Dealer The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentra tions can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coherently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weak ness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired Never sleep in the vehicle while the genset is run ning unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area The engine exhaust fumes contain carbon mon oxide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Thus the exhaust system must be installe
14. GUARDIAN by Generac Power Systems Inc Owner s Manual and Installation Instructions Liquid cooled Recreational Vehicle Generator Model 005432 0 QUIETPACT 85D This manual should remain with the unit INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc This model is designed and man ufactured to supply electrical power for recreational vehicles READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Authorized Service Dealer for start ing operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert per sonnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows DG A After this heading read instructions that if not strictly complied with will result in serious person al injury including death or property damage warninc amp After this heading read instructions that if not strictly complied with may result in personal inju ry or property damage caution amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that
15. ee eg E Sk LX E24 ck cx olx L4 LL X 2L X x X ENCLOSURE PANEL RH WELDMENT ENCLOSURE PANEL TOP ENCLOSURE PANEL LH ENCLOSURE PANEL FRONT ENCLOSURE PANEL REAR WELDMENT INSULATION FRONT PANEL INSULATION LH SIDE PANEL INSULATION RH SIDE PANEL INSULATION TOP FRONT PANEL INSULATION TOP REAR PANEL INSULATION LIFT LUG COVER COVER ACCESS LIFT LUG COVER RADIATOR FILL COVER ELECTRICAL ACCESS GASKET COVER ELECT WASHER SELF LOCKING 1 DIA 12GA SCREW SWT 1 4 20 X 5 8 W W FRAME CONTROL PANEL BLACK DECAL BATTERY DECAL RADIATOR CAP DECAL REMOTE DECAL COOLANT DECAL FUEL RETURN SUPPLY DECAL OIL FILL LEVEL DECAL LIFTING LUG DECAL MAX HOT MIN COLD DECAL WARNING RV SUPPORT COOLANT TANK NUT TOP LOCK FL M6 1 0 FOAM AIR DUCT FACE FOAM AIR DUCT SIDE DECAL RV 8500 WATTS DIAM PL DATA DECAL RV 52X90 DATA ENGINE DECAL CAL DECAL U S TESTING RVIA CSA CLAMP VINYL 1 5 X 281 Z DECAL ULTRA LOW SULFER DIESEL 47 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Cooling System Drawing No 0G7352 A 3015 3 NO SI WvO3 S31V1S 3015 YVAN NO SI WvO3 S31V1S S 0 LISTS PARTS 0 5971 15 8 26 SS TNI 96 8l ANOYOL Wall LYVHO SNOILVOISIOAdS 300801 Section 6 Exploded Views and Parts Lists ey LISTS Recreational Vehicle Generat
16. 9 1 12 2 ITEM PART NO _ DESCRIPTION ITEM PART NO QTY _ DESCRIPTION 1 0G23210152 1 OIL PAN 14 0F28730143 1 HEAD COVER 2 0709390140 20 BOLT 15 0F28730144 1 OIL STOPPER 3 0G23210153 1 BOLT 16 0709390186 1 SCREEN 4 0F28730176 1 SEAL WASHER FOR THERMO SWITCH 17 0F28730145 4 SCREW 5 006451 1 DIPSTICK TUBE 18 0F28730146 3 GASKET 6 0D7124 2 O RING 19 0F28730147 3 CAP NUT 7 0F28730117 1 BOLT 20 0709390188 1 CAP 8 0F28730114 1 GASKET OIL PAN 21 0709390189 1 O RING 9 0F28730167 1 O RING 22 0F28730148 1 BREATHER VALVE 10 0709390245 1 TUBING 23 0F28730149 4 BOLT 11 0709390246 1 SUCTION FILTER 24 0F28730150 3 BOLT 12 0F28730168 2 BOLT 25 0F28730132 2 BOLT 13 0 28730142 1 GASKET eo __ 1 2 3 4 6 7 8 9 0 1 0 28730169 0 28730170 0 28730171 0 28730172 0 28730174 0 28730175 0709390266 0 28730176 002791 0 28730178 1 1 1 2 1 2 1 1 1 1 DESCRIPTION WATER PUMP ASSEMBLY GASKET BOLT BOLT RUBBER HOSE CLAMP PLUG SEAL WASHER THERMO SWITCH GASKET Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 1 0 Liter Diesel Water Pump Drawing No 0G7502 A ITEM _ PART NO 12 0G23210154 13 0 28730180 14 0 28730181 16 0 28730183 17 0 28730184 18 0F28730202 19 0709390247 20 0F28730217 21 0F28730218 TY 1 4 1 1 1 1 1 1 4 DESCRIPTION THERMOSTAT CASE BOLT THERMOSTAT THERMOSTAT COVER GASKET BOLT PULLY PL
17. 11 3 3 Servicing the Engine Air Filter 12 3 4 Spark Arrestor Mulller 12 3 5 Cleaning the Generator 13 3 0 Battery Maintenance ere eon ert 13 3 7 System once 14 3 8 Engine 14 3 9 Major Service 14 Drive Belt 14 3 11 Exercising the 14 3 12 Out of Service Procedure 15 3 13 Service Schedu le eset seta 16 Table of Contents 3 F CONTENTS Recreational Vehicle Generator Part II Installation Instructions Safety R leS 18 Section 1 General Information 20 1 1 Purpose and Scope of the Manual 20 1 2 Safety CEREREM 20 1 3 Standards 20 14 Equipment Description 20 1 5 Generator Engine Operating Speed 20 1 6 Generator AC Connection System 20 Major Features and Dimensions 21 Section 2 Installation 22 2 1 Location and Support 2 teen 22 2 2 Generator Compartments 23 2 3 Cooling and Ventilating
18. Coolant and Engine Coolant sections for procedures and recom mendations 2 5 5 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 may overheat causing engine shutdown and damage to the generator 2 5 6 ENGINE EXHAUST GAS Before starting the generator engine 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 Dd AN The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coher ently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weakness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been insp
19. 757 N NEWCOME STREET WHITEWATER WI 53190 Page 1 68 Section 7 Warranty Recreational Vehicle Generator WARRANTY OBLIGATIONS AND RIGHTS OF THE MANUFACTURER AND OWNER The new model year class of diesel engine and emission application determination for your engine are identified on the emission control information label affixed to the right hand side of your engine s timing gear case The warranty period begins on the date the new equipment is sold to the first retail purchaser Any emission control system parts scheduled for regular inspection that are proven defective during normal use will be repaired or replaced during the warranty period Any warranted part that is scheduled for replacement and that fails prior to replacement will be repaired or replaced under warranty and the repaired or replaced part will be covered under warranty for the remainder of the period prior to the first scheduled replacement The warranty repairs and service will be performed by any Generac Authorized Warranty Service Facility with no charge for parts or labor including diagnosis As the engine owner you are responsible to perform all the required maintenance listed in your Owner s Manual GENERAC will not deny an emission warranty claim solely because you have no record of maintenance however a claim may be denied if your failure to perform maintenance resulted in the failure of a warranted part Receipts cover ing regular maintenance sh
20. CON 1 0 16 ae Section 5 Electrical Data Recreational Vehicle Generator ELECTRICAL Wiring Diagram 120 VAC Drawing No 0G7333 D Page 4 of 4 4 COMPONENTS LOCATED CONTROL PANEL BH1 NOTE ALL WIRES 18 AWG 16 1 16 300V UL LISTED UNLESS 5 1 15 KS 15 SHOWN OTHERWISE END 0 AWG SIZE SP4 17 lt 17 12 zw _ SP2 18 Keo 18 SP9 14 63 14 17 4 Swi r384 _14 22 33 amp 44A TO TS SP7 150 Sm 150 ARE 600V UL LISTED PHC 13 lt 13 18 14 44 SP8 11 44 BH2 12 F1 V Tl 43 161 145 WIRE LEGEND 5A COLOR FUNCTION WIRE 5 CB1 WHITE NEUTRAL 0 1 22 33 sw2 40A RED NON FUSED DC 4 13 161 15 ORANGE FUSED DC 14 5 156 BROWN CONTROL 17 18 157 18 owg BLUE
21. SIGNAL SENSING 44 56 85 150 162 lt lt BLACK AC MISC 11 44 13 157 10 11 XE aun COMPONENTS LOCATED IN 101 92 VOLTAGE REGULATOR COMPARTMENT il a 10 240 35 120 a gt 10 I FO 444 56 2 Q Q TS n 72 T2 T3 xo 10 11A GND o GND1 10 444 121 22 TO 55 12 33 10 33 2 N 77 Tis 120 240 O AVR TEQBRGa DUAL VOLTAGE E aan DPE 1 PAGES 5 amp 4 HA 02 1 GND SP3 14 R2 peal 4 200 4 6 lex exl ex 22 11 ALTERNATOR CONNECTIONS LEGEND ALT ALTERNATOR GP GLOW PLUG AVR AUTOMATIC VOLTAGE REGULATOR HOUR METER BCR BATTERY CHARGE RECTIFIER HWT HIGH WATER TEMP SWITCH BH_ BULKHEAD CONNECTOR LOS LOW OIL PRESSURE SWITCH MAIN CIRCUIT BREAKER PRE HEAT CONTACTOR CB2 FIELD CIRCUIT BREAKER R_ RESISTOR CON CUSTOMER REMOTE CONNECTOR SC STARTER CONTACTOR 0_ DIODE SM STARTER MOTOR ECU ENGINE CONTROL UNIT SP_ SPLICE F1 FUSE SW AUTO MANUAL SWITCH FP FUEL PUMP SW2 PRE HEAT SWITCH FS FUEL SOLENOID TS TERMINAL STRIP GND GROUND o GND PAGE 4 OF 4 43 PART 5 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Engine Alternator Drive and Starter Assembly Drawing No 0G7350 B TORQUE SPECIFICATIONS CHART
22. TOA VOLTAGE REGULATOR R2 200 RI COMPARTMENT 12W e LOCATED IN 10 25W CONTROL PANEL e 14 77 2 Di CUSTOMER CO 15 2 7 REMOTE CONTROL 66 bi I 5 51 0 zw SIART 47 2 2 i LEGEND P p STOP su LEGEND Bow 19 ALT ALTERNATOR FS FUEL SOLENOID ea 150 5 4 150 AVR AUTOMATIC VOLTAGE REGULATOR GP GLOW PLUG PREHEAT BATTERY CHARGE RECTIFIER HM HOUR METER 15 35 B je BCW BATTERY CHARGER WINDINGS HWT HIGH WATER TEMP SWITCH CB MAIN CIRCUIT BREAKER LOS LOW OIL PRESSURE SWITCH n 14 si 156 44 CB2 FIELD CIRCUIT BREAKER PHC PRE HEAT CONTACTOR CON CUSTOMER REMOTE CONNECTOR PW POWER WINDINGS D DIODE R_ RESISTOR Q oro DPE EXCITATION WINDING SC STARTER CONTACTOR 2 eere ECU ENGINE CONTROL UNIT SM STARTER MOTOR UR FUSE SWi AUTO MANUAL SWITCH HM 14 4 FP FUEL PUMP SW2 PRE HEAT SWITCH 1 1 SW1 o START 17 i 17 0 L P p STOP ie 5 11 ij 15 SW2 L 150 PREHEAT 15 15 1 1 a E ens ux I 15 Flex 13 44 LOCATED 15 85 12 ECU 6 0 CONTROL PANEL 14 11 5 11 ix e D1 14 0 4 18 9 3 17 6A 600V 8 2 0 56 7 11 15 lh wo LOCATED IN xe we d ENGINE CONTROL 85 13 E 14 SENE 120 VAC zl 1 Gop
23. and cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base antifreeze Using any high silicate antifreeze boosters or additives will also cause overheating DO NOT use any soluble oil inhibitor for this equipment 39 MAJOR SERVICE MANUAL To obtain a service manual for the generator the nearest Authorized Service Dealer Make sure to iden tify the MODEL NUMBER and SERIES 3 10 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement Drive belt tension was properly adjusted before the unit was shipped from the factory If suspect that drive belt tension is incorrect contact an Authorized Service Dealer 5 11 EXERCISING THE GENERATOR At least once every seven days start and operate the generator Let the unit run for at least 30 minutes to exercise the engine If the generator cannot be exer cised every seven days and it is to be out of service longer than 30 days see Out of Service Procedure 5 12 OUT OF SERVICE PROCEDURE 3 12 1 REMOVAL FROM SERVICE Prepare the generator for storage as follows 1 5 Start the engine let it run until it is thoroughly warmed up at least five minutes then shut off the engine While the engine is still warm from running drain the oil completely see Changing the Engine Oil and or Filter Refill the crankcase with the recom men
24. operating or servicing this equipment carefully read the Notice to Installer and Safety Rules on pages 18 and 19 Comply with all safety rules to prevent death personal injury or damage to equipment and or property Stress safety to all installers operators and service technicians who work on this equipment 1 5 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The following standards booklets latest revision are available from the sources indicated 1 NFPA 1192 Standard for Recreational Vehicles replaces ANSI A119 2 NFPA 501C available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 NFPA 70 NFPA Handbook of the National Electric Code available same as Item 1 3 ANSI RVIA EGS 1 Engine Generator Sets for Recreational Vehicle Safety Requirements avail able from the Recreational Vehicle Industry Association 1896 Preston White Drive Reston VA 22090 4 California Administrative Code Title 25 available from the State of California Documents Section PO Box 1015 North Highlands CA 95660 20 5 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 1 4 EQUIPMENT DESCRIPTION Instructions and information in thi
25. or 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 con ditions from leaking exhaust gases fuel leakage oil leakage etc Never insert any tool or other object through open ings in the generator interior even if the unit is not running Serious injury or damage to the equip ment could be done A ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages that can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate covers guards and bar riers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mount ing to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper
26. or shield the exhaust part s so that the tem perature of any combustible material is not raised to more than 117 F 65 C above the ambient air temperature Terminate the exhaust tailpipe at least 3 feet 91 cm from the vehicle s fuel filler cap and at least 2 inches 51 mm past the outer edge of the vehicle Do not terminate the exhaust system under the vehicle Terminate the exhaust tailpipe such that exhaust gases will not be drawn back into the generator compartment and recirculated Fuel and oil must NOT be able to drip onto any exhaust system part Figure 2 13 Typical Exhaust System lt gt a Go MUFFLER PERMANENTLY MOUNTED INSIDE ENCLOSURE TAILPIPE MUST EXTEND 2 INCHES BEYOND THE COACH BODYWORK If there is any possibility of the tailpipe or muffler being damaged protect these damage prone areas by means of a protective device such as a skid bar Install the generator exhaust system according to safe automotive practices Use enough exhaust system hangers to prevent any part of the system from being dislocated INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator Use exhaust system parts recommended by the manufacturer Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person s installing such unauthorized parts Do not terminate the ex
27. 35 POST c Section 3 Post installation Start up Checks INSTALLATION START UP Recreational Vehicle Generator CHECKS 3 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT Generator is properly located Generator is properly supported Generator is properly restrained GENERATOR COMPARTMENT Compartment construction is proper Holes Openings vapor sealed Compartment size is correct Compartment 15 vapor sealed Sound insulation is correct Floor cutouts are properly completed COOLING AND VENTILATING AIR Airflow is adequate Air inlet opening is correct Compensate for restrictions Check that installation has been tested DIESEL FUEL SYSTEM Fuel tank complies with all applicable codes Fuel system is properly installed and checked for leaks DATE OF INSTALLATION EXHAUST SYSTEM Exhaust system complies with all applicable codes Exhaust system is properly and safely installed ELECTRICAL CONNECTIONS Connections comply with local code requirements and all National Electrical Codes Junction box is properly installed Wiring meets all standards connections are correct Conduit is properly installed and sealed Generator is properly bonded to the vehicle BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Cables are clean and
