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Manual - Northern Tool + Equipment

1. TO 12V BATTERY O 2 SM 0 r 13 he us 4 0K 6 2A ELECTRONIC REGULATOR 16 16 ees 0 scr ca jam 2A 0 16 56 0 0 J3 c3 15 15 Je 14 Ji 1 O 56 a 90 51589 2A 0 22S 11 4 ol 18A Ji 50 0 11 pcp 80 17 17 Ji 70 17 17 31 8 o TERIB 4 SEST BEARING Ji 10 o 66 31 11 O 20 55 J1 12 o 0 J1 13 0 16 2a 14 J1 14 0 18 15 4 RED d Arie FIELD 85 0 0 oF q D 13 18 gt 77 22P 2 D BCR O 44 ss BA gt 66 11 RI 2 _ 0 4 HA 5 17 0 OF OY A 18 18 9 0 0 GI CONN 1 85 18 cow 0 od 01 0 gO sy o n 142 o 14 14 2 M 9 KS 18 15 1 ii A 5 17 5 14A GT REMOTE 0 CONN 2 14 NG PINA is Swi 070 PANEL iS swe 1 op 28 de T CONNECTOR 0 IR 18 0 14A MTI 13 90 x j 15 14 c i BLACK 18 14 CB 18 14 14 85 15 15 85 d LDPLLI zem WHITE 0 0 GREEN 18 r CUSTOMER AC CONNECTION NEUTRAL CONNECTION BLACK P CUSTOMER RED 4 90 cs 14 COPTIONAL 41 Base amp Pulley Drawing 0 1323 Exploded Views amp Part
2. 23 02 J LETS i L2 1 Bt 1 i 0 1 4 LISI 1 im M311L4 1314 68 os SALLVaOd AR 5 123 02 9176 T 1 4 M 137NI 7313 n eo 8D193NND2 13 310W3H 191 666 DI L 9I ET 011 26 t42 L8 E 81 ly ele SS3NalvH CDI gt Andino 29 qd 1 L LIH 1 1 8 lt 33 2 4 LOVE 1 S vov Lv E v 1 1 5 c L878 22 1 m S 7 91 4 121 k post 1ND 4 L91 6 1 L8 S 1 e see 7 G30v1d 8 d SLONDTAA 91 48 a S 1 1 9 lt 6 LT Zs GAL o 1 1 1 UNDE E LSJ Ta I o it L976 1 1 2 921 i 06 Ba ONI 7009 M T e 1 4 i J 3 137NI 1304 0491 6 EI 1 3910939 SI 9389 Nad V 9 i L2 I 811 L9I S 02 1 869 2916 112 1 ANY 40 59312 Lda M a 1 L2 1 611 02 1 N 38 ISAW SLATLA LSQVHX3 LOVE 22 1 Sev 9 f1 i SIAVINI JIV ILON a ler EN D L8 1 1 29 1 v x KIND 1 1 L t 1 2 c I LOVE 6 1 zeee 8967 pu dol W a8d M3IA L 1
3. J 6 14 14 5 lt 15 15 4 18 7 18 3 14 SS 14 2 17 17 1 0 0 12 00 WIRE WIRE No color LENGTH mm FUNCTION 0 WHITE 12 0 305 GROUND 14 RED 12 0 305 ENGINE RUN SIGNAL 15 ORANGE 12 0 305 12 VDC 305 305 305 17 YELLOW 12 0 305 START 305 305 18 BROWN 12 0 305 STOP 14A BLUE 12 0 305 PRIME P N 0D9099 B 2 9 1 REMOTE PANEL MODELS The remote panels mount a rocker type start stop switch a Generator Run advisory lamp and an hourmeter The hourmeter should be used in conjunction with the maintenance operations found in Part 1 of this manual e Part number 0H3068 includes the remote panel and a 30 foot long 6 wire harness 36 3 1 POST INSTALLATION TESTS The air cooled generator set was factory tested and adjusted It should not be necessary to adjust the unit any further except under special circumstances A WARNING Do not make any unnecessary adjustments Factory settings are correct for most applica tions When making adjustments however be careful to avoid overspeeding the engine 3 2 BEFORE INITIAL START UP Before starting complete the following 1 Check the engine crankcase oil level and if necessary fill to the dipstick FULL mark cross hatched area with the rec ommended oil Do not fill above the FULL mark 2 Checkthe fuel supply Gas fuel lines must hav
4. Paper Element w Foam Precleaner ICI 12 volt DC Electric Ignition Syste Misini Solid state w Flywheel Magneto Recommended Spark Plug RC14YC AD oco NUMEN R45S occ tactic ee 65 General Information 1 6 4 GENERATOR SPECIFICATIONS Rotor RPM Rotor Poles Engine RPM Rated Max Continuous AC Output Watts Voltage Rated Max Continuous Current Amps 240V Phase Frequency Battery Charging Current Max Weight Length Width Height 1 1 1 1 60 Hertz 60 Hertz 60 Hertz 60 Hertz All units are reconnectable to 120 and or 240 volts dual voltage output Units are not listed per RVIA ANSI when reconnected for dual voltage output Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine condition etc Maximum power decreases about 3 5 for each 1 000 feet above sea level and will also decrease about 1 for each 6 C 10 F above 16 C 60 F ambient temperature Spark Plug Gap 0 040 inch 1 02 mm Recommended Min 400 Cold Cranking Amps Class Emission Certified 1 7 EVAPORATIVE EMISSIONS INFORMATION This generator is subject to evaporative emission standards which have been implemented by the California Air Resource Board CARB and the Environmental Pr
5. 15 310 Major Service Manual eene 16 S Ml Drive Belli z usu an ee e 16 3 12 Exercising the Generator 16 3 13 Out of Service 16 3 14 RV Generator Service 16 Section 4 Notes 2 22222 2 17 Introduction INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc This model is designed and manufactured to supply electrical power for recreational vehicles READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the near est Authorized Service Dealer for starting 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 personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or care lessly Observe them carefully Their definitions are as follows A DANGER Indicates a hazardous situation or action which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation or action which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation or action which if not avoi
6. 36 2 6 Stopping the Generator s 10 3 2 Before Initial Start up sss 36 27 Applying Loads to 10 93 Intal Saka et iet 36 2 8 Protection Systems 11 3 4 Testing Under Load 37 3 5 Installation Checklist 38 Section 3 12 3 1 Checking the Engine Oil 12 Section 4 Troubleshooting 39 3 2 Changing the Engine Oil and or Oil Filter 12 4 Troubleshooting Guide ssssse 39 3 3 Maintaining the Engine Air 1 13 3 4 Checking the Engine Spark 13 Section 5 Electrical Data 40 3 5 Fuel Filter Gasoline 0 222244 14 3 6 Clear Spark Arrestor eec 14 Section 6 Exploded Views and Parts Lists 42 3 7 X Cleaning the 14 3 8 Battery Maintenance rriari 14 Section 7 52 3 9 Adjusting Valve
7. After installation do nothing that might render the unit in noncompliance with such codes standards and instructions Use the generator set to supply electrical power for operating one of the following electrical loads QUIETPACT 55G amp LP 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 5500 watts 5 5 kW of total power but cannot exceed 45 8 AC amperes of current at 120 volts or exceed 22 9 AC amperes at 240 volts QUIETPACT 65G amp LP 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 6500 watts 6 5 kW of total power but cannot exceed 54 1 AC amperes of current at 120 volts or exceed 27 AC amperes at 240 volts QUIETPACT 75G amp LP 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 7500 watts 7 5 kW of total power but cannot exceed 62 5 AC amperes of current at 120 volts or exceed 31 2 AC amperes at 240 volts A CAUTION Do not overload the generator Some installa tions may require that electrical loads be alter nated to avoid overloading Applying exces sively high electrical loads may damage the generator and may shorten its life Add up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one time This total should not be greater than the wattage capacity of the generator If an electrical device nameplate gives only volts and amps multipl
8. BOE E VEHICLE AC DOUBLE DISTRIBUTION PANEL THROW SWITCHING 30 AMP DEVICE MAIN BREAKER HACR BREAKERS FOR AIR B B CONDITIONERS 4 GFCI BREAKERS POWER SUPPLY CORD Figure 2 16 Installation With Isolation Receptacle DOCKSIDE POWER RECEPTACLE FLEXIBLE CONDUIT oo 7 power SUPPLY LIT CORD M _ _ VEHICLE t DISTRIBUTION PANEL 35 Post Installation Start up Adjustments 2 8 4 BATTERY COMPARTMENT Install the generator battery in its own vented compartment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compartment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid support ing structure where leaks and spills of battery fluid will not cause damage 2 9 OPTIONAL ACCESSORIES A plug in receptacle Figure 2 18 is provided on the generator set above the muffler enclosure Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit starting and stopping the generator engine from any convenient location inside the vehicle Figure 2 18 Remote Panel Plug in Receptacle
9. GROUND TO ENGINE b TO STARTER VIEW 4A A EW VI Enclosure Drawing No 0G7865 C Enclosure Drawing 0G7865 C Exploded Views amp Parts Lists ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 008827 1 PANEL ENCLOSURE ROOF 32 007423 1 STUD 3 8 16 X 2 1 4 BRASS 2 064933 22 SCREW SWT 1 4 20 X 5 8 W W 33 0742600151 1 GND WIRE C PNL TO STUD V T RV 3 029451 11 5FT TAPE ELEC UL FOAM 1 8 X 1 2 34 0A4456 1 WASHER LOCK SPECIAL 3 8 4 008825 1 PANEL SIDE AND BACK ENCLOSURE 35 008502 1 NEUTRAL CONNETCTOR UL 5 003700 14 NUT FLANGE M6 1 0 NYLOK GASOLINE 36 080593 1 STUD 1 4 20 TO 5 16 18 ONLY 3 0742600148 1 WIRE ASM BATT POS QP RV 0D3700 17 NUT FLANGE M6 1 0 NYLOK LP ONLY 38 022129 2 WASHER LOCK M8 5 16 GASOLINE 6 090388 8 SCREW HHTT M6 1 0 X 12 YC ONLY 7 008979 1 PANEL AIR IN DUCT BASE 022129 4 WASHER LOCK M8 5 16 LP ONLY 8 OD8960A 1 PANEL CUSTOMER CONNECTION 39 022259 2 NUT HEX 5 16 18 STEEL 9 023484D 1 BUSHING SNAP 5 875 11 40 045756 8 SCREW HHTT M6 1 0 X 10 YC 10 00594 1 COVER RV AIR CLEANER BOX 41 0A2115 1 WASHER NYLON 250 11 064113 1 STUD WINGNUT M6 1 0 X 20MM NY 42 029451A 6 5 FT TAPE 1 2 X 1 16 CLOSED CELL 12 0 0575 1 FOAM SEALING STRIP 1 X 12FT 43 0 1534 1 PLUG PLASTIC 1 50 GASOLINE ONLY 13 008980 1 PANEL AIR IN DUCT BACK 44 0A5606 1 ELBOW 90DEG 3 8X3 4 LP ONLY 14 0E1376 1 BAFFLE V TWIN RV SHORT 45 0 1528 1 BRACKET LP R
10. cu 28 iS x Section 2 Installation 24 14 Safety usi ee c E eerte eid 5 1 5 Generator AC Connection 5 21 LLL LLL 1 6 Specifications 6 22 Compartments a 1 7 Evaporative Emissions Information 7 Ca Cooling ET 1 8 Exhaust Emissions Information Gasoline 7 AME LLL LLL ed 19 Exhaust Emissions Information Propane 8 29 CE GAS FOOI SYSTEM s vd 2 6 X Exhaust System sss 31 Section 2 8 2 7 Electrical Connections e 33 21 Generator Control 8 2 8 Battery Installation 444 4 34 2 2 Optional Remote Start Stop 9 2 9 Optional Accessories 2222111 36 2 9 Automatic Choke sesssseseseenenennnnnnnnnnne 9 24 Before Starting the 9 Section 3 Post Installation 36 2 5 Starting the Generator 10 3 1 Post Installation
11. 53 Warranty GENERAC POWER SYSTEMS THREE YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS PURCHASED IN THE U S A AND CANADA 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 examination 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
12. Air inlet and outlet openings in the generator compartment must be open and unobstructed for continued proper operation Without sufficient cooling and ventilating airflow the engine generator quickly overheats which causes it to shut down and may damage the generator 24 9 ENGINE EXHAUST GAS Before starting the generator engine inspect for exhaust leaks and ensure there is no way for exhaust gases to enter the vehicle inte rior 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 A DANGER Generator engine exhaust contains DEADLY carbon Monoxide an odorless colorless poi sonous gas Breathing carbon monoxide can cause dizziness throbbing temples nausea muscular twitching headache vomiting weak ness and sleepiness inability to think clearly fainting unconsciousness or even death If you experience any carbon monoxide poisoning symptoms move into fresh air and immediately seek medical attention Never operate the generator set with the vehi cle inside any garage or other enclosed area Adequate unobstructed flow of cooling and ventilating air is critical for expelling toxic car bon monoxide gas and fuel vapors from the generator compartment and for proper genera tor operation Without sufficient cooling airflow deadly carbon monoxide gas can accumulate and the engine generator may quickly over heat causing seri
13. This generator is equipped with a gasoline or LP fuel system Specific installations may provide either a separate fuel tank for the generator or the generator may share the vehicle engine s fuel tank Gasoline Fuel Consumption gph Model 10 Load 50 Load 100 Load 756 NOTE Some installations using a shared fuel tank may have a gen erator fuel pickup tube that is shorter than the vehicle engine s pickup tube Such an arrangement causes the generator engine to out of gas while adequate fuel for the vehicle remains in the tank To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator Leaded REGULAR grade gasoline is an acceptable substitute NOTE Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits 6 A CAUTION The manufacturer does not recommend using any gasoline containing alcohol such as gasohol If using any gasoline containing alcohol it must not contain more than 10 per cent ethanol and it must be removed from the generator during storage Do NOT use any gasoline containing methanol If using gasoline with alcohol inspect more frequently for fuel leaks and other abnormalities LP Fuel Consumption Ib hour The LP powered range of generators are fitted with a nonadjust able factory set system These systems are tamper proof to meet 1997 California Air Resources Board requirement