28. Negative 1 5 6 GENERATOR Rated Maximum Continuous AC Output at 85 29 C Ambient 8 500 Watts 8 5 kW 100 38 C Ambient 7 500 Watts 7 5 kW 120 49 C Ambient 6 000 Watts 6 0 kW Rated Voltage a nas esie viene 120 240 Volts AC Rated Maximum Continuous AC Current at 8 500 Watts 120 Volts ES pde eas 70 8 Amps 240 35 4 Amps 7 500 Watts 120 Volt terret a 62 5 Amps 240 31 25 Amps 6 000 Watts T20 VONS eedem nn oria 50 0 Amps 240 25 0 Amps PHASE c cerei Single Rotor Speed at No Load eterne 3 780 rpm Number of Rotor Poles aus nti eee ene cond 2 Engine 1 950 Rated Brequency e anced 60 2 Battery Charge Voltage 14 Volts DC Battery Charge Current see 2 Amps max Re EAR ERO HERR est 504 Pounds Podio 36 6 inches 929 mm ina ere EY vH 23 8 inches 604 mm Height out Gee ier 23 8 inches 604 mm units are reconnectable to 240 volt only AC output 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 Figure 2 1 Generator Control Panel
29. Number 2 Serial Number 3 kW Rating 4 Rated Voltage 5 Phase 6 Hertz Model 005432 0 1 2 Pole 40 amp Circuit Breaker Hourmeter Oil Fill Opening and Plug Oil Dipstick Engine Start Stop Switch 15 amp Fuse Engine Preheat Switch Fuel Filter Air Filter Oil Filter 11 Starter Motor 12 Preheat Contactor 13 Starter Contactor 14 Radiator 14 15 12 3 4 o O Cc N 22 15 Coolant Recovery Tank FRONT VIEW 13 12 11 10 17 Battery Connections 18 Fuel Connections 19 Alternator 20 Fuel Pump 21 Centrifugal Cooling Fan and Housing 22 Alternator Drive Belt 23 Alternator Drive Belt Tensioner 24 Cooling Fan Drive Belt 25 Cooling Fan Drive Belt Tensioner 26 Engine REARVIEW 94 20 19 1 8 17 1 2 GENERATOR APPLICABILITY These generators have been designed and manufac tured for supplying electrical power to recreational vehicles DO NOT modify the generator nor use it for any application other than for what it was designed If there are any questions pertaining to its applica tion write or call the factory Do not use the unit until advised by a competent authority DIG A For fire safety the generator must have been properly installed in compliance with NFPA 70 latest edition National Electri
30. Oylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Manifolds Generac RV generators manufactured prior to December 31 1997 DO NOT have a transferable warranty Generac RV generators manufactured after January 1 1998 have a transferable warranty to the second owner ONLY for the remainder of the three year limited warranty Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any warranty service warranty expense allowances are subject to the conditions defined in Guardian s Warranty Policies and Procedures Guide THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Guardian generators that utilize non Generac replacement parts Costs of normal maintenance adjustments installation and start up Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as colli
31. also cause overheating DO NOT use any soluble oil inhibitor for this equipment 1 5 5 ENGINE o ENGIN oe ee HERE HI SR Ne ISM Diesel Cylinder Arrangement osiers 3 in line Displ cetnent rit eret 69 02 3 1131 cc 3 03 in 77 mm STOK 3 18 in 81 mm Compression adore 23 56 to 1 Combustion Chamber Pre Combustion Rated Horsepower see 15 0 1 950 rpm Cylinder Block Herten Cast Iron Number of Main 6 4 Number of Teeth on Flywheel esses 104 of Governor Mechanical Fixed Speed Fuel Filter eee Full Flow Spin On Part 69858 Oil Filter eerte ett Full Flow with Bypass Valve Part 126 70939 Oil PLESSULE S 29 71 psi Type of Cooling System Pressurized Closed Recovery Cooling Method eee te eese tenen Liquid cooled of Cooling F i escacier Centrifugal Puller Cooling System Capacity 1 4 U S gals 5 3 L Air Cleaner rs Disposable Filter Part 4880 rir S 12 volt DC Electric Recommended Battery 70 Ah 360 Cold cranking Amps Minimum ratings Maximum Cranking Current 220 Amps Ground
32. housed inside an all weather enclosure clean the enclosure with a soft damp cloth or with sponge and water Once each year have the generator cleaned and inspected by an Authorized Service Dealer Service technicians will use dry low pressure air to clean internal windings Parts inside the control console should be cleaned and inspected at this time as well Finally have the insulation resistance of stator and rotor windings checked If insulation resistances are excessively low the generator may require drying caution Do NOT use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also contaminate the generator fuel system MAINTENANCE 2 0 Section 5 Maintenance Recreational Vehicle Generator 3 6 BATTERY MAINTENANCE lead acid batteries will discharge when not in use The generator battery should be inspected per the Service Schedule The following procedure should be used for inspection Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary Check the battery fluid level of unsealed batteries and if necessary fill with Distilled Water Only Do not use tap water in batteries Have the state of charge and condition checked by an Authorized Service Dealer NOTE Servicing of the battery is to be performed or supervised by knowledgeable personnel accord ing to the requir
33. motor loads the generator will operate at one time This total should be less than the unit s rated wattage amperage capacity Figure 2 15 Connections for 120 Volts Only Dual Circuits pee ven NEUTRAL 74 CRED CWHITED BLACK 1 33A 5 22 CB i e 1 GROUNDED K P uiia WIRE 57 Figure 2 16 Connections 120 240 Dual Voltage 240 V 120 120 v TI Te R T m T3 E lt BLACK GROUNDED UULU NEUTRAL INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator 2 6 4 CONDUIT Route the connections between the generator and junction box through approved flexible conduit The following general rules apply wiring conduit and interconnections must be installed in compliance with applicable codes standards and regulations Cut wiring to the required length and allow extra wire for junction box connections Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation Route conduit so it does not interfere with genera tor movement If using metallic conduit vapor seal the end of the conduit where it enters the junction box Do this because flexible metallic conduit is not vapor proof along its entire length All openings in the generator compartment for the passage
34. of wiring and conduit must be sealed and made vapor tight NOTE Use a high quality silicone rubber base sealant or other approved method such as explosion proof fittings to seal such openings 2 6 5 POWER SUPPLY CORD The power supply cord must comply with all appli cable codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected 2 6 6 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code NFPA 70 551 7 requires that ground fault circuit interrupters GFCIs be installed on all external and some internal electri cal receptacles Contact the manufacturer or dealer for recommendations 2 6 7 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 2 17 An alternate method for isolating different power sources includes using an isolating receptacle Figure 2 18 Whichever method is used be certain that both power sources are NOT connected at the same time Figure 2 17 Transfer Switch Isolation Method 2ND AIR FROM 20 AMP CONDITIONER HACR BREAKER JUNCTION VEHICLE FLEXIBLE WIRING CONDUIT DOUBLE POLE DOUBLE THROW SWITCHING 30 AMP DEVICE VEHICLE AC DISTRIBUTION PANEL MAIN BREAKER HACR BREAKERS FOR AIR CONDITIONERS GFCI BREAKERS POWER SUPPLY CORD Section 2 Installation Recreational Vehicle Gener
35. or fuel line Clean or replace fuel filter or line 7 Engine mechanical parts failure Repair or replace parts 8 Defective engine control board Replace control board The engine starts hard 1 Plugged or damaged Check clean or replace as needed and runs rough air filter 2 Defective fuel pump FP 2 Repair or replace fuel pump 3 Plugged fuel filter or fuel line 3 Clean or replace fuel filter or line 4 Water in fuel 4 Drain fuel system and refill 5 Improper preheat 5 Preheat unit The engine starts but shuts 1 Low engine oil level 1 Check oil and add oil as needed down when the Start Stop 2 Overheated engine 2 Check cooling system for leaks switch is released 3 Defective Start Stop Switch 3 Disconnect Remote Harness on panel or remote Start Stop Check Replace Start Stop Switch 4 Defective low oil 4 Replace pressure switch pressure switch 5 Defective high coolant 5 Replace temperature switch temperature switch 6 No AC output 6 Contact an Authorized Service Dealer 7 Defective engine control board 7 Replace control board The Start Stop switch is 1 Defective Start Stop switch 1 Replace switch set to Stop but the engine 2 Open Disconnected 18 wire 2 Reconnect or close wire continues to run between Start Stop switch and engine control board 3 Open Disconnected 0 wire 3 Reconnect or close wire between Start Stop switch and engine control board 4 Defective engine control board 4 Replace cont
36. per mit starting and stopping the generator engine from any convenient location inside the vehicle Figure 2 20 Remote Panel Plug in Receptacle WIRE 18 STOP WIRE 150 PREHEAT WIRE 15 12 VDC WIRE 40 WIRE 14 GROUND WIRE 17 ENGINE RUN SIGNAL START ELECTRICAL ACCESS PANEL Section 5 Post installation Start up Checks 2 8 1 START STOP CONNECTIONS The following steps are necessary to connect the remote start stop option l If the six wire remote connector is visible below the control panel as shown in Figure 2 20 skip to step 5 Otherwise proceed with step 2 2 Remove the electrical access panel located just below the knock out labeled REMOTE The remote connector will be located inside the elec trical enclosure along the right side 3 Remove the REMOTE knock out taking care not to damage the wiring behind it 4 Feed the remote connector through the hole and fit the supplied grommet into position 5 Wire the remote harness Part 0D2021C sup plied as an accessory with the generator to the vehicle s remote start panel Refer to Figure 2 20 for a wiring legend 6 Plug the remote harness into the mating remote connector on the generator 5 1 POST INSTALLATION TESTS The generator set was factory tested and adjusted It is not necessary to adjust the unit any further except under special circumstances warninc amp Do not make any unnece
37. power supplies at the same time such as genera tor and dockside power Conductors must be rated 221 F 105 or must be of a larger conductor size When connecting vehicle load leads the following rules apply Connect 120 volt single phase 60 2 elec trical loads requiring up to the trip rating of cir cuit breaker CB1 across AC output leads T1 red and T2 white Connect 120 volt single phase 60 Hertz AC elec trical loads requiring up to the trip rating of circuit breaker CB1A across AC output leads T3 black and T2 white Try to keep the load balanced between the two cir cuit breakers and the stator windings The neutral line T2 white on all units is grounded neutral 2 6 5 GENERATOR AC CONNECTIONS Generator AC output leads T1 red T2 white and T3 black come out of the generator as shown in Figure 2 14 Leads T1 red and T3 black are hot while T2 white is the grounded neutral lead There is also a green lead that connects to ground in the junction box of the recreational vehicle These generators use a four position terminal block to connect between stator power leads and vehicle load leads This terminal block is accessible by removing the access panel shown in Figure 2 14 Units are shipped from the factory connected for dual circuits 120 volts AC output See Figure 2 15 Two stator power windings are used with each wind ing capable o
38. sure that sufficient air is avail able to the generator for cooling ventilating and combustion The installer also must provide a path for exhausting the cooling air to the exterior of a com nartment if so eauinned 1431 A Never use discharged cooling air for heating or permit such air to enter the vehicle interior This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases 2 3 1 GENERATOR AIRFLOW This unit uses an impellar fan located on the alter nator drive pulley to cool the alternator s internal components Air is drawn through the alternator and expelled radially behind the drive pulley An engine driven centrifugal blower draws in cooling air through air inlet openings moves that air around the engine generator and across the radiator then discharges that air out the bottom see Figure 2 7 Figure 2 7 Airflow Through Engine Generator AIR INTAKE ALTERNATOR SIDE 25mm Top Of Unit my AIR INTAKE m RaDATOR spe CATO 50 mm Eoch Side Of Unit 2 305mm 12 UNRESTRICTED UNDERFRAME CLEARANCE TO THE GROUND AIR INTAKES ON BOTH SIDES OF UNIT TO BE UNRESTRICTED 2 5 2 COOLING AIR INLET OPENINGS The minimum size of the air inlet opening whether the generator is housed in a conventional compart ment or not is at least 150 square inches 975 cm2 see Figure 2 8 This rule applies whether inlet air is brought in through an openi
39. the space between the generator and such insulation The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense 2 1 2 GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been affixed to the vehicle frame structure by bolting or welding The metal frame work on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams These beams should consist of a 1 1 2 inch square 11 gauge steel tubing OR b 1 1 2 inch 11 gauge angle iron The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the genera tor below the horizontal support tubing by means of suitable structurally sound metal framework The following general rules apply Vehicle construction MUST be capable of support ing the weight of the generator Whether the generator is mounted above the hori zontal support tubing or suspended below the tub ing the supporting frame used must be structur ally sound If the generator cannot be bolted directly to the supporting frame or support tubing con sider using additional tubing angle brackets or other supports to give the supporting frame suf ficient strength 2 1 5 SUSPENDED MOUNTING If the generator will be suspended below the hori zontal support tu
40. tools metal parts on top of the battery Disconnect any charging source prior to connecting or disconnecting battery terminals and Do not use any jumper cables or booster battery to crank and start the generator engine If any battery has discharged remove it for recharging WARNING amp Do not open or mutilate the battery Released electrolyte is known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water If the electrolyte contacts the eyes immediately flush eyes thoroughly with water and seek medi cal attention e Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried 2 8 OPTIONAL ACCESSORIES A plug in connector Figure 2 20 is provided on the generator set below the control panel Use this to connect an optional remote mounted start stop panel to the generator Installation of such a panel will