14. white T3 black and the green ground wire through approved flexible conduit to the electrical junction box on the compartment wall If flexible metal conduit is used between the generator and the compartment junction box the conduit end that terminates 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 trans fer switch or b approved isolation receptacle Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being connected to two different power supplies at the same time such as generator and dockside power Conductors must be rated 221 F 105 C or must be of a larger conductor size 2 7 3 GENERATOR AC CONNECTIONS Generator AC output leads T1 red T2 white and T3 black come out of the generator as shown in Figure 2 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 Line T1 red to T2 white is protected against overload by a cir cuit breaker CB1 Use this line to neutral connection separately to operate 120 volt single phase 60 Hertz AC loads Line T3 black to T2 white also is protected against overload by a circuit breaker CB2 Use this line
15. 003043 87 008836 88 003730 91 035461 92 063662 93 064695 94 0 9506 95 009683 96 009764 9 036933 98 0 0246 99 009394 100 022152 101 022158 102 043116 103 049811 104 047411 105 066849 106 048031 107 0 7065 108 075476 109 082121 110 038150 111 022264 112 051715 113 006029 114 0559340 115 022473 116 090388 117 0E3200 118 0 2110 119 004576 120 003432 Exploded Views amp Parts Lists 2 DESCRIPTION 2 1 1 1 1 1 1 1 2 4 4 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 2 1 4 2 5 2 1 1 4 1 1 1 1 1 2 4 2 2 2 5 1 1 AG CSS FT SPRING CHOKE RETURN WRAP VALLEY UPPER SPCC WRAPPER UPR 1 W M8 WELD NUT WRAP VALLEY RV SPCC WRAPPER UPR 2 W M8 WELD NUT ASSY GROUNDING WIRE ASSY GROUND WIRE CONNECTOR ASSY IGN COIL W DIODE NO ADV WASHER LOCK M6 1 4 SCREW HHTT M6 1 0 X 20 ZINC O RING 59 92 X 66 98 X 3 53MM O RING 21 89 X 27 13 X 2 62MM KEY WOODRFF 4 X 19D ADPTR OIL PAD FLARE TUBE ENGINE OIL RETURN TUBE ENGINE OIL 007 O RING 20 35 X 23 91 X 1 78MM BOLT OIL ADAPTOR WRAP CYL 2 GTV760 RV SPCC INTAKE TUBE 1 25 X 20 GA HOSE CLMP BAND 1 5 8 BOOT INTAKE AIRBOX BOOT CARB ADAPTOR BOLT CARB MOUNT 6 X 1 0 85LG ADAPTER AIR INTAKE CARB GASKET CARB TO ADAPTOR CARBURETOR GASOLINE ONLY CARBURETOR LP ONLY GASKET CARB TO INTAKE MANIFOLD GASKET INTAKE PORT MANIFOLD INTAKE RV SCREW SHC M8 1 25 X 30
16. 25mm 002982 1 COVER ROCKER WITH OIL FILL 093064 1 ASSEMBLY OIL FILL CAP 002979 2 GASKET VALVE COVER 086515 8 KEEPER VALVE SPRING 0D2274 4 RETAINER VALVE SPRING 0D3867 4 SPRING VALVE 078672 2 SEAL VALVE STEM D7 005371 4 WASHER VALVE SPRING 0D3998 4 NUT HEX M8 1 0 G8 0E3273 1 SCREEN CRANKCASE BREATHER 0D5313 4 ROCKER ARM 072694 4 STUD ROCKER ARM PIVOT 0G8552 2 PLATE PUSH ROD GUIDE 0C2976 12 SCREW HHFC 8 1 25 X 65mm 008067 1 ASSEMBLY HEAD 2 002229 2 VALVE INTAKE 086516 2 VALVE EXHAUST 0D9853D 4 PUSHROD 147 083897 4 TAPPET SOLID 0E9323 1 STARTER 022129 2 WASHER LOCK M8 061906 2 SCREW HHC M8 1 25 X 85mm 51 CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and the United States Environmental Protection Agency EPA together with Generac Power Systems Inc Generac are pleased to explain the Emission Control System warranty on your new 2008 and later generator New equipment that use small spark ignited engines must be designed built and equipped to meet stringent anti smog standards for the state of California and the federal government Generac will warrant the emission control system on your generator for the period of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your equipment Your emission control system may include parts such as the
17. CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 2 1 1 FUEL PRIMER Before starting a cold engine if it has not been started in more than two weeks press this switch for approximately ten seconds to bring fuel from the tank to the fuel pump This rocker type switch springs back into its original position when it is released 2 1 2 START STOP SWITCH To crank and start the engine hold this switch in the START posi tion Release the switch when the engine starts To stop an operat ing engine press and hold the switch in the STOP position until the engine shuts off The switch center position is the RUN position 2 1 3 7 5 AMP FUSE The fuse protects the engine s DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine cannot be cranked If the fuse must be replaced use only an identical 7 5 amp replacement fuse Figure 2 1 Typical Control Panel r CONTROL CENTER A O O CIRCUIT BREAKER C O CIRCUIT BREAKER FUSE 75 START FUEL IF GE 0 0580 REV B STOP PRIME GUIDE PRESS PRIME SWITCH FOR 10 SECONDS BEFORE STARTING WHEN STARTING DO NOT PRESS START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT 2 1 4 LINE BREAKERS Protects generator s AC output circiut against overload i e pre vents unit from exceeding wattage amperage capacity The circu
18. 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 Any implied warranties which are allowed by law shall be limited in duration of the terms of the express warranty provided herein 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 CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclu sion 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 PO BOX297 WHITEWATER WI 53190 Part No 0H8812 Rev A 06 02 10 Part No 0H3466 Revision B 06 02 10 Printed in U S A
19. M6 1 0 OFFSET 19 070008 4 WASHER FLAT M8 SS 48 009723 1 ELEMENT AIR FILTER 20 040976 4 SCREW SHC M8 1 25 X 20 612 9 49 21 056893 5 SCREW CRIMPTITE 10 24 X 1 2 50 008981 2 FILTER GASKET RV GASOLINE ONLY 22 023897 5 WASHER FLAT 10 ZINC 008981 1 FILTER GASKET RV LP ONLY 23 01078 1 GASKET EXH BASE GTV760 RV 51 008451 1 WASHER FLAT 281 ID X 1 25 0D 24 0064138 2 GASKET EXHAUST PORT 52 087680 2 NUT WING M6 1 0 25 043116 3 SCREW HHC M6 1 0 X 12 G8 8 5 5 KW 53 003700 3 NUT FLANGE M6 1 0 NYLOK GASOLINE ONLY ONLY 26 022097 4 WASHER LOCK M6 1 4 5 5 KW ONLY 0D3700 1 NUT FLANGE M6 1 0 NYLOK LP ONLY 022097 1 WASHER LOCK M6 1 4 6 5 amp 7 5 KW 54 087769 1 FILTER FUEL GASOLINE ONLY ONLY 55 0E0570 1 ASSEMBLY NON SHTOFF FUEL PUMP 27 022473 3 WASHER FLAT 1 4 M6 ZINC 5 5 KW GASOLINE ONLY ONLY 56 009919 1 ASSEMBLY RV V TWIN FUEL LINE 28 061751 1 FAN NYLON 7 DIA 5 5 KW ONLY GASOLINE ONLY 29 0C1753B 1 PULLEY ALTERNATOR 2200 RPM 5 5 KW 57 0 1330 1 GROMMET 38 1 DIA CROSS SLIT ONLY GASOLINE ONLY 073106B 1 PULLEY ALTERNATOR 2500 RPM 6 5 amp 0E1534A 1 PLUG PLASTIC 1 50 LP ONLY 7 5 KW ONLY 58 0 1658 1 WASHER LOCK SPECIAL 1 4 30 075224 1 PULLEY ENGINE 2100 RPM 5 5 KW 59 005133 1 SCREEN SPARK ARRESTOR ONLY 60 0D5133A 1 RETAINER SPARK ARREST SCREEN 075224B 1 PULLEY ENGINE 2500 RPM 6 5 amp 7 5 61 045764 1 SCREW M4 0 7 X 8 BP KW ONLY 62 0 1078 1 GASKET EXHAUST BASE 43 Exploded Views amp Parts Lists 44
20. be two to three inches 51 to 76 mm shorter than the vehicle engine s pickup tube This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods A CAUTION Do NOT tie 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 An evaporative emissions port model 05750 has a 5 16 hose barb provided for connection to a carbon canister as necessary for specific applications 24 2 GENERATOR FUEL SUPPLY LINE Rigid Fuel Lines Those lines used to supply fuel from a tank to the generator must comply with applicable codes standards and regulations The fol lowing general rules apply to rigid fuel lines Rigid lines should be of annealed seamless drawn aluminum or steel Lines and fittings must comply with SAE J512F Standard Automotive Fittings or with ANSI B126 26 latest edition Route the fuel line so that at least 2 inches 51 mm of clear ance is maintained between the line and any exhaust system parts Do not attach electrical wiring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so if they leak fuel does not drip onto any electrical or exhaus
21. cause of damage to electronic equipment 2 8 5 OPERATION IN HIGH GRASS OR BRUSH WARNING Never operate the generator while the vehicle is parked over high grass weeds brush leaves or any other combustible substance Such materials can ignite and burn from the heat of the exhaust system The generator exhaust sys tem becomes extremely hot during operation and remains hot for a long time after it has shut down 11 Maintenance 3 1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements see the Engine Oil Requirements section Check the engine crankcase oil level at least every eight hours of operation or before it is used To check the engine oil level proceed as follows see Figure 3 1 1 Be sure the generator is as level as possible 2 Remove the dipstick and wipe it dry with a clean lint free cloth 3 Install and tighten the dipstick cap then remove it again The oil level should be at the dipstick Full mark 4 f necessary remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dipstick Full mark DO NOT FILL ABOVE THE FULL MARK A CAUTION Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 5 Install and tighten the oil fill cap and the dipstick before oper ating the engine 3 2 CHANGING THE ENGINE OIL AND OR OIL FILTER A CAUTION Hot oil may cause
22. circuit Figure 2 4 During engine cranking only a positive DC battery voltage is delivered through a diode resistor brushes slip rings and the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Figure 2 4 Field Boost Circuit 16 E eer 4 0 N FIELD 2 8 4 OVERVOLTAGE PROTECTION solid state voltage regulator Figure 2 5 controls the generator s AC output voltage This regulator supplies an excitation current to the rotor By regulating the rotor s excitation current the strength of its magnetic field is regulated and in turn the voltage delivered to connected electrical loads is controlled When the AC frequency is 60 Hertz voltage is regulated at 115 volts Figure 2 5 Solid State Voltage Regulator IN yy SENSING 4 _TO ROTOR ot DIRECT CURRENT 8 FROM STATOR EXCITATION WINDING ALTERNATING CURRENT S O WO The voltage regulator also incorporates a voltage surge protection circuit This circuit prevents troublesome surges in the generator AC output voltage Voltage surge is a common
23. exterior steel wing nut on the left side of the Air Box Compartment counterclockwise and remove 4 Pull the Air Filter Assembly to the right and out of the front of the compartment 5 Remove the foam pre cleaner from the air filter 6 Wash the foam pre cleaner in liquid detergent and water 7 Wrapthe foam pre cleaner in a clean cloth and gently squeeze it dry 8 Saturate the foam pre cleaner in clean engine oil Gently squeeze it in a clean cloth to remove excess oil and to distrib ute the oil evenly DO NOT TWIST Slide the foam pre cleaner onto the air filter 10 With your right hand on the air filter end angle the assembly into the compartment and insert the Offset Stud into the hole on the left side of the Air Box Compartment Before the air filter gasket contacts the sheet metal wall ensure the rubber snout of the carburetor intake adapter is captured within the footprint of the Air Filter 11 Replace the steel wing nut onto the Offset Stud and tighten clockwise 12 Replace the Air Box Compartment Cover back into all three locating tabs and replace the plastic wing screw Tighten clockwise carefully Figure 3 3 Engine Air Cleaner LOCK AIR BOX COVER PLASTIC WASHER WING SCREW PRE CLEANER OFFSET NUT STUD WASHER AIR FILTER 3 9 2 REPLACING THE PAPER AIR FILTER Replace the Paper Air Filter Element after every 250 hours of operation Use the following procedure Figure 3 3 1 At
24. gauge steel tubing OR b 1 1 2 inch 11 gauge angle iron A typical supporting frame with horizontal support tubing is shown in Figure 2 1 Figure 2 1 Typical Horizontal Support Frame SUPPORT TUBING The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the generator below the horizontal support tubing by means of suitable structurally sound metal framework The fol lowing general rules apply Vehicle construction MUST be capable of supporting the weight of the generator Whether the generator is mounted above the horizontal support tubing or suspended below the tubing the supporting frame used must be structurally sound If the generator cannot be bolted directly to the supporting frame or support tubing consider using additional tubing angle brackets or other supports to give the supporting frame sufficient strength Installation 2 1 3 SUSPENDED MOUNTING If planning to suspend the generator below the horizontal sup port tubing the suspension method to use 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 suspended mounting system is shown in Figure 2 2 The location of a suspended mounting system must be carefully planned keep ing the following general rules in mind Protect the generator against road splash and d