41. vehicle circuits The generator has two 40 amp breakers NOTE Refer to section Generator AC Connection System Individual installations will differ If an overload occurs the dual breakers will open the ungrounded i e hot stator leads 11 and 33 in Figure 1 1 When the generator has been con nected for 120 240 dual voltage Figure 2 16 the line breakers will operate on the ungrounded hot stator leads 11 and 44 in Figure 2 16 2 1 5 PREHEAT SWITCH The diesel engine is equipped with glow plugs one for each cylinder When the preheat switch is pressed the glow plugs heat the engine combustion chamber allowing for quicker starts when the engine is cold Pressing the preheat switch also operates the fuel pump OPERATION Section 2 Operation ix Recreational Vehicle Generator 22 OPTIONAL REMOTE START STOP This generator is equipped with a plug in connec tor that can be interfaced with an optional remote panel provided inside the vehicle This option allows for starting and stopping the generator conveniently from within the vehicle Refer to Part II Installation Instructions for details on the remote start stop option 2 5 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 5 1 INSTALLATION Genera
42. wire minimum If the vehicle electrical circuits can be powered by any other source of electricity such as a dock side power receptacle there must be no possibil ity of connecting the different power sources to the vehicle s circuits at the same time The dockside utility power source must be positively isolated from the vehicle s circuits whenever the generator is operating Failure to isolate the vehicle s circuits from the dockside power supply when the generator is running may result in damage to the generator or in serious injury or death to dockside utility power workers due to backfeed of electrical energy In case of an 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 victim is unconscious apply first aid and get immediate 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 SAFETY RULES Safety Rules Recreational Vehicle Generator FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adher
43. 042907 4 SCREW 8 1 25 X 16 8 8 43 0C5605 1 CAP COOLANT FILL 44 0C6976 1 TANK COOLANT OVERFL 45 0C7997 1 HOSE COOL 5 16 SAE 20R4 20 1 LG 46 055934K 2 CLAMP VINYL 1 62 X 343 Z 47 0C4976 1 CAP RAD PRESSURE QP75 48 0C8643 1 TENSIONER SE18 STD 49 0C7040 1 GASKET RADIATOR BSE 50 048705 1 NUT HEX FL 1 2 13 LOCK 51 045771 1 NUT HEX M8 1 25 G8 CLEAR ZINC 52 0C51050ST03 1 BRACKET SUPPORT BLACK 53 024426 1 SCREW HHC 1 2 13 X 1 3 4 G5 54 0G79270ST03 1 PLATE RADIATOR BLANKING 55 029289 A R TAPE ELEC 1 2 FOAM 56 0G8181 1 INSULATION FAN WELDMENT 57 0G8182 1 INSULATION BACK PANEL 58 0G8183 1 INSULATION EXHAUST OUTLET 49 PART 5 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Q Fuel and Electrical Systems Drawing No 0G7355 A M QN a INY S Or o ri i B to p gt lt 24 1 p 4 17 17 50 32 g 31 ZA NS 2 12 30 TO GLOW PLUGS TORQUE SPECIFICATIONS CHART TORQUE 36 IN LBS ITEM 22 Section 6 Exploded Views and Parts Lists CG urs Recreational Vehicle Generator Fuel and Electrical Systems Drawing No 0G7355 A 0 1 0C6946A 1 FUEL PUMP ASSY REWRK 2 052219 3 BARBED STR 1 8NPT X 5 16 3 069598B 2 BULKHEAD FITTING 1 8 NPT 4 022097 7 WASHER LOCK M6 1 4 5 038750 1 SCREW HHC 6 1 0 X 30 C8 8 6 05673
44. 093642 065795 048512 027565 066849 066849 022264 051715 040213 0 5058 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Electrical Enclosure Assembly Drawing No 0G7353 A TORQUE SPECIFICATIONS CHART ITEM TORQUE 17 20 4 IN LBS 15 16 17 18 19 20 21 22 23 24 25 26 27 28 0G7440 1 HARNESS AC OUTPUT 007846 1 HARN ENG CONTROL PANEL 1 1L RV 0C3992 4 SCREW HHTT M4 0 7 X 16 BP 0C7022 1 DECAL CUSTOMER CONNECTION 038150 4 WASHER FLAT 8 ZINC 0C6359 1 GASKET ELECT ENCLOS 049813 6 NUT HEX 6 X 1 0 G8 YEL CHR 023484D 3 BUSHING SNAP SB 875 11 007390 1 GASKET ELEC ENC DVDR 051787 4 SCREW HHC 4 0 7 X 16 C8 8 0A1658 1 WASHER LOCK SPECIAL 1 4 022473 1 WASHER FLAT 1 4 6 ZINC 022097 6 WASHER LOCK 6 1 4 0G7850 1 HARN ENG 1 1L DSL RV NOT SHOWN LISTS 55 i urs Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 0 Intake and Exhaust System Drawing 0G7354 A 16 6 ae 15 22 I pe m M e xl 24 MM 8 4 A A n a 15 ZEE 74 4 FE TLLA 22 gt el 9 2 TO ENGINE Lp d 21 PS AIR INTAKE meg 4 D T 19 ITEM PART NO DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 075674 1 GASKET EXHAUST ADAPTOR 15 022129 10 WASHER LOCK M8 5 16 2 0F28730173 2 NUT 16 045771 5 NUT HEX M8 1 25 G8 CLEAR ZINC 3 0E95
45. 2 ZINC SCREW 1 2 13 X 4 G5 FENDER WASHER 7GA SCREW HHC 3 8 24 X 1 G5 WASHER LOCK M10 SCREW HHC M10 1 25 X 25 08 8 NUT LOCK FLG 5 16 18 SCREW HHC M10 1 5 X 20 G8 8 NUT HEX M6 X 1 0 G8 YEL CHR SCREW HHC 8 1 25 X 25 G8 8 EARTH STRAP SCREW HHC 8 1 25 X 20 G8 8 WASHER LOCK SPECIAL 1 4 NUT HEX FL WHIZ M8 1 25 SCREW HHTT M6 1 0 X 8 ZYC ENGINE 1 1L DIESEL TIER II WASHER FLAT M12 CLAMP VINYL 1 06 X 406 Z SCREW M12 1 25 X 25 G8 8 TENSIONER SE F18 SCREW 1 2 13 X 1 3 4 G5 NUT HEX FL 1 2 13 LOCK WASHER FLAT 5 16 M8 ZINC AIR INTAKE ASSEMBLY WASHER LOCK 6 1 4 SCREW M6 1 0 X 20 G8 8 WASHER LOCK 3 8 45 LISTS Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Enclosure Drawing No 0G7351 B TORQUE 36 IN LBS TORQUE SPECIFICATIONS CHART ITEM 17 34 Lan 14 15 46 Section 6 Exploded Views and Parts Lists CG urs Recreational Vehicle Generator Enclosure Drawing No 0G7351 B 0 0G60920ST03 0G72980ST03 0G60790ST03 0G60810ST03 0G60610ST03 0G7389 0G7390 007391 097392 007393 097394 0G73380AD12 0G73450ST03 0G73470STO3 0C6362 0D7176 004933 0C50960ST03 007023 007024 007025 007026 007027 007028 007029 007030 002340 0C64250ST03 052857 0C7047A 0C7047B 0G7285G 089463 098761 006143 055934V 008407 CO DAR
46. 2 pound den sity When fiberglass is used its coated side should face toward the compartment interior Dd A Do not install sound insulation or any absorbent material on the compartment floor interior Such materials will become soaked with combustible or explosive vapors and liquids and will become a fire hazard Using a combination of sound insulating materials can often reduce noise more effectively than a single material For example a sheet of lead or visco elastic material along with a layer of other acoustical mate rial is more effective than when a single material is used 2 2 5 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement com partment NOTE Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compartment In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise levels Such a compartment might be constructed as follows Figure 2 5 Use 5 8 inch thick or 3 4 inch thick plywood in the compartment Construct the compartment floor of a double thick ness of 5 8 inch or 3 4 inch plywood Line the compartment s interior walls and floor as well as the underside of the floor with 26 gauge galvan
47. 26 0G23210127 0709390217 0709390218 0G23210128 0709390220 0709390221 0709390222 0G23210129 0G23210130 00923210131 0709390230 0709390231 0923210123 O O CO CO CO BOLT BOLT BOLT STANDARD PISTON RING KIT STANDARD PISTON KIT WITH RINGS PISTON PIN SNAP RING CONNECTING ROD ASSEMBLY BUSHING CONNECTING ROD BOLT NUT CONNECTING ROD BOLT STANDARD METAL BEARINGS 0 25 STANDARD METAL BEARINGS 0 50 STANDARD METAL BEARINGS PULLEY NUT BOLT Section 6 Exploded Views and Parts Lists CG Recreational Vehicle Generator 1 0 Liter Diesel Timing and Governor Drawing No 0G7506 A TORQUE SPECIFICATIONS CHART ITEM TORQUE 40 amp 41 18FT LBS ITEM PART NO QTY DESCRIPTION 1 0F28730186 1 HOUSING TIMING GEAR 2 0709390286 1 SPRING PIN 3 0F28730187 1 GASKET 4 0709390288 1 OIL SEAL 5 0G23210146 1 GOVERNOR LEVER ASSEMBLY 6 0709390290 1 TENSION LEVER 7 0709390291 2 SNAP RING 8 0709390136 1 WASHER 9 0709390292 1 COTTER PIN 10 0G23210147 1 SPRING 11 0709390294 1 ARM 12 0F28730190 1 O RING 13 0709390296 1 GOVERNOR LEVER 14 0709390297 1 BOLT 15 0 28730173 3 NUT 16 0F28730191 1 SHAFT 17 0F28730192 2 O RING 18 0709390301 1 SNAP RING 19 0709390302 1 BRACKET 20 0F28730218 2 BOLT 21 071944 1 BOLT 15 ITEM PART NO QTY _ DESCRIPTION 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 0709390304 1
48. 30128 1 ROCKER ARM ASSEMBLY 12 0G23210132 1 OIL PIPE 2 0F28730129 3 INTAKE ROCKER ARM 13 0 28730146 4 GASKET 3 0F28730130 3 EXHAUST ROCKER ARM 14 0709390165 2 EYE BOLT 4 0709390173 6 SCREW 15 0F28730137 1 GASKET 5 0709390174 6 NUT 16 0F28730138 1 O RING 6 0 28730131 1 ROCKER ARM SHAFT 17 0F28730139 4 SHIM 7 0709390177 2 SPRING 18 0F28730140 1 PLUG 8 0F28730132 2 BOLT 19 0F28730141 1 SCREW 9 0709390181 3 STUD BOLT 20 028916 1 90 STREET ELBOW 10 0F28730133 3 NUT 21 0A8584 1 OIL PRESSURE SWITCH 11 042574 1 ADAPTER 63 PARTS Gi 64 LISTS 0G23210113 0709390194 0709390195 0709390196 0709390226 0G23210114 0G23210115 0G23210116 0709390199 0G23210117 0G23210118 0G23210119 0G23210120 0G23210121 0G23210122 GS GS GD O Cuy ak Se ke COMPLETE CRANKSHAFT CRANKSHAFT GEAR KEY DOWEL PIN SPRING PIN BEARING HOLDER ASSEMBLY BEARING HOLDER ASSEMBLY BEARING HOLDER ASSEMBLY DOWEL PIN STANDARD METAL BEARING 0 25 STANDARD METAL BEARING 0 50 STANDARD METAL BEARING STANDARD UPPER METAL BEARING 0 25 STANDARD UPPER METAL BEARING 0 50 STANDARD UPPER METAL BEARING 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 1 0 Liter Diesel Crankshaft Piston and Flywheel Drawing No 0G7505 A 0709390198 0G23210124 0G23210125 0G232101
49. 4270 amp 04614 16 15 To Fuel Pump ITEM NO QTY DESCRIPTION ITEM __ NO QTY DESCRIPTION 1 0F28730215 1 FUEL FILTER SUPPORT ASSEMBLY 12 068736 275 HOSE 3 16 SAE 3082 2 0G23210155 1 FUEL FILTER 13 068736 240MM X HOSE 3 16 SAE 3082 3 0C8008 AR HOSE 5 16 SAE 30R7 14 074823 4 HOSE CLAMP 4 0C8008 250MM HOSE 5 16 SAE 30R7 15 074819 1 FUEL BLEED FITTING 5 040173 3 HOSE CLAMP 16 0709390651 5 FUEL BLEED GASKET 6 0709390378 5 GASKET 17 0709390662 2 HOLLOW BOLT 7 0709390379 1 BANJO FITTING 18 0F28730216 2 BANJO FITTING 8 074808 1 FUEL BLEED FITTING 19 028414A 1 1 8 NPT x 1 4 BARBED STRAIGHT 9 052233 2 1 8 NPT TEE BRASS FITTING MODEL 04270 amp 04614 10 039450 2 1 8 NPT x 3 16 90 DEG BARBED FITTING AR AS REQUIRED 11 030096 1 1 8 NPT x 3 16 BARBED STRAIGHT FITTING 67 Section 7 Warranty WARRANTY Recreational Vehicle Generator FEDERAL AND CALIFORNIA EMISSIONS CONTROL WARRANTY STATEMENT for non road Diesel engines rated under 19 kW YOUR WARRANTY RIGHTS AND OBLIGATIONS The U S Environmental Protection Agency EPA the California Air Resources Board CARB Generac Power Systems Inc GENERAC and the engine manufacturer for this equipment Ishikawajima Shibaura Machinery Co Ltd ISM are pleased to explain the federal and California emission control system warranty on your engine In California new 2000 and later small non road engines must be
50. 44A Q T3 LOCATED IN I 40A VOLTAGE REGULATOR R2 200 RI laor COMPARTMENT 12W 17 0 aw YOR LOCATED IN J CONTROL PANEL __ 22 ira NE Lia 77 2 b CUSTOMER 15 2 7 REMOTE CONTROL 66 2 START 47 2 521 47 Sp STOPS e cig LEGEND ALT ALTERNATOR FS FUEL SOLENOID EE 150 551 gt 5150 AVR AUTOMATIC VOLTAGE REGULATOR GP GLOW PLUG PREHEAT BATTERY CHARGE RECTIFIER HM HOUR METER BCW BATTERY CHARGER WINDINGS HIGH WATER TEMP SWITCH MAIN CIRCUIT BREAKER LOS LOW OIL PRESSURE SWITCH NR CB2 FIELD CIRCUIT BREAKER PRE HEAT CONTACTOR CHY CON CUSTOMER REMOTE CONNECTOR PW POWER WINDINGS D_ DIODE R_ RESISTOR eu 2 oro x DPE EXCITATION WINDING SC STARTER CONTACTOR ECU ENGINE CONTROL UNIT SM STARTER MOTOR AN Fl FUSE 1 AUTO MANUAL SWITCH FP FUEL PUMP SW2 PRE HEAT SWITCH 0 14 SW1 START 17 i 17 0 e STOP gt 18 44 AR 15 SW2 1 150 PREHEAT 15 15 a EE e 6 15 Ela 13 LOCATED IN 15A 85 12 ECU 6 0 CONTROL PANEL 14 11 5 44 cx zi x D1 14 tio 4 18 9 3 17 6A 600 8 2 0 4 56 7 1 15 LOCATED IN 0 ENGINE CONTROL 85 4 13 14 a s 120 240
51. 81A 1 AIR CLEANER 152 4 17 058443 3 SCREW CRIMPTITE 1 4 20 X 5 8 4 0 4366 1 HOSE AIR INLET TIER 2 DIESEL 18 0C5105 1 BRACKET SUPPORT 5 0C4727 1 MUFFLER 1 0 L D RV 19 022145 5 WASHER FLAT 5 16 M8 ZINC 6 025145 2 BOLT U 5 16 18 X 1 25 W SADDLE 20 039253 2 SCREW HHC M8 1 25 X 20 C8 8 7 0G69970STO3 1 RAIL ENGINE LH 21 043107 4 SCREW 8 1 25 X 25 8 8 8 0C5022 1 INSUL EXHAUST QP75 22 035586 2 CLAMP HOSE 20 87 1 75 9 035685 3 CLAMP HOSE 28 1 32 2 25 23 075673 1 MANIFOLD EXHAUST 10 0C4878 1 OUTLET EXHAUST FLEX 24 042907 2 SCREW HHC M8 1 25 X 16 C8 8 11 0C6243 1 GASKET EXH OUTLET 25 022145 2 WASHER FLAT 5 16 M8 ZINC 12 0C6244 1 PLATE EXH OUTLET 26 0709390357 1 GASKET EXHAUST ISM 13 051730 2 SCREW HHC M8 1 25 X 60 C8 8 27 0F28730132 4 BOLT 14 071956 2 WASHER FLAT M8 56 PART Section 6 Exploded Views and Parts Lists 5 Ds Recreational Vehicle Generator 1 0 Liter Diesel Camshaft Drawing 0 6250 8 ITEM PART NO TY DESCRIPTION 1 0F28730164 1 CAMSHAFT ASSEMBLY 2 0709390233 1 CAMSHAFT GEAR 3 0709390195 1 KEY 4 0709390234 1 GEAR 5 0709390235 3 SPACER 6 0709390236 1 BALL BEARING 7 0709390237 1 SLIDER 8 0709390238 1 PLATE 9 0709390241 1 BOLT 10 0709390240 1 BOLT 57 5 5 LISTS Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Q 1 0 Liter Diesel Oil Pump Drawing No 0F6231 6 8 ITEM PART NO TY DESCRIPTION 1 0709390250 1 IDLER G
52. 825 0 454005 03 0 1457 032300 055920 043181 022159 022676 097396 007341 049226 007340 0G7845 051714 0 447605 03 0C50960ST03 0D4372 OF2664K 005210 0C5209 0C7649 057824 063992 022985 084135 0C6440 006873 049813 076040 051713 022097 036900 009283 009391 022155 qol NJ NS s Gm NS T WS ss saw WS k isa NS SWITCH RKR DPST COVER ENG CONTRL BOX HOURMETER HOLDER FUSE SWITCH SPST SPADE PNL MNT SCREW PHM M3 0 5 X 10MM WASHER LOCK 4 FUSE 15A X AGC15 DECAL ENGINE CONTROL BOX BOOT NUT PRE HT SWCH WASHER LOCK M5 CIRCUIT BREAKER HARN CONTROL PANEL 1 1L G15 RV NUT HEX M3 0 5 G8 YEL CHR BOX ENG CONTROL RV FRAME CONTROL PANEL PLUG OIL FILL ASSY DIPSTICK W TWIST 1 1L HOSE 3 8 ID LOW PRES OIL WATER 5 31 LG HOSE 1ID LOW PRES OIL WATER 9 84 LG CLAMP HOSE 38 87 CLAMP HOSE 16 87 1 50 SCREW HHTT M4 0 7 X 16 BP WASHER FLAT 6 ZINC RUBBER GROMMET WIRES GASKET ENGINE CNTRL CB 0040A 2P NUT HEX M6 X 1 0 G8 YEL CHR SCREW 5 0 8 X 16 WASHER FLAT M5 WASHER LOCK 6 1 4 SCREW PPHM 6 32 X 1 4 GASKET HOURMETER GASKET ROCKER SWITCH VPS WASHER LOCK 6 53 i Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 0 Base Frame Drawing 002557 11 7 12 ej 8 TORQUE SPECIFICATIONS CHART ITEM TORQUE 11 18 FT LBS
53. 9 2 RELAY SOLENOID 12VDC PNL MNT 7 049813 5 NUT HEX M6 X 1 0 G8 YEL CHR 8 055934D 1 CLAMP VINYL 1 06 X 406 Z 9 022473 5 WASHER FLAT 1 4 M6 ZINC 10 040173 2 CLAMP HOSE 45 5 62 62 11 028414A 1 BARBED STR 1 8NPT X 1 4 W VS 12 0C7649 3 CLAMP HOSE 38 87 13 047411 1 SCREW 6 1 0 X 16 8 8 14 0 7968 1 NUT HEX JAM 3 8 16 BRASS 15 022237 1 WASHER LOCK 3 8 16 075763 3 BOOT BATTERY CABLE 17 075763A 3 BOOT BATTERY CABLE 18 023484F 2 BUSHING SNAP SB 1000 12 19 022127 1 NUT HEX 1 4 20 STEEL 20 0536210201 1 ASSY WIRE 13 22 00 21 0536210197 1 ASSY WIRE 16 11 50 22 0A2053 1 SCREW HHC M6 1 0 X 65 C8 8 23 0742600158 1 WIRE ASSY GROUND DIESEL RV 24 075234 1 RES WW LUG 1R 5 25W 25 030340 1 HOSE 1 4 ID SAE 30R7 41 LG 26 0C8008 1 HOSE 5 16 SAE 30R7 25716 27 0C8008 1 HOSE 5 16 SAE 30R7 14 76 LG 28 0C8009 1 CLAMP FUEL PUMP 29 0D2021H 1 WIRE ASSY 0 PHC SC 30 0D8914 1 FILTER FUEL 1 0L RV DIESEL 31 032552 2 BARBED EL 90 5 16 X 1 8 32 099827 2 CAP BLACK VINYL 5 16 51 umm Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 0 Customer Controls Assembly Drawing 0G7356 B TORQUE 20 4 IN LBS TORQUE SPECIFICATIONS CHART ITEM 3 PART Section 6 Exploded Views and Parts Lists 5 Use Recreational Vehicle Generator 2 Customer Controls Assembly Drawing 0 7356 080