25. lower speed than the rotor 1 6 GENERATOR AC CONNECTION SYSTEM These air cooled generator sets are equipped with dual stator AC power windings These two stator windings supply electrical power to customer electrical loads by means of a dual 2 wire connection system Generators may be installed to provide the following outputs 1 120 VAC loads only one load with a maximum total wattage requirement equal to the generator s rated power output in watts and 120V across the generator output terminals see Fig 1 1 2 120 240 VAC loads one load with a maximum total wattage requirement equal to the generator s rated power output and 240 V across the generator output terminals or two seperate loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120 V across the generator output terminals see Fig 1 3 Figure 1 1 Connection for 120 Volts Only TA lt 33 CB1 O RED Z 2 T3 gt BLACK g C M 5 gt lt gt 120V az x5 2 z 120v 7 NG u m WHITE T2 117 GROUNDED NEUTRAL 3ONVN3INIVN 03410034 119 853229 MODO IND3J 6 o T Sa c
26. outlined in the following sections 2 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a minimum clearance of 1 2 inch 13 mm on the front and top 1 inch 25 mm on the sides and from the back for air circulation AFTER the compart ment has been lined with metal and sound insulation Figure 2 4 NOTE Refer to Figure 1 2 Major Features and Dimensions Figure 2 4 Clearances Plywood Compartment 1 2 Clearance on Top 1 Clearance 2 2 2 COMPARTMENT CONSTRUCTION The generator compartment should be either constructed 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 manufacturer recommends that the compartment be constructed of 1 2 inch thick plywood not strandboard with the floor made of a double thickness of 1 2 inch plywood with the grain of the wood at cross section for added strength Figure 2 5 METAL LINED 75 INCH THICK BASE r enr o CT FH TUBULAR METAL SUPPORT FRAME T VEHICLE CHASSIS la GRADE 5 BOLTS METAL LINED BOTTOM If constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel All seams splices and joints of th
27. repair or replace ment Before performing any maintenance on the generator discon nect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dan gerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc Safety Rules ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and 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 stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle have the generator prop erly grounded bonded either by solid mounting to the vehicle frame or chassis or by means of an approved bonding conduc tor DO NOT disconnect the bonding conductor if so equipped DO NOT reconnect the bonding conductor to any generator part that might be removed or disassembled during routine mainte nance If the grounding c
28. symptoms move into fresh air and immediately seek medical attention Never operate the generator set with the vehicle inside any garage or other enclosed area Adequate unobstructed flow of cooling and ventilating air is critical for expelling toxic carbon monoxide gas and fuel vapors from the generator compartment and for proper genera tor operation Without sufficient cooling airflow deadly carbon monoxide gas can accumulate and the engine generator may quickly overheat causing serious damage to the generator Do not operate the genset in any confined space The exhaust system must be installed in accordance with the genset installation manual Do not alter the installation or permit even partial blockage of ventilation systems as this can seri ously affect the safe and proper operation of the generator Safety Rules Do not operate the generator if the exhaust system is leaking or has been damaged or if you have experienced carbon monoxide poisoning symptoms during use Shut down the generator and do not operate it until it has been inspected and or repaired Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and
29. temperatures i e in cold ambient temperatures choke valve closes more Once the engine starts an element heats the temperature sensitive strip to a normal operating condition opening the choke valve This may take about three minutes in cooler weather 2 4 BEFORE STARTING THE ENGINE Instructions and information in this manual assume the genera tor has been properly installed connected serviced tested and adjusted by a qualified installation technician or installation contractor 24 1 INSTALLATION Generator installation must have been properly completed so it complies with all applicable codes standards and regulations and with the manufacturer s recommendations 24 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommend ed oil before starting Refer to sections Engine Specifications Checking the Engine Oil Level and Changing the Engine Oil and or Filter for oil servicing procedures and recommendations A 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 24 3 FUEL SUPPLY The engine must have an adequate supply of proper fuel to oper ate Before starting it check that sufficient fuel is available NOTE Depending on the installation the generator may have either a separate fuel tank or it may share the vehicle engine s fuel tank 24 4 COOLING AND VENTILATING AIR
30. the Generac Authorized Warranty Service Dealer nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California and federal law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac Note that this warranty shall not apply to any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replace ment of the defective part s 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 The ECS Warranty applies only to the emission control system of your new equipment If there is any conflict in terms between the ECS Warranty and the Generac Warranty the Generac Warranty shall apply Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty service evidence must be presented showing the date of
31. to absorb moisture from the air Salt and moisture when combined form a good electrical conductor which is detrimental to the generator A CAUTION Do NOT use 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 3 8 BATTERY MAINTENANCE All lead acid batteries will discharge when not in use The genera tor battery should be inspected as follows 3 6 1 WEEKLY Inspect the battery posts and cables for tightness and corro sion Tighten and clean as necessary Check the battery fluid level of unsealed batteries and if nec essary fill with Distilled Water Only Do not use tap water in batteries 3 8 2 EVERY SIX MONTHS Have the state of charge and condition checked This should be done with an automotive type battery hydrometer NOTE Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precau tions Keep unauthorized personnel away from batteries Damage will result if the battery connections are made in reverse DANGER Do not dispose of the battery in a fire ha battery is capable of exploding Stored batteries 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 explosi
32. to flow 2 5 6 FUEL SUPPLY LINES LP gas lines must be accessible but protected against possible damage Do NOT connect electrical wiring to any LP gas fuel line or run wiring alongside the lines Route gas lines away from hot engine exhausts Retain gas lines with metal clamps that do not have sharp edges Install an approved length of flexible hose between the gaseous fuel solenoid valve and rigid fuel supply lines The flexible line must be nonmetallic nonorganic and nonconductive It must be approved for use with LP gas DANGER Gaseous fuel lines between the tank and the secondary regulator are under a positive pres sure about 11 inches water column Gas pres sure at the outlet side of the secondary regula tor however is a negative pressure and can draw flame inside a line or fitting and cause an explosion 2 5 7 EXCESS FLOW VALVE LP gas tanks should have an excess flow valve according to NFPA 501C This valve and the gas lines must be carefully sized so the valve will close when a fuel line is severed or broken Consult the Natural LP Gas Association for information and limitations of excess flow valves Manual shutoff valves on the supply tank and elsewhere in the sys tem must be fully open when operating the generator The excess flow valve functions properly only if all valves are fully open 2 5 8 LEAKAGE TESTS Do not place the generator into service until the gas system has been prop
33. 00 HOUSING Replace Spark Plugs 17 18 PART Il INSTALLATION INSTRUCTIONS Safety Rules DANGER For fire safety installation of a generator into a recreational vehicle must comply strictly with article 551 NFPA 70 ANSI C1 1975 AND ANSI A119 2 1975 NFPA 501C Standard for Recreational Vehicles Part 3 Installation of Electrical Systems In addition installation must comply with the manufacturer s instructions and recommendations NOTICE TO INSTALLER These Installation Instructions have been published by the manu facturer 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 similar products manufactured The manufacturer also assumes that personnel have been trained in the recommended installation procedures for these products and that such training includes a use of common hand tools b use of special tools and c use of any tools and or equipment from other suppliers The manufacturer cannot possibly know of and advise the rec reational vehicle trade of all conceivable methods procedures or techniques by which to perform an installation Nor can the manu facturer anticipate every possible hazard that might result from each installation method procedure or technique The manufactur er has not undertaken any such wide evaluation Therefore people who use a method proce
34. 2 57 075210A 1 58 022264 2 59 051715 2 60 007605 2 61 09719 1 62 089047 2 63 075234 1 64 DA2053 1 65 058000 2 66 008941 1 67 029451 2 3 FT 68 080583 1 0E1812 1 69 081375 1 DESCRIPTION CIRCUIT BREAKER 3 X 1 WASHER FLAT 4 ZINC WASHER LOCK M3 NUT HEX M3 0 5 G8 YEL CHR ASSY POTTED RV CNTL WASHER LOCK M5 NUT HEX M5 0 8 G8 YEL CHR BUSHING SNAP NUT FLANGE M6 1 0 NYLOK PANEL BOTTOM CONTROL SCREW HHC M3 0 8 X 20 68 8 SCREW PPHM M4 0 7 X 16 RECTIFIER BATTERY CHARGE RELAY 12V 25A SPST NUT LOCK TRIC M6 X 1 0 Y ZNC SCREW HHC M6 1 0 X 35 68 8 BLK WASHER LOCK SPECIAL 1 4 WIRE ASM GRD STD CONN NUT HEX M6 X 1 0 G8 YEL CHR BUSHING SNAP GROUND WIRE C PNL TO STUD V T RV RUBBER U CHANNEL SCREW PHM M3 0 5 X 10MM BLOCK 1 POSITION WASHER LOCK 8 M4 NUT HEX M4 0 7 G8 YEL CHR SCREW HHC M3 0 8 X 60 G8 8 ASY POTTED REG W FIN SPACER 25 X 43 X 55 ST ZNC RESISTOR WW LUG 1R 5 25W SCREW HHC M6 1 0 X 65 68 8 NUT TRIC M5 X 8 COMPARTMENT AIR BOX TAPE 1 2 X 1 16 CLOSED CELL WIRE HARNESS QP RV GASOLINE ONLY NOT SHOWN WIRE HARNESS QP RV LP ONLY NOT SHOWN WIRE ASS Y STARTER TO C PNL NOT SHOWN 49 Exploded Views amp Parts Lists 760 V twin Engine Drawing No 0F1997 C 50 760 V twin Engine Drawing No 0F1997 C ITEM PART NO QTY DESCRIPTION 1 005730 1 ASSEMBLY CRANKCASE RV 2 0 9843 1 SEAL 38 I D CRANKCASE 3 090388 6 SC
35. ATTERY RED III BLK SC 13 RED 16 5 T 0 13 16 e sc 0 SCR 24 O F1 14 E P 15 10 lt gt 14 0 14 0 o Swe T CH 16 COPTIONAL PCB 0 15 J1 1 2 56 e Je 2 90 cs 0 o 1 3 2 16 18A mM gt SP1 15 la 4 gt 18 zi any 2 5 gt 18A IM2 gt SP2 J1 6 2 17 Y START 1 0B 15 2 7 2 17 Lo Ji 8 gt a J1 9 4 HTD 14 gt 85 0 9 J1 103 66 a 12 85 85 4 0 9 21 12 0 1 132 66 J1 142 18 4 PANEL JI 152 18 17 CONNECTOR 01 1 1 17 2 14 14 3 3 15 18 4 4 gt 14 15 45 s z 6 lem 88 uz az spss 1 7 13 ba 8 B a 77 66 MA 151814170 BATTERY CHARGE WINDING Vv vp ft 55 STUP c TUN RN START 0 VA AAA POWER WINDING 4 PAANAN 33 44 ON ees 15 NG Gp 22P 9T PRIME L j ELECTRONIC REMOTE PANEL r4 VDLTAGE OPTIONAL REGULATOR RED ad o PUR ON 9 4 T1 2 6 WINDING OF AID AANO 4 77 FIELD WHITE 120V 20 0 55 BLACK 120V 304 QP65 5 120V 35 QP75 RED 120V 304 55 amp 0 65 190v 354 QP75 o NEUTRAL CONNECTION BY CUSTOMER 40 LEGEND BCR BATTERY CHARGE RECTIFIER CIRCUIT CIRCUIT CB2 CIRCUIT CIRCUIT CIRCUIT CB3 CIRCUIT CIRCUIT BREAKER 30A 55 8 QP65 MODELS
36. BER and SERIES Manuals can be obtained from the internet website or a Service dealer 3 11 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 3 12 EXERCISING THE GENERATOR The manufacturer recommends starting and operating the genera tor at least once every seven days Let the unit run for at least 30 minutes to exercise the engine 3 13 OUT OF SERVICE PROCEDURE 3 13 1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days and it is to be out of service longer than 30 days prepare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 5W 30 oil having classification For Service SE 16 4 Attach a tag to the engine indicating the viscosity and clas sification of the oil in the crankcase 5 Remove the spark plug and pour two or three tablespoons of clean fresh engine oil into the spark plug threaded openings Reinstall and tighten the spark plug 6 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concret
37. BREAKER BREAKER BREAKER BREAKER BREAKER BREAKER 35A QP75 MODEL 20 55 MODEL 304 0 65 MODEL 35A QP75 MODEL 2 5A QP55 MODEL 3 0A QP65 amp QP75 MODELS CHOKE HEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY ES EVAP SOLENOID GASOLINE MODELS ONLY F1 FUSE 7 5 FUEL PUMP OR LPG SHUT OFF VALVE FS FUEL SOLENOID GT TERMINAL GROUND HM METER HOUR OPTIONAL HTO SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO 2 CYL Li LIGHT RUN OPTIONAL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE PCB ENGINE CONTROLLER R1 RESISTOR 1 OHM 25w SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SW1 SWITCH START STOP SWe SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TERMINAL CONN 4 E r CONNECTOR Electrical Schematic V twin Drawing 0E1057 F Electrical Data
38. EGULATOR MOUNTING 15 0E1377 1 BAFFLE V TWIN RV LONG LP ONLY 16 008628 3 5 FOAM AIR OUT COMPARTMENT 46 0 1495 2 SCREW HHTT M4 0 7 X 10 BP LP ONLY 17 008910 1 PANEL MUFFLER SHIELD 47 039253 2 SCREW M8 1 25 X 20 68 8 LP 18 008826 1 PANEL ENCLOSURE SIDE ONLY 19 009162 1 PANEL FRONT amp SIDE ENCLOSURE 48 022145 1 WASHER FLAT 5 16 8 ZINC GASOLINE 20 005644 2 SLIDE LATCH FLUSH ONLY 21 008828 1 PANEL ENCLOSURE DOOR 022145 3 WASHER FLAT 5 16 M8 ZINC LP ONLY 22 0E0585 1 FOAM PANEL DOOR 1 2 THK QP RV 49 008979 1 PANEL AIR IN DUCT 23 081486 1 HARNESS AC OUTPUT 5 5 6 5 amp 7 5 50 061669 1 PLUG PLASTIC GASOLINE ONLY KW ONLY 51 069598 1 BULKHEAD ADAPTER YA x 1 4 x 34 16 0E1774 1 HARNESS AC OUTPUT 5 0 amp 7 0 KW 50 MODEL 05750 ONLY Hz ONLY 52 058043 1 BARBED STRAIGHT NPT x 5 16 24 009099 1 CUST CONN 4KW RV REMOTE MODEL 05750 ONLY 25 074908 4 SCREW HHTT M5 0 8 X 10 BP 53 035579 1 BUSHING REDUCER TO 1 8 26 022473 1 WASHER FLAT 1 4 M6 ZINC MODEL 05750 ONLY 27 022097 1 WASHER LOCK M6 1 4 54 035578 1 NIPPLE CLOSE 1 8 NPT MODEL 05750 28 022507 1 SCREW 1 4 20 X 1 2 G5 ONLY 29 0742600149 1 WIRE ASM NEG RV 55 060247 1 SOLENOID VALVE 12 VDC MODEL 30 007968 4 NUT HEX JAM 3 8 16 BRASS 05750 ONLY 31 022237 2 WASHER LOCK 3 8 956 028414A 1 BARBED STRAIGHT 1 8 NPT MODEL 05750 ONLY 45 Exploded Views amp Parts Lists Engine Accessories Drawing No 0G7866 E TO L
39. F or open position 7 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine NOTE The generator set was thoroughly tested and adjusted at the factory before shipping No additional adjustment should be necessary Only qualified service technicians who have been trained should perform adjustments outlined in this manual 3 4 TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 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 temperature Switch The switch has normally open 0 contacts When the engine temperature is too high switch contacts close and the engine shuts down automatically THE MANUFACTURER RECOMMENDS THAT THE GENERATOR BE TESTED FOR ADEQUATE COOLING Post Installation Start up Adjustments 3 7 Post Installation Start up Adjustments 3 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT O Generator is properly located O Generator is properly supported O Generator is properly restrained GENERATOR COMPARTMENT O Compartment construction is proper C Holes Openings are vapor sealed O Compartmen
40. GENERAC ESSERE ESSENT Owner s Manual GENERAC Air cooled Recreational Vehicle Generators Quietpact 55 65 and 75 This manual should remain with the unit Table of Contents Part Operating Instructions Part 11 Installation Instructions Introduction rot nte tnr ncn 1 Safety Rules 20 Read This Manual 44022000 202 0 1 Notice to Installer die 20 COMENS Sae A 1 Operation and 1 Section 1 General Information 22 How to Obtain Service ie ree feos 1 1 1 Purpose and Scope of the Installation Instructions 22 Authorized Service Dealer Locator 1 DNE TIRES 22 1 3 Standards Booklets a 22 Safety Rules 2 14 Equipment Description ko 22 Section 1 General Information 4 Engine Operating 22 MA 1 6 Generator AC Connection System 22 1 1 Generator Identification sse 4 1 2 Generator Applicability ee 5 Major Features and HUMES IONS
41. INYINI NIV 119 N 2215 111454 V Qella gt A2J SAWS Ad NVICIYND LOVIN 870 11 ie E S30V1d v gt L 91 291 TIIS Ly l2 L t 91 6 1 i L 91 S S6S 2 1 8I J 869 dAL 100 119 AK MIV LOH pend L 8 1 21 YS i q WG Y L 91 El 11 1 99v Ln 8 6 2 psa EMT z S _ E V Lv 8H 94v 91 6 SE S3HINI NW NI 33V SNOISNIWIC 6 dol 4 3IA 28 Installation 2 3 2 TESTING THE INSTALLATION The manufacturer recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of overheating enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate NOTE The installation must be tested especially if bringing in air from below the generator set 2 4 GASOLINE FUEL SYSTEM Gasoline is highly flammable and its vapors Aare explosive Comply with all codes standards and regulations pertaining to gasoline fuel sys tems used in recreational vehicle generators Properly install and maintain the fuel system and keep it entirely free of leaks Gasoline vapors must not enter the vehicle interior The installation of a gasoline fuel system Figure 2 10 fo
42. NOILY901 3 WV 1 L 91 G 2 1 LSNWHX MIV LOH Installation Figure 1 3 Connection for 120 240 Volts eT E D CBI RED A A x 120 i VAC T2 12 240 N WHITE 4 VAC 120 VAC Ad _ CB2 T3 Y Y 44 STATOR POWER L GROUNDED NEUTRAL WINDINGS The AC connection system on air cooled generators uses a GROUNDED neutral A separate green ground wire is connected to the recreational vehicle s junction box Loads connected across T1 Red to T2 White and T3 Black to T2 White must not exceed ratings for the specific generator see Generator Specifications NOTE Do NOT connect loads in excess of circuit breaker ratings 2 1 LOCATION AND SUPPORT 2 1 1 GENERATOR LOCATION NOTE Be sure the installation complies with all standards and codes listed in the Standards Booklets section of this manual The most desirable location for the generator set is between the vehicle s main frame members However this is seldom possible Most units must be installed on the side of the vehicle and are difficult to reinforce Many recreational vehicles have been factory equipped with an area for the generator set Some vehicles may even have a genera tor compartment provided by the vehicle manufacturer Plan the generator location based on the following The generator set must be installed on a framework that is part of the recreational vehicle as outlined in the Generator Supp
43. NPT X 3 8 ASSEMBLY OIL DRAIN HOSE OIL DRAIN DIPSTICK ASSEMBLY CAP amp DIP STICK SCREW TAP R 10 32 X 9 16 GASOLINE ONLY BARBED TEE 1 4 NYLON 05750 ONLY SCREW HHTT 3 8 16 X 1 1 4 CZ WASHER LOCK SPECIAL 3 8 SCREW SWAGE 1 4 20 X 1 Z YC OIL FILTER SWITCH OIL PRESSURE HOBBS SUPPORT OIL FLTR FLARE WASHER LOCK M3 SCREW PPHM M3 0 5 X 8 SWITCH OIL HIGH TEMP GASOLINE ONLY SWITCH OIL HIGH TEMP LP ONLY ASSEMBLY GOVERNOR LEVER SPRING GOV 5 5 KW amp 5 0 KW 50HZ ONLY SPRING GOV 6 5 7 5 KW amp 7 0 KW 50HZ ONLY BUSHING GOVERNOR ROD ROD GOVERNOR BOOT CHOKE SOLENOID GASOLINE ONLY 5 4 40 X 1 4 SEMS GASOLINE ONLY ASSY BI METAL HEATER GASOLINE ONLY SOLENOID CHOKE GASOLINE ONLY SCREW HHC M5 0 8 X 10 G8 8 WASHER LOCK M5 WASHER FLAT M5 LINKAGE CHOKE GASOLINE ONLY COTTER PIN GASOLINE ONLY NUT LOCK HEX M5 0 8 SS NYL INS ASSEMBLY GOV ADJUSTMENT SCREW HHC M8 1 25 X 20 G10 9 WASHER LOCK M8 5 16 WASHER FLAT 5 16 M8 ZINC LINKAGE CHOKE BELLCRANK CARB ASSEM CHOKE BRACKET GASOLINE ONLY BRACKET CHOKE LP ONLY 5 4 40 X 5 165 5 ITEM PART NO 58 009404 59 009801 60 0 3018 61 009680 62 001143 63 0 177 64 084997 65 063222 66 022097 67 063110 68 001546 69 001547 70 082774 71 OA5358 72 009312 73 009314 74 001557 75 049028 76 0D9682A 77 009270 78 048031 79 009269 80 0 0142 81 078643 82 009219 83 0E0573 84 008807 0 1217 85 0 0572 86
44. P REGULATOR 115 116 46 Engine Accessories Drawing 0G7866 E ITEM PART NO 1 045756 2 001131 011696 4 069763 5 0D9782A 6 003034 7 0603033 8 051754 9 0A5992 10 003032 11 063031 12 00637250 13 0049280 14 0234848 15 009679 16 0E8775 17 0 1167 18 056893 19 0E7585A 20 0E0998 21 064853 22 043790 23 004403 24 0 0361 25 0 0393 26 002824 27 066950 28 075246 29 0 4456 30 042311 31 070185 32 009235 33 0 5360 34 043182 35 001085 36 01497 075281 37 009399 38 009513 0 1498 39 001366 40 009395 41 077075 42 0 7094 43 008590 44 008591 45 045770 46 049226 47 051713 48 009402 49 077091 50 082025 51 0 1247 52 055173 53 022129 54 022145 55 009403 56 0 1246 0D9400 57 0 7095 DESCRIPTION c L L ON No Na i i N NO Po Pp NS SH ca N SCREW M6 1 0 X 10 GUARD FAN 12KW HSB HOUSING BLOWER V TWIN RV NUT GROMMET 1 4 PLUG HOSE BREATHER NUT HEX M24 2 0 G8 YEL CHR WASHER BELLEVILLE 25MM BOLT SCREW HHC M8 1 25 X 12 G8 8 WASHER SHAKEPROOF INT M8 SS PLATE FAN FAN NYLON FLYWHEEL ASSY PLATE BACKING WITH CUT OUT BUSHING SNAP WRAP CRANKCASE RV SPCC VERTICAL SHAFT RV ENGINE WRAP CYL 1 RV SPCC SCREW CRIMPTITE 10 24 X 75 SPARK PLUG CLAMP VINYL 9 5 0 0 TUBE TUBE OIL DRAIN amp CHECK BARBED EL 90 3 8
45. PO N N e C mk MO Eo qol k ak lx XE qx NG S ok SCREW HHC M8 1 25 X 90 68 8 WASHER FLAT 5 16 M8 ZINC TENSION SPRING WASHER SPRING CENTER NUT LOCK FL M8 1 25 SCREW HHC M6 1 0 X 16 08 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC WASHER NYLON 404 STANDOFF 1 2 HEX SCREW HHTT M5 0 8 X 16 ASSY BRUSH HOLDER BEARING CARRIER UP STATOR ASSEMBLY 5 5 KW ONLY STATOR ASSEMBLY 6 5 KW ONLY STATOR ASSEMBLY 7 5 KW ONLY BEARING BALL ROTOR ASSEMBLY 5 5 KW ONLY ROTOR ASSEMBLY 6 5 KW ONLY ROTOR ASSEMBLY 7 5 KW ONLY BEARING STUD RV STATOR D C BEARING CARRIER LOW NYLON SLIDE SLIDE NYLON SUPPORT SLIDE SPRING GEN MOUNT WASHER SPRING CENTER CIRCUIT BREAKER 30 X 1 5 5 amp 6 5 KW ONLY CIRCUIT BREAKER 35 X 1 7 5 KW ONLY CIRCUIT BREAKER 20 X 1 5 5 KW ONLY CIRCUIT BREAKER 30 X 1 6 5 KW ONLY CIRCUIT BREAKER 35 X 1 7 5 KW ONLY SCREW RHM 6 32 X 1 4 SIMS FUSE 7 5 AMP HOLDER FUSE SWITCH SPDT ON MOM ON SWITCH 6A SPDT SCREW HHC M5 0 8 X 25 G8 8 PANEL TOP CONTROL YS rer ES Exploded Views amp Parts Lists ITEM PART 34 054502 1 35 031879 4 36 043182 4 37 051714 4 38 092234 1 39 049226 5 40 051716 3 41 0034848 2 42 003700 1 43 009378 1 44 052619 1 45 075476 2 46 065795 1 47 0602174 1 48 092120 4 49 049721 2 50 0 1658 2 51 074260 146 1 52 049813 4 53 0234840 1 54 074260 151 1 55 084867 1 56 043181
46. REW M6 1 0 X 12mm 4 005372 1 ASSEMBLY BREATHER 5 003005 1 GASKET BREATHER COVER 6 0 3372 1 SEPARATOR OIL BREATHER 7 0D8067A 1 ASSEMBLY HEAD 1 8 0029810 1 COVER ROCKER 9 071983 4 RETAINER PISTON PIN 20 10 062751 2 PISTON FLAT TOP DIA 90 COATED 11 002565 2 RING SET PISTON DIA 90 12 0 1466 2 PIN PISTON 13 004041 1 ASSEMBLY CAMSHAFT amp GEAR 14 002983 1 SHAFT GOVERNOR 15A 0C2985A 2 ROLLER BEARING GOVERNOR PLATE 15B 062985 1 ROLLER BEARING GOVERNOR 16 004042 1 ASSEMBLY GOVERNOR GEAR 17 OA7811 1 SPOOL GOVERNOR MACHINED 18 062977 1 GASKET CRANK CASE 19 005943 1 SEAL OIL PASSAGE 20 0E3790A 1 ASSY CRANK GTV 760 BELT DRIVE 21 0E3222 2 ASSEMBLY CONNECTING ROD 22 002978 2 GASKET HEAD 23 24 0G6431A 3 SCREW SHC M6 1 0 X 30mm SEMS 25 002994 1 SCREEN OIL PICKUP 26 002997 1 COVER GEROTOR 27 002995 1 GEROTOR INNER 28 002996 1 GEROTOR OUTER 29 063011 2 COVER OIL RELIEF 30 003009 2 SPRING OIL RELIEF 31 0603010 2 BALL 1 2D OIL RELIEF 32 050873 1 1 4 NPT PIPE PLUG 33 34 35 36 37 38 39 40 Exploded Views amp Parts Lists ITEM PART NO DESCRIPTION 002991 2 E RING GOVERNOR ARM 0D1667A 1 ARM GOVERNOR 002988 1 THRUST WASHER GOVERNOR 002992 1 BUSHING GOVERNOR LOWER 005732 1 ASSEMBLY SUMP WITH SLEEVE 002993 1 SEAL GOVERNOR SHAFT 0 9842 1 SEAL 42 I D CRANKSHAFT 0D9756 1 CONNECTOR 3 8NPT TO INVTD FLR 3 80D 0C3006 10 SCREW HHFC M10 1 5 X 55mm 080318 8 SCREW HHFC M6 1 0 X