54. ATE BOLT umm Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 0 1 0 Liter Diesel Cylinder Block Drawing No 067505 23 19 6 21 22 lt lt 14 P 9 ITEM PART NO _ DESCRIPTION ITEM PART _ DESCRIPTION 1 0G23210100 1 CYLINDER BLOCK 17 0709390116 2 DOWEL PIN 2 0709390104 1 BLANK PLUG 18 0709390117 2 DOWEL PIN 3 0F28730101 1 SEALING CAP 19 0709390118 2 SPRING PIN 4 0F28730102 2 SEALING CAP 20 0F28730111 2 STUD BOLT 5 0F28730103 1 SEALING CAP 21 0F28730112 1 STUD BOLT 6 0F28730104 2 SEALING CAP 22 0F28730113 1 STUD BOLT 7 0709390106 4 BLANK PLUG 23 0G23210104 1 OIL SEAL 8 0709390105 4 BLANK PLUG 24 0709390124 1 DRAIN COCK 9 0F28730105 1 COMPLETE IDLE GEAR SHAFT 25 0709390125 1 CONNECTOR 11 0023210101 1 BUSHING STANDARD 26 0G23210156 1 OIL FILTER 0G23210102 1 0 25mm U S BUSHING 27 0G23210105 6 TAPPET 0023210103 1 0 50mm U S BUSHNG 28 0G23210106 6 PUSH ROD 12 0F28730110 1 BEARING 29 0F28730115 1 RELIEF VALVE 13 0709390113 1 EXPANSION PLUG 30 0F28730219 1 O RING 14 0709390114 1 BALL BEARING 15 0709390131 1 SNAP RING MM MILLIMETER 16 0709390115 2 DOWEL PIN U S UNDERSIZE PART Section 6 Exploded Views and Parts Lists 5 Ds Recreational Vehicle Generator lip 1 0 Liter Diesel Rocker Arm Assembly Drawing 0G7504 A 0 L gt ITEM TY DESCRIPTION ITEM NO TY DESCRIPTION 1 0F287
55. ATION Figure 2 6 Compartment Floor Cutout 1017 40 07 980 38 571 3350 13 75 1 630 24 75 Im 70 2 75 I 252 1001 340 541 213 90 5 254 10 0 4 38 15 4 PLACES 79 134 e1 3571 134 5 257 r 68 2 75 i y i every 8 i a hal Now ee ON q 1 1 i 1 198 7 75 4 N 1 i x X N PA UN 365 14 57 FRONT SERVICE 508 80 07 536 21127 OPENING FOR AIR OPENING FOR DOOR AND AIR QUTLET EXHAUST amp ALD ONES INLET 559 22071 303 203 COOLANT DRAIN Bun EE 692 27 25 1 N x N 2 N 4 i ree e 1 1 77 301 70 751 i 571 o o S ta NOTE FOR A FULL SIZE TEMPLATE CONTACT GENERAC SERVICE DEPARTMENT AT 1 262 544 4811 CLEARANCE FROM EDGE OF GENERATOR 25 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator 2 5 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling ventilation and engine combustion be supplied to the generator set Without sufficient airflow the engine generator quickly overheats Such overheating can cause serious operating difficulties and also may cause fire and personal injury The installer must make
56. EAR ASSEMBLY 2 0709390251 1 THRUST WASHER 3 0709390252 1 SPRING 4 0709390253 1 ROTOR 5 0709390254 1 OIL PUMP COVER 6 0709390255 AR 0 10MM SHIM 0709390532 AR 0 15MM SHIM 0709390533 AR 0 20MM SHIM 0709390258 AR 0 50MM SHIM 7 0709390259 1 SPRING 8 0709390260 1 COLLAR 9 0709390261 1 SNAP RING 10 0709390262 1 FRONT PLATE 11 0F28730165 1 GASKET 12 0F28730166 3 BOLT AR AS REQUIRED 58 0 0923210107 028730119 028730120 028730121 028730122 0709390151 0709390153 0709390154 0709390155 0709390156 0709390152 mnm Section 6 Exploded Views and Parts Lists ey CYLINDER HEAD ASSEMBLY SEALING CAP SEALING CAP STUD BOLT INTAKE VALVE EXHAUST VALVE VALVE GUIDE SEAL INTAKE SPRING RETAINER KEY VALVE GUIDE SEAL EXHAUST LISTS Recreational Vehicle Generator 1 0 Liter Diesel Cylinder Head Drawing No 0G7500 A 14 12 0G23210108 13 0023210109 0023210110 14 028730125 15 028730126 16 0709390162 17 0023210111 18 0923210112 HEAD GASKET 1 2mm HEAD GASKET 1 3mm THICK HEAD BOLT HEAD BOLT LIFTING EYE BOLT VALVE SEAT INTAKE 59 umm Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 0 1 0 Liter Diesel Engine Block Drawing No 0G7501 A
57. F COP 69 2 G 3 DUAL VOLTAGE nm zog 2 CUSTOMER BATTERY 2 3 AA T 12 05 GP GP WIRE LEGEND M COLOR FUNCTION WRE 3 HWT S o9 1 WHITE NEUTRAL 0 1 22 33 V GP RED 5 DC 4 13 4 ORANGE FUSED DC 14 15 ES BROWN CONTROL 17 18 157 BLUE SIGNAL SENSING 44 56 85 150 162 BLACK AC MISC 11A 13 44A 157 0 0 0 PAGE 2 OF 2 39 Section 5 Electrical Data Recreational Vehicle Generator ELECTRICAL _ s DATA Wiring Diagram 120 240 Dual Voltage Drawing 0G7333 D Page 1 of 4 COMPONENTS LOCATED CUSTOMER REMOTE ENGINE CONTROL COMPARTMENT CONNECTOR
58. FFLE s I I I I O AIR OUT AIR IN Figure 2 11 Air Inlet in Vehicle Skirt VEHICLE FLOOR I VEHICLE SKIRT AIR WS y MINIMUM CLEARANCE 1 2 5 5 COMPENSATING FOR RESTRICTIONS Materials such as screening louvers or expanded metal can restrict the free flow of air Compensate for this restriction by making the actual air opening proportionately larger Some materials may offer only a 60 percent free air inlet area Other more efficient materials may pro vide up to a 90 percent free air inlet area The per centage of free air inlet opening is usually available from the material s supplier or manufacturer To determine the actual air inlet opening size required divide 150 square inches 975 cm by the percentage of free air inlet area for the mate rial being used For example If planning to use screening with an 80 percent free air inlet area divide 150 975 by O 8 which results in 187 5 square inches 1 218 75 cm2 Minimum actual size of air inlet opening in this case is 187 5 square inches 1 218 75 cm2 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator 2 5 4 TESTING THE INSTALLATION The manufacturer recommends testing the installa tion to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of
59. GOF p ONLY 8 9 CUSTOMER F BATTERY Z z 12 05 1 GP CP WIRE LEGEND v COLOR FUNCTION WIRE 5 x HWT 5 i L WHITE NEUTRAL 0 1 22 44 V TL um RED 5 DC 4 13 4 ORANGE FUSED DC 14 5 BROWN CONTROL 17 18 157 BLUE SIGNAL SENSING 11 56 85 150 162 AC MISC 11 13 33 157 1 2 id 38 Section 5 Electrical Data Recreational Vehicle Generator ELECTRICAL Electrical Schematic 120 240 VAC Output Drawing No 0G7332 C bu DATA LOCATED IN ALT VOLTAGE REGULATOR 1 1 o Ll CONPARTMENT 11 11 11 MA TOT 2 77 SIGE 120 g a xg I gt I 11 6 55 SEN 22 22 1 22 22 22 12 4 AVR F 4 33 33 33 O 12 5 d I 9 I l i l END BAG D2484 1 66 600 44 44
60. HICLE FRAME BATTERY GROUND GROUND VEHICLE FRAME 2 7 4 BATTERY COMPARTMENT Install the generator battery in its own vented com partment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage DIG A Do not dispose of the battery in a fire The battery is capable of exploding Storage batter ies give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explo sion 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 tool or equip ment near the battery Discharge static electric ity from body before touching the battery by first touching a grounded metal surface A battery presents a risk of electrical shock and high short circuit current The following pre cautions are to be observed when working on batteries e Remove watches rings or other metal objects 34 e Use tools with insulated handles Wear rubber gloves and boots Do not lay
61. OLE L 19 9 m 891 S D L8v U S162 SS322V 492 sSOLVIdva Pell 2 553229 ALIAVAD 30 331N32 2 9 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator 2 1 LOCATION AND SUPPORT Be sure the installation complies with all standards and codes listed in the Standards Booklets section of this manual 2 1 1 GENERATOR LOCATION The most desirable location for the generator set is between the vehicle s main frame members Many recreational vehicles have been factory equipped with an area for the generator set Some may even have a generator compartment provided by the vehicle manufacturer Plan the generator location based on the following The generator set must be installed on a frame work that is part of the recreational vehicle as outlined in the Generator Support section The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from under neath the supporting framework The location must provide easy access to frequent ly serviced components such as filters oil drains and other common maintenance parts The location must provide sufficient room to allow minimum clearances for air circulation If sound insulation is to be used on the compart ment walls and ceiling the minimum recom mended clearance applies to
62. R HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coher ently b vomiting c twitching muscles d throbbing temples e dizziness f headaches g weakness and h sleepiness IF FEELING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Do not operate the generator until its exhaust system has been inspected and properly repaired caution AN Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can dam age the other engine 2 5 1 MUFFLER AND SPARK ARRESTOR The exhaust muffler supplied with this unit is a spark arrestor type that meets code and standard require ments of the U S Forest Service Any person s installing an unapproved muffler or an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable for any damage injury or warranty expense that might be caused by such unapproved installation or modi fication INSTALLATION Ps Section 2 Installation 2 5 2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any combus tible material such as wood felt cotton organic fibers or other like material If the 3 inch 76 mm clearance cannot be maintained locate insu late
63. SEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC BOX 297 WHITEWATER WI 53190 Revision 02 05 Part OG6773 Revision B 04 01 08 Printed in U S A
64. TION BOX Install an approved square electrical junction box with a blank cover on the interior or exterior wall of the area planed for installation of the generator NOT on the generator Route the generator s AC output leads into this junction box through approved flex ible conduit This is the point of first termination for generator AC output leads 2 6 2 WIRING Wiring should be of stranded copper to reduce the chance that vibration may cause breakage Wire gauge size should be large enough to handle at least 115 percent of the installed generator s rated maximum current 30 If neutral conductors are used they must be the same size as other leg wires Route power supply conductors from generator AC output leads red T2 white black and the green ground wire through approved flexible conduit to the electrical junction box on the com partment wall If a flexible metal conduit is used between the generator and the compartment junction box the conduit end that terminates at the compartment junction box must be vapor sealed Flexible metal conduit is NOT vapor tight along its entire length From the junction box route power supply wires through approved conduit to either a double pole double throw transfer switch or b approved iso lation receptacle Connecting to a transfer switch or isolation receptacle must prevent vehicle electri cal circuits from being connected to two different
65. all in diameter may cause a drop in voltage which causes starting problems For the best cold weather starting the voltage drop between battery terminals and the generator connection point should not exceed 0 12 volts per 100 amps of cranking current The generator is rated at about 160 DC amps of cranking current to operate the starter and glow plugs Select battery cables based on a cable length and b prevailing ambient temperatures Generally the longer the cable and the colder the weather the larger the cable size must be as shown in the chart CABLE LENGTH in Feet meters CABLE SIZE 11 to 15 3 4 to 4 5 00000 16 to 20 4 5 to 6 warm weather use No 2 cable up to 20 feet 2 7 3 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or to the insulated lug on the unit frame Figure 2 19 NOTE Check to be sure the cable boot for the positive cable has been installed 33 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the vehicle frame ground connection Figure 2 19 3 Connect a cable from the vehicle frame ground to the negative post on the generator frame 4 Connect cables so the connectors are clean and tight Figure 2 19 Connecting Battery Cables POS VE
66. ant mixture see Coolant as neces sary the tank should be kept within the levels indi cated on the adjacent decal If desired a high quality rust inhibitor to the recommended 50 50 coolant mixture may be added If added consistently the recommended mixture will protect the unit against freezing temperatures Periodically remove the radiator pressure cap locat ed behind the access cover above the user control panel to make sure the coolant recovery system is functioning properly Coolant should be at the bot tom of the radiator filler neck If the coolant level is low inspect the gasket in the radiator pressure cap Replace the cap if necessary To have the pressure cap tested contact an Authorized Service Dealer Inspect both the cooling system and coolant recovery system for leaks 14 Dd A Do not remove the radiator pressure cap while the engine is hot otherwise serious burns from boiling liquid or steam could result AN Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radiator recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them caution AN Do not use any chromate base rust inhibitor with ethylene glycol base antifreeze otherwise chromium hydroxide green slime will form
67. ator Figure 2 18 Installation With Isolation Receptacle INSTALLATION Ps EXE A If the vehicle s electrical circuits can be powered by any other source of electricity such as a dockside power receptacle there must be no possibility of connecting the different power sources to the vehicle s circuits at the same time The dockside utility power source must be positively isolated from the vehicle s circuits whenever the generator is operating Failure to isolate the vehicle s circuits from the dockside power supply when the generator is running may result in damage to the generator or in serious injury or death to dockside utility power workers due to backfeed of electrical energy Installation and connection of the gen erator must comply with NFPA 70 Article 551 and NFPA 1192 latest editions 2 7 BATTERY INSTALLATION 2 71 RECOMMENDED BATTERY Install a battery that meets the following require ments The battery must be a 12 volt automotive type storage battery Use a battery with minimum ratings of 70 amp hours and 600 cold cranking amps NOTE If the battery is to be used to power other vehicle accessories as well as to start the generator a bat tery with a larger capacity may be necessary DOCKSIDE POWER RECEPTACLE FLEXIBLE CONDUIT Dasg 7 power kasi ar CORD VEHICLE AC DISTRIBUTION PANEL 2 7 2 BATTERY CABLES Using battery cables that are too long or too sm