47. SEMS BARBED STR 1 4NPT X 3 8 CLAMP HOSE OETIKER STEPLESS 17mm HOSE 3 8 IDX6 L BRAIDED WRAPPED COOLER OIL DUCT OIL CLR RV SPCC PLASTITE 1 4 15 X YA SCREW PPHM 10 32 X 3 8 SCREW HHTT 4 40 X Y PLATE THROTTLE WASHER LOCK 10 NUT HEX 410 32 STEEL SCREW HHC M6 1 0 X 12 08 8 WASHER FLAT M6 SCREW HHC M6 1 0 X 16 G8 8 SCREW HHTT M5 0 8 X 8 BP CLAMP HOSE 8 53 1 00 LP ONLY HOSE 12 ID LP ONLY SCREW PPHM 4 0 7 X 16 GASOLINE ONLY CLIP J VINYL COAT 375 ID GASOLINE ONLY WASHER FLAT 8 GASOLINE ONLY WASHER LOCK 8 GASOLINE ONLY NUT HEX M4 0 7 G8 YC GASOLINE ONLY SCREW HHTT M6 1 0 X 16 ZYC CLAMP VINYL 1 06 X 406 LP ONLY WASHER FLAT 1 4 M6 LP ONLY SCREW HHTT M6 1 0 X 12 LP ONLY CLAMP VINYL 437 X 281 SCREW SWAGE 1 4 20 X 1 2 OIL CHECK TUBE BRACKET 3 8 NPT TO INVTD FLR 3 8 OD 47 Control Panel Drawing No 0E1013 B Exploded Views amp Parts Lists Control Panel Drawing No 0E1013 B ITEM PART NO 1 002375 2 022145 3 029459 4 075215 052858 6 047411 7 022097 8 022473 9 080925 10 009921 11 066849 12 066386 13 009674 14 0 0363 0 0364 0 0362 15 073159 16 077005H 077004 073163 17 031971 18 077006 19 009675 20 0 5351 21 073146 22 061878 23 075242 24 075237 25 090145 0 1529 26 090144 090145 0 1529 27 025105 28 0 9611 29 032300 30 092113 31 087798 32 055440 33 009377 DESCRIPTION TJ CO
48. aintenance of this equipment is carried out by an Authorized Service Dealer 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 When working on 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 Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement Before performing any maintenance on the generator discon nect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dan gerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc ENGINE EXHAUST HAZARDS Generator engine exhaust contains DEADLY carbon monox ide an odorless colorless poisonous gas Breathing carbon monoxide can cause dizziness throbbing temples nausea muscular twitching headache vomiting weakness and sleepi ness inability to think clearly fainting unconsciousness or even death If you experience any carbon monoxide poisoning
49. al vehicle Qualified electricians who are familiar with applicable codes standards and regulations should install electrical wiring The wiring should comply with codes standards and regula tions 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 compartment if used must be vapor sealed to prevent entry of flammable explosive or poisonous gases into the vehicle 2 7 1 ELECTRICAL JUNCTION BOX Install an approved square electrical junction box with a blank cover on the interior or exterior wall of the area planned for installa tion of the generator NOT on the generator Route the generator s AC output leads into this junction box through approved flexible conduit This is the point of first termination for generator AC output leads 27 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 If neutral conductors are used they must be the same size as other leg wires Route power supply conductors from generator AC output leads T1 red T2
50. 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 pertaining to fire extin guishers consult the local fire department EXPLOSION HAZARDS Do smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris e Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws governing the storage and handling of gasoline CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNING This product contains or emits chemicals known to the State of California to cause cancer birth defects and other reproductive harm General Information 1 1 GENERATOR IDENTIFICATION Please record the following information from the gen
51. approved components in the fuel sup ply system All components must be properly installed in accordance with applicable codes Improper installation or use of unauthorized components may result in fire or an explosion Follow approved methods to test the system for leaks No leakage is permitted Do not allow fuel vapors to enter the vehicle interior Figure 2 11 Typical Propane Gas Fuel System CARBURETOR REGULATOR UEL LOCKOFF SOLENOID PRIMARY REGULATOR VAPOR WIDTHDRAWAL TANK 30 2 5 2 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system consider seriously the following items All fittings lines hoses and clamps must be tight and free of leaks Apply a pipe sealant to threads when assembling thread ed connections This reduces the possibility of leakage Test the entire fuel system for leaks using approved test meth ods Optimum gas pressure at the inlet to the gaseous fuel solenoid valve and secondary regulator is 11 inches water column The installer s fuel supply connection point is at the gaseous fuel solenoid valve This is a 3 4 inch female connection Provide a suitable 3 4 inch NPT male connector to attach to the fuel supply line Use a length of approved flexible fuel hose between the gaseous fuel solenoid valve and rigid gas piping The flexible line should be at least 6 inches longer than necessary 2 5 3 VAPOR WITHDRAWAL LP gas is stored in pre
52. at www guardiangenerators com Safety Rules SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe 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 Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique utilized does not render the generator unsafe A DANGER Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to re
53. ategory Compliance Period 500 Hours gt 66 cc lt 225 cc B 250 Hours e sormus 1 9 EXHAUST EMISSIONS INFORMATION PROPANE The Environmental Protection Agency EPA and the California Air Resource Board CARB require that this generator comply with exhaust emission standards The generator is certified to meet all applicable exhaust emission levels This generator is certified for use as a mobile engine It is important that you follow the mainte nance specifications listed in this manual to ensure that the engine complies with emission standards for the duration of its life This engine is certified to operate on propane fuel LP The emission control system on the generator consists of the following Fuel Metering System Mixer assembly Fuel regulator and lines Air Induction System Intake pipe manifold hir cleaner Ignition System Spark plug Ignition module Catalytic Converter if equipped The Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal and California emission requirements See the table below to determine the com pliance period for this generator The displacement of the engine is listed on the Emissions Compliance Label Displacement Category Compliance Period 500 Hours gt 66cc lt 225cc 250 Hours gt 225 2 1 GENERATOR
54. 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 stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mounting to the vehicle frame or chas sis 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 wire minimum If the vehicle electrical circuits can be powered by any other source of electricity such as a dockside power receptacle there must be no possibility of connecting the different power sources to the vehicle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operating Failure to isolate the vehicle circuits from the dockside power supply when the generator is running may result in damage to the generator or serious injury or death to dockside utility power workers due to backfeed of electrical energy In case of accident caused by electric shock immediately shut down the source of electrical po
55. bon monoxide which can be DEADLY This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death This exhaust system must be installed properly in strict compliance with applicable codes and standards Following installation do nothing that might render the system unsafe or in noncompli ance with such codes and standards The generator compart ment 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 ventilating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or permit even partial blockage of ven tilation 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 Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing
56. burns Allow engine to cool before draining oil Avoid prolonged or repeat ed skin exposure with used oil Thoroughly wash exposed areas with soap Change the engine oil after the first 25 hours of operation Thereafter change the oil every 100 operating hours Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures Change the engine oil filter after the first 25 hours of operation and every 100 operating hours thereafter To change the oil and or oil filter proceed as follows 1 Run the engine until it is thoroughly warmed up at least five minutes then shut OFF the engine 2 With the engine still warm from running remove the oil drain plug Figure 3 1 Drain the oil into a suitable container 3 After the oil has drained replace the oil drain plug If only changing the oil go to step 7 4 With the oil drained remove the old oil filter by turning it coun terclockwise Figure 3 2 5 Apply a light coating of clean engine oil to the gasket of the new filter 6 Screwthe 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 3 After the oil has drained replace the oil drain plug If only changing the oil go to step 7 4 With the oil drained remove the old oil filter by turning it coun terclockwise Figure 3 2 12 Figure 3 1 011 Dipstick Fill Tube and Location of Oil D
57. carburetor ignition system fuel system catalytic converter and other associ ated emission related components if equipped MANUFACTURER S WARRANTY COVERAGE This emission control system is warranted for two years If during such warranty period any emission related part on your equipment is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Dealer OWNER S WARRANTY RESPONSIBILITIES As the generator owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your generator but Generac cannot deny warranty solely due to the lack of receipts As the generator owner you should be aware that Generac may deny any and or all warranty coverage or responsibility if your generator or a part component thereof has failed due to abuse neglect improper maintenance or unapproved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Dealer 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 Dealer To locate
58. consult the local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Gasoline is extremely FLAMMABLE its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws governing the storage and handling of gasoline Fuel lines must be properly installed and fastened and free of leaks There must be no possibility of gasoline vapors entering the vehicle interior It is required that an approved flexible nonconductive fuel line between the generator fuel connection point and rigid fuel lines be installed If the generator is equipped with a liquid propane LP gas fuel system install the unit so it complies with all codes standards and regulations pertaining to such systems LP gas is highly explosive The gas tends to settle in low areas where even the slightest spark can ignite it and cause an explosion Do not allow gas vapors to enter the vehicle 21 General Information 11 PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with
59. ded could result in minor or moderate injury NOTE Notes contain additional information important to a procedure and will be found within the regular text body of this manual These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates is as follows This symbol points out important safety infor mation that if not followed could endanger personal safety and or property of others HA eg symbol points out potential explosion haz N This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator driver is responsible for proper and safe use of the vehicle and its equipment and the safety of all vehicle occupants We strongly recommend that the operator read this manual and thoroughly understand all instructions before using this equipment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts In addition the
60. dure or technique that the manufacturer does not specifically recommend must first completely satisfy themselves that their safety the safety of the vehicle s occupants and the product s safety is not endangered by the method proce dure or technique selected Information illustrations specifications etc contained in these Installation Instructions are based on the latest information avail able at the time of publication Every effort has been expended to be sure that such data is both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time without prior notice A DANGER 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 responsi ble and capable persons to operate or maintain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators Generator exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death 20 GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and m