68. ators 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 periodically by an Authorized Service Dealer Normal maintenance service and replacement of parts are the responsi bilities of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual oper ating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator minimizes problems and operating expenses See the Authorized Service Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact an Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting an Authorized Service Dealer or the factory about parts and service always supply the complete model number and serial number of the unit as given on its data label which is located on the generator Model No Serial No AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 or locate us on the web at www generac com Part Owner s Manual Introduction Inside Front Cover R
69. bing the suspension method used with the vehicle frame members must a be able to support the weight of the generator AND b provide sufficient restraint for the generator One typical sus pended mounting system is shown in Figure 2 1 The location of a suspended mounting system must be carefully planned keeping the following general rules in mind Protect the generator against road splash and debris Baffles or splash guards may be required to protect certain areas of the generator To make sure the generator is adequately protected road test the installation through mud water and slush Figure 2 1 Typical Suspended Mounting System HORIZONTAL SUPPORT BRACES The installer must make certain that the selected location will permit adequate cooling and ventilat ing airflow 2 1 4 GENERATOR RESTRAINT Use four 3 8 16 hardened steel bolts Grade 5 to fasten the generator to the supporting frame or the support tubing These bolts must pass through a the generator mounting base b the compartment floor if a compartment is used and c the support ing framework Figure 2 2 All bolts must be long enough so that when tight they engage at least 3 8 of an inch 9 5 millimeters Refer to the Generator Compartments section for the location of the genera tor mounting holes Figure 2 2 Typical Generator Restraint
70. ble Fuel Line Use a length of approved flexible fuel hose between the generator fuel supply fitting and rigid fuel lines This prevents breaking of the line caused by vibra tion shifting settling or movement The following rules apply The flexible hose must comply with SAE 41137 SOR7 Standard for Fuel and Oil Hose It must be approved for use with diesel fuel and low per meability The hose should be at least 6 inches 152 mm longer than is needed to prevent the hose from rupturing if the generator shifts or settles 2 4 3 GENERATOR FUEL RETURN LINES The same general rules that apply to fuel supply lines also apply to fuel return lines NOTE Locate the diesel fuel return line at least 12 inches from the tank fuel pickup tubes to prevent air bubbles from entering the fuel supply lines Recreational Vehicle Generator 2 5 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved exhaust system parts must be used A properly installed exhaust sys tem must be vapor tight quiet and completely safe A AN The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING O
71. cal Code Article 551 and NFPA 1192 latest edition Standard for Recreational Vehicles The gener ator also must have been installed in strict com pliance with the manufacturer s detailed instal lation instructions After installation do nothing that might render the unit in noncompliance with such codes standards and instructions Use this generator to supply electrical power for operating 120 240 volt single phase 60 Hertz AC electrical loads These loads can require up to 8 500 watts 8 5 kW of power but cannot exceed 70 8 AC amps of current at 120 volts or 35 4 AC amps at 240 volts caution A Do not overload the generator Some installa tions may require that electrical loads be alter nated to avoid overloading Applying excessive ly high electrical loads may damage the genera tor and 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 electri cal 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 1 5 SAFETY Before attempting to use the generator set care fully read the Safety Rules section of this manual Comply strictly with these rules to prevent a
72. ccidents and damage to equipment and or property We sug gest copying and posting the Safety Rules in poten tial hazard areas of the vehicle Stress safety to all operators and potential operators of this equipment Section 1 General Information GENERAL Recreational Vehicle Generator INFORMATION 14 GENERATOR AC CONNECTION SYSTEM This generator is equipped with dual stator AC power windings These two stator windings supply electri cal power to customer electrical loads by means of a dual two wire connection system Note however that the neutral is grounded The generator may have been installed so that it powers 120 volt AC electrical loads only Figure 1 1 It can be rewired to connect 120 240 volt AC elec trical loads This procedure should be done by an Authorized Service Dealer or other qualified installer Refer to the installation portion of this manual for more information Figure 1 1 Connections for 120 Volts Only Dual Circuits pow Je T1 Te T3 CRED NEUTRAL BLACK CB GROUNDED 44 cuu WIRE 32 1 5 SPECIFICATIONS 1 5 1 FUEL REQUIREMENTS The generator is equipped with a diesel fuel system Use clean fresh No 1D or No 2D diesel fuel with minimum Cetane number of 40 The diesel fuel must also conform to American Society of Testing and Materials ASTM specifications Never use any dirty or contaminated fuel When addi
73. d oil filter capacity is approximately 4 35L 4 6 U S quarts Do NOT use special additives See Checking the Engine Oil Level and Changing the Engine Oil and or Filter sections for oil level checking and changing procedures 1 5 4 COOLANT Use a 50 50 mixture that is half low silicate ethylene glycol base antifreeze and half soft water Use only soft water and only low silicate antifreeze If desired a high quality rust inhibitor to the recommended coolant mixture may be added When adding coolant always add the recommended 50 50 mixture DIG A Do not remove the radiator pressure cap while the engine is hot otherwise serious burns from boiling liquid or steam could result Section 1 General Information AN Ethylene glycol base antifreeze is poisonous Do not use mouth to siphon coolant from the radiator recovery bottle or any container Wash hands thoroughly after handling Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze even though it is poisonous to them caution Do not use any chromate base rust inhibitor with ethylene glycol base antifreeze or else chromium hydroxide green slime will form and cause overheating Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding eth ylene glycol base antifreeze Using any high silicate antifreeze boosters or additives will
74. d properly in strict compliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards The generator com partment 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 seriously damages the generator Do not alter the installation or permit even partial blockage of ventilation provisions as this can also seriously affect the safe operation of the generator When working this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental startup First disconnec
75. ded oil see Engine Oil Requirements Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor Clean and wipe the entire generator 3 12 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Check the tag the engine for viscosity and clas sification Verify that the correct recommended oil is used in the engine see Engine Oil Requirements If necessary drain and refill with the proper oil Check the state of the battery Fill all cells of unsealed batteries to the proper level with distilled water DO NOT USE TAP WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery Clean and wipe the entire generator Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incor rectly Turn OFF all electrical loads Add fuel if necessary and then start the engine Allow the unit to warm up thoroughly Apply electrical loads to at least 50 percent of the units rated wattage capacity When the engine is thoroughly warmed up shut it down The generator is now ready for service Section 5 Maintenance Recreational Vehicle Generator MAINTENANCE 15 MAINTENANCE S o Section 3 Maintenance Recr
76. designed built and equipped to meet the state s stringent anti smog standards In other states new 2000 and later non road diesel engines rated under 19 kW must be designed built and equipped to conform to applicable EPA regulations ISM must warrant the emission control system on your engine for that period of time listed below provided there has been no abuse neglect or improper maintenance of your small non road diesel engine Your California and EPA emission control system may include parts such as the fuel injection system and other emission related assemblies Where a warrantable condition exists GENERAC will repair your engine at no cost to you including diagnosis parts and labor on behalf of ISM Although ISM is ultimately responsible for this warranty GENERAC has agreed to carry out ISM s warranty repair responsibilities and GENERAC should be your primary contact for emission related warranty service MANUFACTURER S WARRANTY COVERAGE For 2000 and later small non road diesel engines first sold in California and for 2000 and later non road diesel engines rated under 19 kW first sold in all other states the applicable warranty period is two 2 years or 1 500 hours whichever comes first If any emission related part on your engine is defective the part will be repaired or replaced by a Generac Authorized Warranty Service Facility on behalf of ISM PARTS COVERED This emission control system warranty applies to the
77. e 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 instruc tions and recommendations Following proper installation do nothing that might alter a safe installation and render the unit in noncompli ance with the aforementioned codes standards 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 system Keep the extinguisher properly charged and be familiar with its use If there are any questions per taining to fire extinguishers consult the local fire department EXPLOSION HAZARDS A 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 fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and han dling of fuels Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipm
78. ead This Manual Thoroughly IFC 0 A O Operation and Maintenance IFC How to Obtain ServiGe eer vent oreet ne see veo ed een ce IFC Authorized Service Dealer Locator Number IFC ilg 9 A 2 Section 1 General Information 4 1 1 Generator Identification 2 4 12 Generator Applicability 1 5 1 9 Safety sean ed 5 1 4 Generator AC Connection System 5 1 5 Speclflcations stre 5 Section 2 Operation 7 2 1 Generator Control 2 7 2 22 Optional Remote Start Stop 8 2 3 Before Starting the Engine 8 2 4 Starting the Generator 211 9 2 5 Stopping the 9 2 6 Applying Loads to Generator 9 2 7 Protection Systems 10 2 8 Additional Information eese 10 Section 5 11 3 1 Checking the Engine Level 11 3 2 Changing the Engine Oil and or Oil Filter
79. eational Vehicle Generator 5 13 SERVICE SCHEDULE ATTENTION It is recommended that all service work be performed by the nearest Authorized Service Dealer SYSTEM COMPONENT PROCEDURE X Action Inspect R Replace Adjust as Needed To Be Completed by an Authorized Service Dealer Fuel level Fuel lines and connections Fuel Filter LUBRICATION Oil level Oil Filter Oil line leakage COOLING Engine cooling system Coolant level Enclosure louvers EXHAUST Exhaust system Retorque Exhaust Manifold Clean out Muffler Spark Arrestor BATTERY Electrolyte fluid level Charge and condition FAN ALTERNATOR BELTS Tension and condition ENGINE Retorque cylinder head Retorque intake manifold Starter motor Air filter Compression Valve clearance Governor Safety devices Injection system GENERAL Overall condition Exercise system COMPLETE TUNE UP 16 D Daily M Monthly H Hours AFTER 25 D BEFORE USE AFTER 25 EVERY 250H 6M EVERY 250H 6M EVERY 8 H D AFTER 25 H EVERY 250 H 6M AFTER 25 H EVERY 250 H 6 M EVERY 100 H AFTER 25 H EVERY 100 H M AFTER 25 H D BEFORE USE EVERY 500 H Y EVERY 250H 6M EVERY 750 H EVERY 750 H EVERY 750H EVERY 750H EVERY 500 H EVERY 750H EVERY 750H EVERY 750 H EVERY 750H EVERY 750H AFTER 25 H W W Y W Weekly Y Yearly PART Il INSTALLATION INSTRUCTIONS SAFETY RULES Safety Rules Recreatio
80. ect any leakage immediate ly 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load See the Testing Under Load section Run the unit at least 30 minutes with loads applied 6 Turn off all electrical loads by setting the genera tor s line breakers to their OFF or OPEN posi tion 7 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine warninc amp The generator set was thoroughly tested and adjusted at the factory before shipping No additional adjustment should be necessary Only trained qualified service technicians should per form adjustments outlined in this manual 5 4 TESTING UNDER LOAD Apply electrical loads equal to about 50 to 75 percent of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling airflow is available Do not allow the unit to overheat during prolonged operation NOTE The generator engine is equipped with a high cool ant temperature switch The switch has normally open N O contacts When the engine coolant temperature is too high switch contacts close and the engine shuts down automatically THE MANUFACTURER RECOMMENDS THAT THE GENERATOR BE TESTED FOR ADEQUATE COOL ING
81. ected and repaired A AN Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installa tion manual Make sure there is ample fresh air when operating the genset in a confined area 2 4 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 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 start the generator from either the generator con trol panel or from the optional remote panel proceed as follows 1 Turn OFF electrical loads using the means pro vided in the vehicle such as a main line circuit breaker or transfer switch NOTE If starting from the generator control panel turn OFF loads by setting the generator s main line 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 started stabi lized and warmed up 2 If the
82. ed precautions Keep unauthor ized personnel away from batteries Damage will result if the battery connections are made in reverse A DIG A Do not dispose of the battery in a fire The battery is capable of exploding Storage batter ies release explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explo sion 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 tool or equip ment near the battery Discharge static electric ity from body before touching the battery by first touching a grounded metal surface A battery presents a risk of electrical shock and high short circuit current The following precau tions are to be observed when working on bat teries Remove watches rings and other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery Disconnect any charging source prior to connect ing or disconnecting battery terminals and Do not use any jumper cables or booster battery to crank and start the generator engine If any bat tery has discharged remove it for recharging 13 MAINTENANCE o Section 3 Maintenance Recreatio
83. engine is cold press the Preheat switch for a maximum of 15 to 30 seconds 3 While pressing the Preheat switch to crank the engine hold the engine Start Stop switch in the START position When the engine starts release the switches caution Ak AN If the engine does not start after it has been cranking for 15 seconds release the Start Stop switch wait 15 seconds and try again Holding the switch for longer than 15 seconds can dam age the starter motor 4 Letthe engine run at no load for a few minutes to stabilize and warm up 5 Turn ON electrical loads using the means pro vided in the vehicle such as a main line circuit breaker or transfer switch Section 2 Operation OPERATION Recreational Vehicle Generator 2 5 5 1 Turn OFF all electrical loads using the means provided in the vehicle such as a main line cir cuit breaker or transfer switch 2 Let generator run at no load for a few minutes to stabilize internal engine generator tempera tures caution Ak Do not stop the engine generator immediately after running under load This can overheat and damage the engine and or generator 3 Press and hold the Start Stop switch in the STOP position until the engine shuts off 2 6 APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Before applying electrical loads let the
84. ent into service There must be no possibility of fuel vapors enter ing the vehicle interior It is required that an approved flexible noncon ductive fuel line between the generator fuel connec tion point and the rigid fuel lines be installed 19 Section 1 General Information Recreational Vehicle Generator 1 1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the products installation requirements Give serious consideration to all information and instructions in the manual both for safety and for continued reliable operation of the equipment Because of the different recreational vehicle mod els and the variations between the models it would be extremely difficult if not impractical to provide detailed instructions for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all appli cable codes standards and regulations pertaining to the installation and use of this product If any portion of this manual appears to be in conflict with such codes standards or regulations the applicable codes standards or regulations must take prece dence over the manual 1 2 SAFETY Before handling installing
85. eted or screwed Manufactured lock seams are shown in Figure 2 4 Installer constructed compartments typically utilize a standard lap joint Figure 2 4 Types of Lock Seams mL ACME LOCK FOLD LOCKED STANDING OFF SET DOUBLE LOCK DOUBLE SEAM EC GORDON SEAM LOCK SEAM STANDARD LAP JOINT After the compartment has been metal lined and vapor sealed line the compartment inte rior walls and ceiling with an approved nonflam mable sound insulating material See the Sound Insulating Materials section DIG A Do not install any flammable material directly above or around the compartment Heat trans ferred through the compartment structure may be sufficient to ignite char or discolor seat cushions fiberboard and other flammable mate rials Use approved nonflammable insulating materials in high temperature areas 2 2 2 SOUND INSULATING MATERIALS Once installers have determined that a compartment is properly constructed and metal lined they can add acoustical material This may include additional seal ant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a nonflam mable type One excellent insulating material is a 1 inch 25 mm thick fiberglass having a
86. f California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this manual and with the unit The gen erator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique uti lized does not render the generator unsafe A Despite the safe design of this generator operating this equipment imprudently neglect ing its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate and maintain this equipment Parts of the generator are rotating and or hot during operation Exercise care near running generators Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator N GENERAL HAZARDS N
87. f supplying half of the unit s rated watt age amperage capacity The circuit from each winding is protected against overload by a line breaker and CB1A Line breakers and have a trip rating of 40 amps Figure 2 14 Generator Output Leads T1 Red Neutral White T3 Black T2 Neutral E White Ground Green 2 63 1 Generator Conversion to 120 240 Volt Dual Voltage NOTE Conversion of this generator from 120 volts only dual circuits to 120 240 volt dual circuits or vice versa requires rerouting wires within the unit enclosure It is recommended that this conversion be performed by an Authorized Service Dealer Figure 2 16 shows the stator power winding con nections for 120 240 volt dual voltage The stator power windings are connected in series Lead 11 11A connects to T1 Red lead 44 44A connects to Black while leads 22 and 33 are grounded and con nect to T2 NEUTRAL White A tie bar connects the two switch handles on line breaker CB1 To convert from 120 volt dual circuits to 120 240 volt dual voltage disconnect battery power from the generator and reverse stator lead wires 33 and 44 as follows NOTE It is necessary to feed stator lead wires 33 and 44 through grommets on the electrical enclosure and engine control box in order to perform the rerout ing outlined below The front and top unit enclo sure panels as well as the user con
88. following engine emission control parts Fuel Injection Pump Fuel Injectors Intake Manifold Exhaust Manifold Air Cleaner Element Miscellaneous Hoses Bolts and Connectors OWNER S WARRANTY RESPONSIBILITIES As the engine owner you are responsible for the performance of the required maintenance listed in your Owner s Manual GENERAC and ISM recommend that you retain the original purchase documentation and all receipts covering maintenance on your engine but GENERAC and ISM cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the engine owner you should be aware however that GENERAC and ISM may deny you warranty coverage if your engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty Service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 If you have any questions regarding your warranty rights and responsibilities you should contact GENERAC at the following address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC
89. generator stabilize and warm up for a minute or two DO NOT overload the generator 2 6 1 LETTING THE ENGINE STABILIZE The generator supplies correctly rated voltage only at the proper governed speed Some electrical appli ances may be extremely sensitive to voltage Incorrect voltages can damage such appliances Electrical loads applied on the engine at reduced operating speeds such loads imposed on the engine when sufficient power is not available may shorten engine life Never turn ON electrical loads until after the generator engine has started and stabilized at no load 2 6 2 NOT OVERLOAD THE GENERATOR Read the rated wattage amperage capacity of the gen erator on the generator data label located below the user control panel Applying electrical loads in excess of the unit s rated capacity may trip the line breaker or cause the engine generator to 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 gen erator 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 multiply that load s rated VOLTS times AMPS to obtain WATTS OPERATION Section 2 Operation ix Recreational Vehicle Generator Induction
90. haust system under opening window or vent that can be opened or is not permanently sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all applicable codes standards and regula tions 2 6 ELECTRICAL CONNECTIONS Be sure to read the Generator AC Connection System section The following general rules apply to electrical connec tions in a recreational vehicle Qualified electricians who are familiar with appli cable codes standards and regulations should install electrical wiring The wiring should comply with codes standards and regulations The National Electrical Code NFPA 70 and state and local codes apply Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent damage from road shock Wiring must be of adequate size have approved insulative qualities and be properly supported Conduit and wire openings into the generator com partment if used must be vapor sealed to prevent entry of flammable explosive or poisonous gases into the vehicle 2 6 1 ELECTRICAL JUNC
91. he 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 an 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 nonconduct ing implement such as a dry rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help SAFETY RULES Safety Rules Recreational Vehicle Generator Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation must always comply with NFPA 70 latest edition National Electrical Code Article 551 and NFPA 1192 lat est edition Standard for Recreational Vehicles along with all applicable codes standards laws and regulations Adhere strictly to local state and federal electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recom mendations After proper installation do nothing that might a
92. isture when combined form a good electrical conductor 3 1 CHECKING THE ENGINE OIL LEVEL Check the engine crankcase oil level every eight hours of operation or at least once daily before using the generator For oil capacities and requirements see Engine Oil Requirements To check the engine oil level proceed as follows see Figure 3 1 1 Be sure the generator is as leveled as possible 2 Remove the dipstick and wipe it dry with a clean lint free cloth 3 Install the dipstick and fully seat the T handle then remove it again The oil level should be at the dipstick Full mark 4 If necessary remove the oil fill plug and slowly add oil until it reaches the dipstick FULL mark DO NOT FILL ABOVE THE FULL MARK cauroN A Never operate the engine with the oil level below the ADD mark on the dipstick Doing this could damage the engine 5 Install the oil fill plug and the dipstick before operating the engine MAINTENANCE Section 3 Maintenance Recreational Vehicle Generator Figure 3 1 Oil Maintenance Features OIL FILL OIL DIPSTICK OPENING AND PLUG REMOVABLE FRONT PANEL TRANSPARENT FOR VIEWING PURPOSES OIL FILTER OIL DRAIN PLUG LATCHES m SERVICE DOOR 5 2 CHANGING THE ENGINE OIL AND OR OIL FILTER caution Ak AN Never operate the engine with the oil level below the ADD mark on the dipstick Doing this could damage the engine Cha
93. ized steel Vapor seal all compartment seams and joints Over the galvanized steel lining install a combina tion of acoustical materials as mentioned in the Sound Insulating Materials section Dd A To prevent fire or explosion do not install any insulation or other absorbent materials on the interior or underside of the compartment floor Seal all compartment door edges to prevent noise leakage around the door perimeter Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 25 mm thick fiberglass with 2 pound density Figure 2 5 Typical Noise Abatement PLYWOOD 5 8 OR 3 4 EXTERIOR SOUND INSOLATION MATERIAL DOUBLE LAYER PLYWOOD BASE FIBERGLASS PLYWOOD 5 8 OR 3 4 THICK INSTALLATION Section 2 Installation Recreational Vehicle Generator 2 2 4 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items Figure 2 6 Engine exhaust and cooling air outlets Generator cooling air inlet and front service door Four holes for passage of generator mounting bolts See the Generator Restraint section Rear service door Dd A Fuel lines and exhaust piping must not pen etrate into the vehicle living area INSUL
94. letely satisfy themselves that their safety the safety of the vehicle s occupants and the product s safety are not endangered by the method procedure or technique selected Information illustrations specifications etc tained in these Installation Instructions are based on the latest information available at the time of publica tion Every effort has been expended to be sure that such data are both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time with out prior notice A A AN 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 Parts of the generator are rotating and or hot during operation Exercise care near running generators AN Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator N GENERAL HAZARDS N For safety reasons the manufacturer recommends that the installation initial startup and main tenance of this equipment is carried out by an Authorized Service Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can ca
95. lter the installation and render the unit in noncompliance with the aforementioned codes standards 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 there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS A Do not smoke around the generator Wipe off any fuel or oil spills immediately Ensure that no combustible material is 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 of debris fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the unit s fuel system fre quently and correct any leaks immediately Before placing this equipment into service the fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes Section 1 General Information Recreational Vehicle Generator 1 1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA LABEL or information label located below the user control panel 1 Model
96. nal Vehicle Generator warninc amp Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Immediately wash with water all skin areas that come into contact with the electrolyte If the electrolyte contacts the eyes immediately flush eyes thoroughly with water and seek medi cal attention Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters of water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried 5 7 COOLING SYSTEM Air intake and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation Avoid obstructions such as high grass weeds brush leaves and snow Without sufficient cooling and ventilating air flow the engine generator quickly overheats which causes it to shut down 3 8 ENGINE COOLANT Check the coolant level in the coolant recovery tank at least once daily or prior to use Add the recom mended cool