61. e generator compartment and for proper genera tor operation Without sufficient cooling airflow deadly carbon monoxide gas can accumulate and the engine generator may quickly over heat causing serious damage to the genera tor Do not operate the genset in any confined space The exhaust system must be installed in accor dance with the genset installation manual Do not alter the installation or permit even partial blockage of ventilation systems as this can seriously affect the safe and proper operation of the generator Do not operate the generator if the exhaust system is leaking or has been damaged or if you have experienced carbon monoxide poi soning symptoms during use Shut down the generator and do not operate it until it has been inspected and or repaired Never sleep in the vehicle while the genset is running unless the vehicle has a working car bon monoxide detector A CAUTION Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the gen erator engine Also water from one engine can damage the other engine 2 6 1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U S Forest Service Use only mufflers and parts approved by the manufacturer Any person s installing an unapproved muffler an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable
62. e been properly purged and leak tested in accordance with applicable fuel codes All fuel shutoff valves in the fuel supply lines must be open DANGER If a liquid propane LP gas fuel system has been installed it must be properly tested for leaks before operating the system in compli ance with ANSI A119 2 NFPA 501C No leakage is permitted Be sure that gasoline fuel vapors do not enter the vehicle interior 3 3 INITIAL START When certain that the unit has been properly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s main circuit breakers to their OFF or open position 2 Refer to Part Starting the Generator for cranking and starting instructions The engine may require more cranking for initial starting since the fuel lines have to be primed use of the primer switch will shorten this time 3 Letthe engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load see Testing Under Load Run the unit at least 30 min utes with loads applied 6 Turn off all electrical loads by setting the generator s main circuit breakers to their OF
63. e compartment walls unless vapor tight by design should be caulked to prevent poison ous flammable or explosive vapors from entering the vehicle interior 25 Installation Figure 2 5 Typical Compartment Construction CROSS SECTION VIEW METAL LINING era FIREPROOF HAY SOUND INSULATION SR HE METAL LINING psu VAPOR sin PLYWOOD AT ALL TIMES EE METAL LINING LE NI NOTE Caulking must be done so that the caulking material will stay in place permanently Pressing such materials as putty tape onto joints and seams is not acceptable A high quality silicone rub ber 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 living area must be sealed vapor tight with silicone rubber base sealant If flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartment s electrical junction box NOTE Flexible metal conduit due to its unique construction is NOT vapor tight along its entire length Seams and joints of the galvanized steel whether used as a liner or for the compartment itself must be lapped and mechanically secured Such seams may be manufactured welded bolted riveted or screwed Manufactured lock seams are shown in Figure 2 6 Installer constr
64. e or earthen floor 7 Clean and wipe the entire generator 3 13 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Check the tag on the engine for oil viscosity and classification Verify that the correct recommended oil is used in the engine see Engine Oil Requirements If necessary drain and refill with the proper oil 2 Check the state of the battery Fill all cells of unsealed batter ies 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 4 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 5 Turn OFF all electrical loads Add fuel if necessary and then start the engine 6 Allow the unit to warm up thoroughly 7 Apply electrical loads to at least 50 percent of the unit s rated wattage capacity 8 When the engine is thoroughly warmed up shut it down 9 The generator is now ready for service 3 14 RV GENERATOR SERVICE INTERVAL 50 HoUIS saaan Clean Spark Arrestor 1st 50 Hours then every 500 Hours Adjust Valve Lash 100 FOUNS ten Change Engine Oil Filter 100 HOUS aa AN Clean Air Pre filter 100 Hours Ulan Inspect Spark Plugs 250 HOST ees Replace Paper Air Filter Element 400 HOUES i iE tie cetero Replace Fuel Filter 5
65. e positioned D LD LD DL OPTIONAL ACCESSORIES Q Check that remote start stop panels if used are installed properly Q Check that hourmeter kit if used is installed properly o Check that any other options and accessories if used are installed properly POST INSTALLATION TESTS Q Check that all tests are completed properly 41 TROUBLESHOOTING GUIDE Problem Engine won t crank Engine cranks won t start Engine starts hard runs rough Engine starts then shuts down No AC output voltage Cause 1 2 G3 gt gt On TS z KO CO IS Ww 7 5 amp fuse blown Loose or corroded or defective battery cable s Battery is discharged or defective Defective Start Stop switch Defective starter contactor Defective starter motor Defective Engine Control Board Out of fuel Fuel shutoff valve is closed Fuel pump not operating Automatic choke not operating properly Engine is flooded Fuel filter is clogged Engine spark plugs defective Bad ignition magneto on engine Bad carburetor Dirty air cleaner Dirty engine air cleaner Automatic choke is sticking Defective spark plugs Defective ignition magneto Engine oil level is low Bad low oil pressure switch Defective high temp switch Water in fuel Defective remote harness Main breaker s open Transfer switch if so equipped is set to wrong position Failure in vehic
66. ebris 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 2 Typical Suspended Mounting System The installer must make certain that the selected location will permit adequate cooling and ventilating airflow to be supplied 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 sup porting framework Figure 2 3 All bolts must be long enough so that when tight at least three threads are visible past the retaining lock nuts Refer to Generator Compartments for the location of the generator mounting holes Figure 2 3 Typical Generator Restraint 2 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compart ment that the installer constructs the compartment MUST meet certain specifications as
67. eel lining install a combination of acousti cal materials as mentioned in Sound Insulating Materials A DANGER To prevent fire or explosion do not install any pa 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 Figure 2 7 Typical Noise Abatement PLYWOOD EXTERIOR 5 8 OR 3 4 THICK SOUND INSOLATION MATERIAL PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 inch 25 mm thick fiberglass with a 2 pound density 2 2 5 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items Figure 2 8 e Engine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts See Generator Restraint A DANGER Fuel lines and exhaust piping must not pen etrate into the vehicle living area 2 3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling ventilating and engine combustion be supplied to the generator set Without sufficient airflow the engine generator quickly overheats Such overheating can cause serious operating difficulties and also may cause fire and personal injury The installer must make sure that sufficient a
68. el To adjust valve clearance if necessary Make sure the engine is at 60 to 80 F Make sure that the spark plug wire is removed from the spark plug and out of the way Remove the four screws attaching the valve cover with a 2 or 3 Phillips screwdriver Loosen the rocker jam nut Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm Figure 3 7 Figure 3 7 Valve Clearance Adjustment Rocker Pivot Ball Arm Jam Nut NOTE Hold the rocker arm jam nut in place as the pivot ball stud is turned Maintenance When valve clearance is correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in Ibs torque After tightening the jam nut recheck valve clearance to make sure it did not change Install new valve cover gasket Re attach the valve cover NOTE Start all four screws before tightening or it will not be possible to get all the screws in place Make sure the valve cover gasket is in place Install spark plugs Re attach the spark plug wire to the spark plug On the GT 530 and GT 990 repeat the process for the other cylinder 3 10 MAJOR SERVICE MANUAL To obtain a service manual for the generator contact the near est Authorized Service Dealer Make sure to identify the MODEL NUM
69. enerator with gasoline Contact the California Air Resource Board or the Environmental protection agency for further information CARB regulations can be found in 13 CCR 882750 2773 EPA regulations can be found in 40 CFR Part 90 1 8 EXHAUST EMISSIONS INFORMATION GASOLINE The Environmental Protection Agency EPA and the California Air Resource Board CARB require that this generator comply with exhaust emission standards The generator is certified to meet all applicable exhaust emission levels This generator is certified for use as a mobile engine It is important that you follow the mainte nance specifications listed in this manual to ensure that the engine complies with emission standards for the duration of its life This engine is certified to operate on gasoline The emission control system on the generator consists of the following Fuel Metering System Carburetor assembly Fuel pump and lines Air Induction System Intake pipe manifold Air cleaner Ignition System Spark plug Ignition module Catalytic Converter if equipped The Emissions Compliance Period referred to the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal and California emission requirements See the table below to determine the com pliance period for this generator The displacement of the engine is listed on the Emissions Compliance Label Displacement C
70. erator DATA DECAL or information decal 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage 5 Phase 6 Hertz P 5 10 3 1 1 15 Behind Access Panel HI O 19 em DO 496 9 18 20 REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake Screen 11 Fuel Pump Behind access panel 2 Data Plate 12 Oil Filter 3 Engine Start Stop Switch 13 Oil Drain Plug 4 7 5 amp Fuse 14 Oil Dipstick and Filler Tube 5 Circuit Breaker 15 Air Filter Behind access panel 6 Optional Remote Panel Receptacle 16 Spark Plugs 7 Generator AC Output Leads 17 Exhaust Outlet 8 Starter Contactor 18 Fuel Filter 9 Fuel Inlet 19 LP Fuel Inlet 10 Fuel Primer Switch 20 Evaporative Port General Information 1 2 GENERATOR APPLICABILITY These generators have been designed and manufactured for sup plying electrical power for recreational vehicles DO NOT modify the generator or use it for any application other than for what it was designed If there are any questions pertaining to its applica tion write or call the factory Do not use the unit until advised by competent authority A DANGER AN For fire safety the generator must have been properly installed in compliance with ANSI 119 2 1975 NFPA 501C 1974 Standard for Recreational Vehicles Part III Installation of Electrical Systems The generator also must have been installed in strict compliance with the manufacturer s detailed installation instructions
71. erly tested for leaks To test the system a separate source of 12 volts DC to open the gaseous fuel solenoid valve is needed The leak test must comply fully with NFPA Paragraph 318 All con nections hoses valve regulators fittings and other fuel system parts must be tested under gas or air pressure of not less than 90 psi 620 kPa while using soap and water or an equivalent solution to check for leaks Other approved methods of testing for leaks may be used if appropriate DO NOT USE ANY FLAME TO TEST FOR LEAKS 2 6 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used A properly installed exhaust system must be vapor tight quiet and completely safe A DANGER Generator engine exhaust contains DEADLY carbon Monoxide an odorless colorless poi sonous gas Breathing carbon monoxide can cause dizziness throbbing temples nausea muscular twitching headache vomiting weak ness and sleepiness inability to think clearly fainting unconsciousness or even death If you experience any carbon monoxide poisoning symptoms move into fresh air and immediately seek medical attention Never operate the generator set with the vehi cle inside any garage or other enclosed area 31 Installation Adequate unobstructed flow of cooling and ventilating air is critical for expelling toxic car bon monoxide gas and fuel vapors from th