97. nal Vehicle Generator DANGER For fire safety installation of a generator into a recreational vehicle must comply strictly with 70 latest edition National Electrical Code Article 551 and NFPA 1192 latest edition Standard for Recreational Vehicles In addition installation must comply with the manufacturer s instructions and recommendations NOTICE TO INSTALLER These Installation Instructions have been published by The manufacturer to aid in the installation of the products described in this manual The manufacturer assumes that installation personnel are familiar with the procedures for installing such products or simi lar products manufactured The manufacturer also assumes that personnel have been trained in the rec ommended installation procedures for these products and that such training includes a use of common hand tools b use of special tools and c use of any tools and or equipment from other suppliers The manufacturer cannot possibly know of nor advise the recreational vehicle trade of all conceiv able methods procedures or techniques by which to perform an installation Nor can the manufacturer anticipate every possible hazard that might result from each installation method procedure or tech nique The manufacturer has not undertaken any such wide evaluation Therefore people who use a method procedure or technique that the manufac turer does not specifically recommend must first comp
98. ner maintenance 128 3 4 SPARK ARRESTOR MUFFLER The exhaust muffler supplied with the generator is a spark arrestor type The exhaust mufflers for recreational vehicle generators do not have a spark arrestor screen but are of the more efficient toroid or swirl type To remove carbon and combustion deposits from the muffler proceed as follows see Figure 3 3 1 Place the unit above a noncombustible surface and ensure that the generator exhaust piping is cool 2 Remove the two screws holding the spark arres tor access plate to the rear floor pan 3 Remove the spark arrestor access plate and gas ket 4 Remove the hex pipe cap from the end of the spark arrestor cleanout pipe 5 Thread on a 3 8 NPT pipe coupling and pipe nipple to extend the cleanout pipe at least 10 inches 250 mm below the rear floor pan addi tional piping may be added to direct the muffler exhaust away from the cooling air discharge flow beneath the unit Figure 3 3 Spark Arrestor Muffler Maintenance 3 8 NPT HEX PIPE CAP GASKET lt gt lt ACCESS PLATE 6 Start and run the engine for approximately 15 minutes 7 Shut down the engine and allow the piping to cool 8 Remove the 3 8 NPT coupling and piping 9 Apply a graphite base anti seize compound to the cleanout pipe threads 10 Reinstall the hex pipe cap spark arrestor access plate gasket and two screws WARNING amp The exhaust system
99. ng fuel DO NOT overfill the tank Allow room at the top of the tank for fuel expansion Depending on the installation the generator may have either a separate fuel tank or share the vehicle s engine fuel tank 11 22 GENERAL Recreational Vehicle Generator INFORMATION NOTE Some installations using a shared fuel tank may have a generator fuel pickup tube that is shorter than the vehicle s engine pickup tube Such an arrangement causes the generator engine to run out of fuel while adequate fuel for the vehicle engine remains in the tank Also appropriate care should be taken in applica tions where extremely low ambient temperatures are possible to ensure the temperature of the die sel fuel is not allowed to fall below levels where gelling could occur 1 5 2 FUEL CONSUMPTION GAL HR wes om 1 5 5 ENGINE OIL REQUIREMENTS Use a high quality detergent oil with American Petroleum Institute API classification For Service CC Detergent oils keep the engine cleaner and reduce carbon deposits Use oil having the following SAE viscosity rating based on the ambient tempera ture range anticipated before the next oil change Oil Grade Recommended SAE 15W 40 or SAE 40 Temperature Above 100 F 38 C 40 to 100 4 4 to 38 SAE 10W 30 or SAE 30 SAE 5W 20 or 5W 30 in units from the factory Below 40 F 4 4 C Crankcase an
100. ng in the compartment door an opening in the vehicle skirt through duct work or by any other means NOTE Screening louvers or expanded metal that cover air openings restrict airflow Compensate for this by making the actual air opening proportionately larger See the Compensating for Restrictions section Figure 2 8 Air Inlet in Compartment Door 599 5 XX 555599 XX 0000900006 s 2400000002 RRL 150 SQUARE INCHES UNRESTRICTED gt MINIMUM OPENING 1 When the unit is installed on a suspended mounting system one of several different methods of supplying airflow may be used as follows lt 5 30000 5 XO Se RRRS RRO XXX 100 5 55 2 500000500 e 3 Provide door in the vehicle skirt having an air inlet opening Figure 2 9 Figure 2 9 Suspended Mount Inlet Door Use duct work Figure 2 10 The installer must be sure air is available to the sides of the generator for proper air intake Provide an opening in the vehicle skirt and space around the generator for cooling airflow Figure 2 11 Recommended clearance around all sides of the generator is at least two inches 50 mm Figure 2 10 Air Inlet Using Duct work ANTI SPLASH m t 1 L s ls BA
101. nge the engine oil and oil filter after the first 25 hours of operation See the Service Schedule sec tion for subsequent oil and filter changes Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures To change the oil and or oil filter proceed as follows see Figure 3 1 1 Runthe engine until it is thoroughly warmed up for at least five minutes then shut OFF the engine 2 Immediately after the engine shuts remove the front service door located beneath the unit by retracting the two latches and pivoting the door downward If space allows remove the front panel by removing the four retaining bolts Be careful not to let the panel fall 3 Remove the air filter see Servicing the Engine Air Filter 4 Remove the oil drain plug and drain the oil into a suitable container Removing the oil fill plug will allow the crankcase to drain faster 5 After the oil has drained replace the oil drain plug Go to step 9 if changing oil only 6 With the oil drained remove the old oil filter by turning it counterclockwise 7 Apply a light coating of clean engine oil to the gasket of the new filter 11 S o Section 3 Maintenance Recreational Vehicle Generator 8 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 9 Remove the dipstick and
102. nvenience or loss of use of this engine or equipment e Damages or repair costs caused by the owner s unreasonable delay in making the engine available for inspection and repair f Diagnosis or inspection fees that do not result in eligible warranty service being performed g Equipment with an altered or disconnected hourmeter where the hours cannot be determined h Equipment normally operated outside the United States i Accident caused damage acts of nature or other events beyond GENERAC S control j Warranty repairs undertaken or attempted by the owner or any other person who is not affiliated with a Generac Authorized Warranty Service Facility OBTAINING WARRANTY SERVICE To obtain service under this warranty promptly contact your nearest Generac Authorized Service Dealer or a Generac Authorized Warranty Service Facility If available provide the GENERAC representative with the original purchase receipt showing the initial date of purchase and all available maintenance records Page 2 Section 7 Warranty WARRANTY Recreational Vehicle Generator GENERAC POWER SYSTEMS THREE YEAR LIMITED WARRANTY FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS NOTE ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES For a period of 3 three years of operation from the date of original sale Generac Power Systems Inc Generac will at its option repair or replace any part which upon examina
103. oblems Air that is trapped in the diesel fuel system results in hard starting and rough engine operation Dirt that enters the fuel system also may cause prob lems Lines and piping must be properly installed and tightened to prevent dirt from entering Diesel fuel must be kept clean Factory installed generator fuel system components include a a fuel filter b a 12 volt DC electric pump c an injection pump and d interconnecting lines and fittings Connect a fuel supply line to the supply fitting and a return line from the fuel return fitting back to the tank NOTE Fuel supply and return fittings located on the gen erator are 1 8 NPT Use a length of approved flexible fuel hose between the fuel connection fittings and rigid fuel lines see the Generator Fuel Supply Lines and Generator Fuel Return Lines sections 2 4 1 FUEL TANK Either the generator must share the vehicle s engine fuel tank or a separate fuel tank for the generator set must be installed fuel tanks installed on the vehi cle must be constructed installed and restrained so they comply with applicable codes standards and regulations If the generator is to share the vehicle s engine tank separate fuel pickup tubes are required for the engine and the generator The manufacturer recommends that the fuel pickup tube be two to three inches 51 to 76 mm shorter than the vehicle s engine pickup tube This prevents the generator from de
104. of this product gets extremely hot and remains hot after shutdown High grass weeds brush leaves etc must remain clear of the exhaust Such materials may ignite and burn from the heat of the exhaust system amp AN Failure to provide and maintain a spark arres tor may be in violation of the law If this gen erator is used on any forest covered brush covered or grass covered unimproved land the vehicle owner or operator must maintain the spark arrestor in good condition In the state of California the preceding is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands wnRNING Be sure to reinstall the hex pipe cap tightly to the spark arrestor cleanout pipe Vibration could cause a loose cap to fall out resulting in hot engine exhaust being drawn through the cen trifugal cooling fan and out beneath the unit This could result in damage to the generator or in discharge of hot exhaust sparks beneath the unit 3 5 CLEANING THE GENERATOR Keep the generator as clean and as dry as possible Dirt and moisture that accumulate on internal gen erator windings have adversely affect insulation resistance Periodically clean the generator s exterior surfaces A soft brush may be used to loosen caked on dirt Use a vacuum system or dry low pressure air to remove any accumulations of dirt The generator is
105. or Cooling System Drawing No 0G7352 A 0 1 00647605703 1 COVER PLATE SCRL WLDMNT 2 0G64470ST03 1 HOUSING FAN SCROLL WLDMNT 3 0C4552 1 FAN SQUIRREL CAGE 4 0C4554 1 SHAFT FAN 5 0C4555 1 BEARING CARRIER 6 0C4557 1 KEY SQ 3 16 X 5 8 STEEL 7 0C4556A 1 PULLEY FAN DIA 114 8MM 8 0C4553 1 BEARING 2 ROW BALL 9 049869 1 WASHER FLAT M16 10 081810 1 NUT HEX M16 1 5 G8 YEL CHR 11 070265 1 WASHER LOCK M16 12 004933 7 SCREW SWT 1 4 20 X 5 8 W W 13 043146 2 SCREW HHC M6 1 0 X 10 C8 8 14 022097 8 WASHER LOCK M6 1 4 15 049815 4 SCREW HHC M5 0 8 X 16 G8 8 16 022152 4 WASHER LOCK 10 17 051716 4 NUT HEX 5 0 8 G8 CLEAR ZINC 18 052857 13 NUT TOP LOCK FL M6 1 0 19 0C4312 1 RADIATOR 1 0L RV 20 043116 4 SCREW HHC M6 1 0 X 12 G8 8 21 022473 6 WASHER FLAT 1 4 M6 ZINC 22 0C8645 1 PULLEY 3 FLAT FLNGD 23 0C8507 1 BRACKET TENSIONER 24 039253 2 SCREW HHC M8 1 25 X 20 C8 8 25 022129 6 WASHER LOCK M8 5 16 26 0C6549A 1 V BELT 61 0 GREEN 27 0C5108 1 FILLER NECK ASY RAD 28 0C6236 1 HOSE TEE 29 0C7384 1 HOSE COUPLING 30 0C5543 1 HOSE RADIATOR LWR 31 0C4460 1 HOSE WATER PUMP LWR 32 0F4352 1 COOLANT HOSE TIER 2 DIESEL 33 0C5544 1 HOSE LWR INTERMEDIAT 34 086133A 8 CLAMP HI TORQUE 1 1 75 35 035473 2 CLAMP HOSE 12 50 1 25 36 050968 1 HOSE COOL 3 4 ID 20R3 28 3 LG 37 059981 1 SCREW HHC M10 1 5 X 30 C10 9 38 046526 1 WASHER LOCK M10 39 047411 2 SCREW HHC M6 1 0 X 16 C8 8 40 0C7997 1 HOSE COOL 5 16 SAE 20R4 10 6 LG 41 0C7649 4 CLAMP HOSE 38 87 42
106. ould be retained in the event of questions and these receipts should be passed on to each subsequent owner of the engine It is recommended that replacement parts used for maintenance or repairs be GENERAC authorized and approved parts to maintain the quality originally designed into your emission certified engine However any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner Such use will not reduce the warranty obligations of GENERAC Add on or modified parts may not be used for maintenance or warranty repairs Such use will be grounds for disallowing a warranty claim and GENERAC will not be liable to warrant failures of warranted parts caused by the use of an add on or modified part LIMITATIONS This warranty shall not cover any of the following a Systems and parts that were not first installed on the new equipment or engine as original equipment by GENERAC b Conditions resulting from tampering misuse abuse improper adjustment engine alteration use of add on or modified parts use of replacement parts that are not the same in performance and durability as GENERAC approved replacement parts accident failure to use the recommended fuel or oil use of unapproved fuel or oil additives or failure to perform required maintenance c Replacement parts used for required or scheduled maintenance d Consequential damages such as loss of time inco
107. overheating enlarge the air open ings Never place a unit into service until absolutely certain that cooling and ventilation is adequate NOTE The installation must be tested especially if bring ing in air from below the generator set 2 4 DIESEL FUEL SYSTEM The installation of a diesel fuel system Figure 2 12 for a recreational vehicle generator set must comply with applicable codes standards and regulations The entire fuel system must be completely free of leaks There must be no possibility of fuel vapors entering the vehicle interior Figure 2 12 Generator Fuel System FUEL FUEL SUPPLY RETURN DH A A All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Properly install and maintain the fuel system and keep it entirely free of leaks Fuel vapors must not enter the vehicle interior 27 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator Because diesel fuels are less volatile than gasoline or gaseous fuels they are considered safer from the standpoint of storage and handling As a result installers may tend to be careless in their installation practices which can result in poor engine perfor mance For example a poorly tightened fuel line may not show any signs of leakage however air can be drawn into the loose connection and cause pr
108. pleting the entire fuel supply during prolonged generator operat ing periods cauroN Ak AN Do NOT tee the generator fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not run ning generator operation may drain the vehicle engine supply line making it difficult to start the vehicle engine 2 4 2 GENERATOR FUEL SUPPLY LINES 2 4 2 1 Rigid Fuel Lines Those lines used to supply fuel from a tank to the generator must comply with applicable codes stan dards and regulations The following general rules apply to rigid fuel lines Rigid lines should be of annealed seamless drawn aluminum or steel Lines and fittings must comply with SAE J512E Standard Automotive Fittings or with ANSI B126 26 latest edition Route the fuel line so that at least 2 inches 51 mm of clearance is maintained between the line and any exhaust system parts Do not attach electrical wiring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so that if they leak fuel does not drip onto any electrical or exhaust system parts Use nonferrous metal straps without sharp edges to secure fuel lines Fuel system components must be accessible but protected from abrasion chafing road damage and kinking 2 4 2 2 Flexi