72. for any damage injury or warranty expense that might be caused by such unapproved installation or modification Failure to provide and maintain a spark arrestor may be in violation of the law If this generator is used on any forest covered brush covered or grass covered unimproved land a spark arrestor must be provided The vehicle owner or operator must maintain this device in good condition In the state of California the preceding is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands When installing replacing the tailpipe or spark arrestor compo nents verify that the tailpipe has a hole to securely fasten the spark arrestor components see Figure 2 13 Use only manufacturer supplied hardware Substitution of parts may cause damage to the screen or a loose fit to the tailpipe 32 Figure 2 13 Spark Arrestor Installation O D 38 1 1 50 3 5 9 64 DRILL 24 0 95 BOTTOM SIDE ONLY 2 6 2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any combustible 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 or shield the exhaust part s so that the temperature of any combustible material is not raised more than 117 F 65 C above the ambient air temperature Extend t
73. he compartment interior A DANGER f Do not install sound insulation or any absorbent material on the compartment floor interior Such materials will become soaked with combus tible 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 material is more effective than when a single material is used Installation 2 2 4 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement compartment NOTE Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compart ment 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 7 Use 5 8 inch thick or 3 4 inch thick plywood in the compart ment Construct the compartment floor of a double thickness of 5 8 inch or 3 4 inch plywood Line the compartment interior walls and floor as well as the underside of the floor with 26 gauge galvanized steel Vapor seal all compartment seams and joints Over the galvanized st
74. he exhaust system at least 1 inch 25 mm past the outer edge of the vehicle Do not terminate the exhaust system under the vehicle Terminate the exhaust tailpipe such that exhaust gases will not be drawn back into the generator compartment and recircu lated If there is any possibility of the tailpipe or muffler being dam aged protect these damage prone areas by means of a protec tive device such as a skid bar Install the generator exhaust system according to safe automo tive practices Use enough exhaust system hangers to prevent any part of the system from being dislocated 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 unauthor ized parts Do not terminate the exhaust system under any opening win dow 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 appli cable codes standards and regulations Installation 2 7 ELECTRICAL CONNECTIONS The following general rules apply to electrical connections in a recreation
75. ir is available to the generator for cooling ventilat ing and combustion The installer also must provide for a path for exhausting the cooling air to the exterior of a compartment if so equipped 4a DANGER A Never use discharged cooling air for heating or Apermit such air to enter the vehicle interior This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases 2 9 1 GENERATOR AIRFLOW Engine operation drives cooling fans for the two stage cooling air system A pressure fan draws cooling air into the top of the generator Figure 2 9 This airflow cools the engine generator and electronic components The second part of the cooling system a suction fan draws air that is heated from a hot engine into a col lector pan at the base of the unit This heated air although cooler than exhaust muffler is then deflected out the bottom toward the ground Figure 2 9 Airflow Through Engine Generator 4 h 27 Figure 2 8 Compartment Floor Cutout Drawing 0G3529 A Installation INI 1000 a jd SI V3JelV jd V 45 8 ev hy dob 31V 1dW3L NOILYTIYLSNI ISAW SLITIN NV S
76. ise 13 Replace the Air Box Compartment Cover back onto all three locating tabs and replace the plastic screw Tighten clockwise carefully 3 4 CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug to clean 2 Remove the spark plug and check the condition Replace the spark plug if worn or if reuse is questionable 3 Checkthe spark plug gap using a wire feeler gauge Adjust the gap to 0 040 inch 1 02 mm by carefully bending the ground electrode Figure 3 4 Figure 3 4 Setting the Spark Plug Gap C im Maintenance CAUTION Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end If necessary re form the wire terminal to obtain a tight fit 3 5 FUEL FILTER caso ine ONLY Remove and replace the fuel filter Figure 3 5 once each year or every 400 hours of operation whichever comes first Figure 3 5 Fuel Filter ia TO FUEL PUMP CUSTOMER FUEL CONNECTION 3 6 CLEAN SPARK ARRESTOR The engine exhaust muffler has a spark arrestor screen Inspect and clean the screen every 50 hours of operation or once each year whichever comes first NOTE If u
77. it breaker ratings are as follows Moss Grou Beater Grout 30 20 NOTE If this generator has been reconnected for dual voltage AC out put 120 240 volts install line breakers having an amperage rating that is different than that stated above The replacement line breakers consist of two separate breakers with a connect ing piece between the breaker handles so that both breakers will operate at the same time If the unit is reconnected for dual voltage it is no longer RVIA or CSA listed 2 2 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel is available that allows start ing and stopping the generator engine conveniently from inside the vehicle The remote panel includes a Start Stop switch hourmeter generator run lamp a fuel prime switch and a wire harness 2 3 AUTOMATIC CHOKE This engine is equipped with an automatic choke that consists of two main components a choke solenoid and prechoke 2 3 1 CHOKE SOLENOID During engine cranking Start Stop switch at START a solid state choke module signals the choke solenoid to activate and cycle choke on choke off until the engine starts The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking When the engine starts the choke stops cycling 2 3 2 PRECHOKE The choke system also has a temperature sensitive metal strip that adjusts choke valve angle according to ambient
78. l 2 wire connection system Generators may be installed to provide the following outputs 1 120 VAC loads only one load with a maximum total watt age requirement equal to the generator s rated power output in watts and 120V across the generator output terminals Figure 1 1 shows the generator lead wire connections for 120VAC ONLY Figure 1 1 Connection for 120 Volts Only Ks PA n 83 O cB1 O Cd x ps x 1 9 9820 BLACK zo 120v 92 9 oz lt gt gt 120v o T2 44 EN WHITE 117 x T2 WHITE GROUNDED NEUTRAL General Information 2 120 240 loads one load with a maximum total watt age requirement equal to the generator s rated power output and 240V across the generator output terminals or two sep erate loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120V across the generator output terminals Figure 1 2 shows the generator lead wire connections for 120 240 VAC loads Also refer to the Line Breakers section for circuit breaker ratings This procedure should be done by an Authorized Service Dealer or other qualified installer Figure 1 2 Connection for 120 240 Volts 11 STO T1 KI CBI RED A A 120 VAC T2 v 240 WHITE VAC 120 VAC CB2 T3 44 BLACK i STATOR POWER GROUNDED NEUTRAL WINDINGS 1 6 SPECIFICATIONS 1 6 1 FUEL REQUIREMENTS
79. l attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried 3 9 ADJUSTING VALVE CLEARANCE After the first six 6 months of operation check the valve clear ance in the engine adjust if necessary Important If feeling uncomfortable about doing this procedure or the proper tools are not available please contact the Authorized Dealer for service assistance This is a very important step to insure longest life for the engine To check valve clearance The engine should be cool before checking If valve clearance is 0 002 0 004 0 05 0 1mm adjustment is not needed Remove spark plug wires and position wires away from plugs Remove spark plugs Make sure the piston is at Top Dead Center TDC of its com pression stroke both valves closed To get the piston at TDC remove the intake screen at the front of the engine to gain access to the flywheel nut Use a large socket and socket wrench to rotate the nut and hence the engine in a clockwise direction While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is at its highest point of trav
80. 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 Cylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Manifolds INTERNATIONAL YEAR ONE or 1000 hours whichever occurs first Limited comprehensive coverage on labor and parts listed All COMPONENTS Extended Warranties are not available on units sold into International Markets Generac RV generators manufactured after January 1 2006 have a transferable warranty to the second owner ONLY for the remainder of the three year limited war ranty Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any warranty service All warranty expense allowances are subject to the conditions defined in Generac s Warranty Policies and Procedures Guide THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac generators that utilize non Generac replacement parts Costs of normal maintenance adjustments installation and start up Repairs or diagnostics performed by individuals other than Generac authorized dealers not authorized in writing by Generac Power Systems Failures caused by any contaminated fuels oils coolants o
81. latter portion of this manual contains infor mation necessary for the proper installation of these generators 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 responsibility of the owner operator and as such are not considered defects in materials or workman ship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and acces sories 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
82. le electrical system Generator component failure Troubleshooting Correction 1 2 Om m de CO PO Replace blown fuse Tighten clean or replace as necessary Recharge or replace battery Replace switch Replace starter contactor Replace starter motor Contact an authorized service dealer Refill fuel tank Open fuel shutoff valve s Repair or replace pump Repair replace or adjust Wait 5 10 minutes try again Replace filter if clogged Clean regap or replace as needed Replace if defective Adjust repair or replace Clean or replace as needed Clean or replace as needed Free choke linkage as needed Clean regap or replace Replace it if defective Add oil as needed Replace if bad Replace if bad Drain fuel tank and refill Disconnect remote harness Contact authorised service facility Close main breaker s Reset transfer switch See vehicle manual Contact an authorized service facility Electrical Data Electrical Schematic V twin Drawing No 0E1057 F B
83. ll be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in the Owner s Manual to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the period prior to the first scheduled replacement point for that part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 Notwithstanding the provisions of subsection 4 above warranty services or repairs must be provided at Generac Authorized Service Facilities 6 When
84. nder the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and maintenance of this equipment is carried out by an Authorized Service Dealer The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentrations 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 vomiting d twitching muscles e throbbing temples f dizziness g headaches h weakness and i sleepi ness 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 running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset instal lation manual Make sure there is ample fresh air when operat ing the genset in a confined area The engine exhaust fumes contain car