109. 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 essential for preventing accidents Four commonly used safety symbols accompany the Danger Warning and Caution blocks Here are the types of information indicated by each symbol This symbol points out important safety infor mation that if not followed could endanger personal safety and or property to self and others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator i e the driver is responsible for the proper and safe use of the vehicle and its equipment and for the safety of all vehicle occupants Before using this equipment we strongly recommend that the operator read this manual and thoroughly under stand all instructions We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them to operate the equipment in case of an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for generator model number 005432 0 In addition the latter portion of this manual contains information necessary for the proper installation of these gener
110. rol board There is no AC output from 1 Maindine circuit breaker open 1 Resetline breaker the generator to ON or CLOSED 2 Fault with vehicle circuit 2 Reset and replace if necessary breaker and or fuses 3 Generator internal failure 3 Contact an Authorized Service Dealer Section 5 Electrical Data Recreational Vehicle Generator ELECTRICAL DAA gt Electrical Schematic 120 240 Output Drawing 0G7332 C CB1 LOCATED IN ALT VOLTAGE REGULATOR B mu _ 2 CONPPARTMENT 11 11 11 7 2 77 40A 2 55 SECs 120 8 11 6 55 I I 22 22 1 22 22 22 72 2 AVR F 4 44 44 44 Q 72 gt 162 I ugs 5 I I i I z B 5 5 1 120 lt D2A9 1 4 66 600V 33 33 33A Q T3 al LOCATED IN
111. s section pertain to liquid cooled generators designed specifically for installing in recreational vehicles This unit operates 120 240 volt single phase 60 Hertz AC electrical loads that require up to 70 8 amps at 120 volts or 35 4 amps at 240 volts 1 5 GENERATOR ENGINE OPERATING SPEED The generator s two pole revolving field rotor is driven by a three cylinder 1 1 liter diesel engine The generator supplies 120 240 volts AC at 60 Hertz when the rotor is operating at 3 600 rpm Engine speed is held nearly constant by a mechanical fixed speed governor at 1 950 rpm 1 6 GENERATOR AC CONNECTION SYSTEM The generator is equipped with dual stator power windings as shown in Figure 1 1 Figure 1 1 Connections for 120 Volts Only Dual Circuits pem NEUTR 3 SRED CWHIT Jei 5 T b BLACK GROUNDED 44 11 22 NEUTRAL 33 L 1 Z WIRE The AC connection system uses a GROUNDED neutral A separate green ground wire is connected to the recreational vehicle s junction box For this unit each stator winding can support 120 volt 60 Hertz AC electrical output 3 600 rpm When the two stator windings are connected in series the unit can generate an output of 240 volts AC NOTE Do NOT connect loads in excess of circuit breaker ratings
112. sion theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CON
113. ssary adjustments Factory settings are correct for most applica tions When making adjustments however be careful to avoid overspeeding the engine 5 2 BEFORE INITIAL STARTUP Before starting complete the following 1 Check the engine crankcase oil level and if nec essary fill to the dipstick FULL mark cross hatched area with the recommended oil Do not fill above the FULL mark 2 Check the fuel supply Fuel lines must have been properly purged and leak tested in accordance with applicable fuel codes All fuel shutoff valves in the fuel supply lines must be open 3 3 INITIAL START When absolutely certain that the unit has been prop erly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s line breakers to their OFF or open position POST 252 INSTALLATION Recreational Vehicle Generator START UP CHECKS 2 Refer to Part I the Starting the Generator sec tion for cranking and starting instructions The engine may require more cranking for initial starting since the fuel lines have to be primed use of the preheat switch will operate the genera tor s electrical fuel pump and shorten this time 3 Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step corr
114. t the cable from the battery post indicated by a NEGATIVE NEG or Reconnect this cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts resulting in dangerous operating conditions due to leaking exhaust gases fuel leakage oil leak age etc Never insert any tool or other object through open ings in the generator interior even if the unit is not running Serious injury or damage to the equip ment could be done N 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 run ning Before operating the generator ensure all appropriate covers guards and barriers are in place If work must be done 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 generator 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 t
115. tage surge is a common cause of damage to electronic equipment 2 8 ADDITIONAL INFORMATION 2 8 1 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 an Authorized Service Dealer thoroughly clean and dry the generator 2 8 0 OPERATION IN HIGH GRASS OR BRUSH Never operate the generator while the vehicle is parked over high grass weeds brush leaves or other combustible substance 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 2 8 5 EFFECTS OF MOISTURE AND DIRT Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and mois ture 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 reduces insu lation resistance and will eventually cause problems Dirt will make the problem worse since it tends to hold moisture in contact with windings Salt as from sea air will also worsen the problem since it tends to absorb moisture from the air Salt and mo
116. tight Cables are connected properly Proper ventilation is provided D OUCCCHLDIo U Terminals are coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES Check that remote start stop panels if used installed properly Check that all other options and accessories if used are installed properly POST INSTALLATION TESTS Check that all tests are completed properly NAME OF INSTALLER SIGNATURE OF INSTALLER 36 Section 4 Troubleshooting Recreational Vehicle Generator 4 1 TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank 1 System control fuse blown 1 Replace fuse 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defective engine Start Stop 3 Replace Start Stop switch switch 4 Defective starter contactor 4 Replace contactor 5 Defective starter motor 5 Replace starter motor 6 Low or defective battery 6 Charge or replace battery 7 Defective engine control board 7 Replace control board The engine cranks but 1 Vehicle fuel shutoff valve closed Open valve if so equipped will not start 2 Out of fuel Replenish fuel 3 Defective fuel solenoid FS Replace solenoid 4 Defective fuel pump FP Repair or replace fuel pump 5 Open 14 wire from Check connections and engine control board insulation of 14 wires 6 Plugged fuel filter
117. tion inspection and testing by Generac or a Generac Authorized Warranty Service Facility is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac generators sold and rated for Recreational Vehicle RV applications as Generac has defined Recreational Vehicle generator applications The factory recommends exercising the unit one half hour every month WARRANTY SCHEDULE COMMERCIAL APPLICATIONS YEAR ONE 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components WARRANTY SCHEDULE CONSUMER PERSONAL APPLICATIONS YEARS ONE AND TWO 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components YEAR THREE 100 one hundred percent only on selected part s and labor listed Any labor and part s not listed and removal and reinstallation are the owner s responsibility Rotor Stator Computer Control Board part numbers 0A6060 and 0A3369 and inverter if applicable with regard to the generator
118. tor installation must have been properly com pleted so that it complies with all applicable codes standards and regulations and with the manufac turer s recommendations NOTE Be sure the installation complies with all stan dards and codes listed in the Standards Booklets section of this manual 2 5 2 ENGINE LUBRICATION Before starting the engine have the engine crankcase properly serviced with the recommended oil Refer to the Engine Oil Requirements Checking the Engine Oil Level and Changing the Engine Oil and or Filter sections for oil servicing procedures and recommen dations caution Any attempt to crank or start the engine before it has been properly serviced it with the recom mended oil may result in an engine failure 2 5 5 FUEL SUPPLY The engine must have an adequate supply of proper fuel to operate Before starting it check that suffi cient fuel is available NOTE Depending on the installation the generator may have either a separate fuel tank or share the vehicle s engine fuel tank Some installations using a shared fuel tank may have a generator fuel pickup tube that is shorter than the vehicle s engine pickup tube Such an arrangement causes the generator engine to run out of fuel while adequate fuel for the vehicle engine remains in the tank 2 5 4 COOLANT LEVEL Check the engine coolant level prior to initial use and at recommended intervals Refer to the
119. trol panel must be removed to perform this After re routing wires should be properly tied down to prevent chafing or contact with moving internal components 1 Remove stator lead wire 44 as shown in Figure 2 15 from the ground stud adjacent to the four position terminal block Reroute stator lead 33 from the line side terminal of CB1A renamed as in Figure 2 16 to the ground stud location previously occupied by stator lead wire 44 2 Move smaller gauge 18 AWG wire labeled 11 not shown from the top of to the top of Renumber this wire 44 3 Reroute stator lead wire 44 removed in step 1 to the line side terminal on CB1 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator 4 Renumber ground wire 44 located between the four position terminal block and ground in Figure 2 15 as ground wire 33 as shown in Figure 2 16 5 Renumber wire 33A from Figure 2 15 as wire 44A in Figure 2 16 6 Remove the 12 AWG jumper wire from between line breakers and CB1A as shown in Figure 2 15 7 Install a tie bar between the two line breaker switch handles caution Do NOT connect electrical loads excess of any circuit breaker rating or problems will develop with circuit breaker tripping which causes a loss of AC output Also do NOT exceed the genera tor s rated wattage capacity Add the watts or amps of all lighting appliance tool and
120. type motors such as those that run the vehicle s furnace fan refrigerator air conditioner 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 calculate the watts needed to start electric motors in the system To that figure add the run ning wattages of other items that will be operated by the generator For the first two or three hours of operation do not apply electrical loads over 75 percent of the unit s rating 2 PROTECTION SYSTEMS The engine has several safety switches that cause it to automatically shut down under the following conditions low oil pressure high coolant tempera ture and engine overspeed See Figure 2 2 for the location of these devices If automatic shutdown does occur refer to Troubleshooting Guide 271 LOW OIL PRESSURE SWITCH This switch is normally closed N C but is held open by engine oil pressure during engine running Should operating oil pressure drop below approximately 10 psi the switch contacts close and the engine shuts down automatically 2 72 HIGH COOLANT TEMPERATURE SWITCH This normally open N O thermostatic switch has a sensing tip that is immersed in captive coolant Should the coolant temperature exceed approximate ly 115 C 240 F the switch contacts close and the engine shuts down automatically Fig
121. ure 2 2 Engine Protective Devices HIGH COOLANT LOW OIL TEMPERATURE PRESSURE SWITCH SWITCH ey a 10 2 7 3 OVERSPEED SHUTDOWN DC control circuit board senses engine speed from the frequency of the alternator AC output Should the alternator output frequency exceed approximately 72 Hertz 4 320 alternator rpm circuit board action initiates an automatic engine shutdown 2 7 4 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 3 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 electrical loads is controlled When the AC frequency is 60 Hertz voltage is regulated at 120 volts voltage to frequency ratio is 2 to 1 Figure 2 3 Solid state Voltage Regulator SO 11 SENSING 22 ALTERNATING CURRENT 4 ROTOR 0 DIRECT CURRENT 9 5 FROM STATOR EXCITATION WINDING ALTERNATING CURRENT S S Ko The voltage regulator also incorporates a volt age surge protection circuit This circuit prevents troublesome surges in the generator AC output volt age Vol
122. use unconsciousness or even death This exhaust system must be installed properly in strict com pliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards The generator com partment 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 seri ous damage to the generator Do not alter the installation or permit even partial blockage of ventilation provisions 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 physically or mentally fatigued Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental startup First disconnect the cable from the battery post indicated by a NEGATIVE NEG
123. wipe it dry with a clean lint free cloth This will be used later to check the oil level 10 Remove the oil fill plug and slowly add the proper type and amount of recommended oil see Engine Oil Requirements 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 11 Install the oil fill plug and the dipstick 12 Reinstall the air filter 13 Reattach the front service door or front panel make sure the latches are fully engaged and the bolts are fully tightened 14 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 SERVICING THE ENGINE AIR FILTER To access the engine air filter Figure 3 2 remove the front service door located beneath the unit by retracting the two latches and pivoting the door downward Loosen the hose clamp at the base of the air filter and remove the filter Place the hose clamp on the new filter and install it making sure it is positioned properly before reattaching the service door Make sure the service door latches are fully engaged Figure 3 2 Engine Air Filter REMOVABLE FRONT PANEL TRANSPARENT EE FOR VIEWING PURPOSES E AIR FILTER FRONT SERVICE LATCHES DOOR See the Service Schedule for recommended air clea

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