85. on can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or 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 precautions are to be observed when working on batteries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery Disconnect any charging source prior to connecting or disconnecting battery terminals and Do not use any jumper cables or booster battery to crank and start the generator engine If any battery has discharged remove it for recharging WARNING Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medica
86. onductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting 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 equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installation do noth ing that might alter a safe 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 by the National Fire Protection Association are
87. ort section The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from underneath the supporting framework The location must provide easy access to frequently serviced components such as filters oil drains spark plugs and other common maintenance parts The location must provide sufficient room to allow minimum 24 clearances as outlined in Generator Compartments If sound insulation is to be used on the compartment walls and ceiling the minimum recommended applies to 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 If mounting the generator in an enclosed compartment the base of the generator must rest flat on the floor without any gaps When using a suspended mounting system ensure the base of the generator is flush with the surrounding bodywork If the unit is mounted higher in the structure heated air may recirculate into the generator causing it to overheat 2 1 2 GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding The metal framework on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams These beams should consist of a 1 1 2 inch square 11
88. otection Agency EPA If this generator is offered for sale in the state of California it must be covered by a CARB evaporative Executive Order If this generator is offered for sale to the final consumer in any other state certified low permeation fuel line must be used to supply fuel to the genera tor as required by EPA Anyone who installs or configures a fuel system to supply this generator with gasoline is required to comply with all applicable evaporative emission regulations If this generator is configured such that it shares the primary fuel system of a vehicle in which it is installed reduced certification requirements may apply See the CARB guidance document MAC 05 05 located at http www arb ca gov msprog macs mac0505 mac0505 pdf for further details If this generator is installed such that it uses a dedicated fuel system detailed evaporative emission requirements apply contact a repu table fuel system manufacturer to purchase a complete fuel sys tem certified for use with this generator or consult the California Code of Regulations if you wish to obtain certification on your own See the installation instructions in this manual for connecting fuel system vapor lines to the engine This generator is not legal for sale in the state of California unless all CARB evaporative emission requirements are adhered to and is not legal for sale in any other state unless certified low per meation fuel line is used to supply the g
89. ous damage to the genera tor Do not operate the genset in any confined space The exhaust system must be installed in accor dance with the genset installation manual Do not alter the installation or permit even partial blockage of ventilation systems as this can seriously affect the safe and proper operation of the generator Do not operate the generator if the exhaust System is leaking or has been damaged or if you have experienced carbon monoxide poi soning symptoms during use Shut down the generator and do not operate it until it has been inspected and or repaired Never sleep in the vehicle while the genset is running unless the vehicle has a working car bon monoxide detector 2 5 STARTING E 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 crank and start the generator engine proceed as follows 1 Turn OFF electrical loads using the means provided 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 set
90. pors should be supplied to the secondary regulator inlet at about 11 inches water column positive pressure The engine pistons draw air in during the intake stroke Figure 2 12 This air passes through a carburetor venturi which creates a low pressure that is proportional to the quantity of air being pumped The low pressure from the carburetor venturi acts on the regulator dia phragm to pull the diaphragm toward the source of low pressure A lever attached to the diaphragm opens a valve to permit gas glow through the carburetor Figure 2 12 LP Gas Carburetion Diagram AIR GAS AT FLOW POSITIVE 4 PRESSURE NU GAS AT LOW PRESSURE ZERO PRESSURE AREA The greater the airflow through the carburetor venturi the lower the pressure at the venturi throat The lower the pressure at the venturi throat the greater the diaphragm movement and the greater the movement of the regulator valve The more the regulator valve opens the greater the gas flow that is proportional to airflow through the generator The following facts about the secondary regulator must be empha sized The regulator must be sensitive to venturi throat pressure changes throughout the operating range The regulator must be properly adjusted so it will stop the flow of gas when the engine is not running no air flow through the carburetor The slightest airflow and vacuum in the venturi throat should move the regulator valve off its seat and permit gas
91. r 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 gasoline vapors entering the vehicle interior Figure 2 10 Generator Fuel System Fuel Pump Behind Access Cover J Fuel Filter C3 Side of Unit S V t H Fuel Line Factory installed generator fuel system components include a fuel filter D 12 volt DC electric pump c engine carburetor and d interconnecting lines and fittings Connect a fuel supply line to the fuel filter inlet Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines 24 1 FUEL TANK Either the generator must share the vehicle engine s fuel tank or a separate fuel tank for the generator set must be installed All fuel tanks installed on the vehicle must be constructed installed and restrained so they comply with applicable codes standards and regulations The generator has an evaporative emissions port to evacuate accumulated gasoline vapors whtn necessary If the generator is to share the vehicle engine s tank separate fuel pickup tubes are required for the engine and the generator The manufacturer recommends that the fuel pickup tube
92. r conditioner etc need about 2 1 2 times more watts of power for starting than for running for a few seconds during motor starting Be sure to allow for this when connecting electrical loads to the generator First figure the watts needed to start electric motors in the system To that figure add the running wattages of other items that will be oper ated by the generator Do not apply heavy electrical loads for the first two or three hours of operation 2 8 PROTECTION SYSTEMS 28 1 LOW OIL PRESSURE SWITCH This switch Figure 2 3 has normally closed N C contacts that are held open by engine oil pressure during cranking and operat ing Should oil pressure drop below a preset level switch contacts close and the engine automatically shuts down The unit should not be restarted until oil is added 2 8 2 HIGH TEMPERATURE SWITCH This switch Figure 2 3 which has normally open N O contacts is mounted near the oil filter The contacts close if the tempera should exceed approximately 270 F 132 6 for gasoline models and 284 F 140 C for LP models initiating an engine shutdown Figure 2 3 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE ENGINE OIL OIL PRESSURE FILTER SWITCH 2 8 3 FIELD BOOST The Controller Circuit Board houses a field boost diode and resistor that are not part of the automatic choke circuit These two compo nents are part of a field boost
93. r 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 collision 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 Living 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
94. rain Plug Cil Dipstick Oil Drain Hose 5 Apply a light coating of clean engine oil to the gasket of the new filter 6 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn 7T Remove the dipstick and fill crankcase with the proper type and amount of recommended oil see Engine Oil Requirements The engine crankcase can hold about 1 8 liters or 1 9 quarts with oil filter change DO NOT FILL ABOVE THE FULL MARK 8 Install and tighten the dipstick before operating the engine 9 Start the engine and check for leaks 10 Dispose of used oil at a proper collection center NOTE Check the oil level and fill to the FULL mark after checking for leaks The filter will retain some oil Figure 3 2 Engine Oil Filter ENGINE OIL FILTER TWIST COUNTER CLOCKWISE TO LOOSEN 3 3 MAINTAINING THE ENGINE AIR CLEANER 3 3 1 CLEANING THE FOAM PRECLEANER Clean and re oil the foam pre cleaner every three months or every 100 hours of operation whichever occurs first Service the foam pre cleaner more frequently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 3 1 At the Air Box Cover turn the plastic wing screw counter clockwise to loosen 2 Remove the Air Box Cover by pulling up and left to clear the three locating tabs 3 Turn the
95. re applying electrical loads let the generator stabilize and warm up for a minute or two DO NOT overload the generator 2 7 1 LETTING THE ENGINE STABILIZE The generator supplies correct rated voltage only at the proper governed speed Some electrical appliances may be extremely sensitive to voltage Incorrect voltages can damage such appli ances If electrical loads are applied 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 7 2 DO NOT OVERLOAD THE GENERATOR Read the rated wattage amperage capacity of the generator on the generator data label see Generator Identification Applying electrical loads in excess of the unit s rated capacity will cause the engine generator to automatically shut down To avoid overloading add up the wattage of all connected electrical lighting appliance tool and motor loads This total should not be greater than the generator s rated wattage capacity Most lighting appliance tool and motor loads indicate their required watts on their nameplate or data plate For light bulbs simply note the wattage rating of the bulb f a load does not show its rated wattage multiply that load s rated VOLTS times AMPS to obtain WATTS Induction type motors such as those that run the vehicle s furnace fan refrigerator ai
96. re available from the sources indicated 1 NFPA Standard 501C Standard for Recreational Vehicles available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 NFPA 70 NFPA Handbook of the National Electric Code available same as Item 1 3 ANSI C1 1975 and ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI A119 2 NFPA 50106 available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 available from the State of California Documents Section PO Box 1015 North Highlands CA 95660 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 22 1 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to air cooled generators These generators are designed specifically for install ing in recreational vehicles They operate 120 volt single phase 60 Hertz AC electrical loads 1 5 GENERATOR ENGINE OPERATING SPEED The generator s revolving field rotor is driven by a two cylinder four cycle engine through a pulley and drive belt arrangement The generator supplies 120 volts AC at 60 Hertz when the rotor is oper ating at 3 600 rpm The drive belt arrangement allows the engine to operate at a
97. s Lists CARB 42 Base amp Pulley Drawing No 0E1323 H Exploded Views amp Parts Lists ITEM PART NO QTY DESCRIPTION ITEM PART NO DESCRIPTION 1 0E0196 1 FRAME 760 ENGINE 31 0E0586 1 GASKET BOTTOM AIR OUT QPRV 2 022129 12 WASHER LOCK M8 5 16 32 007176 4 WASHER SELF LOCKING 1 DIA 12GA 3 022145 15 WASHER FLAT 5 16 M8 ZINC 33 0 1334 1 SCREEN BOTTOM AIR OUT 4 022259 6 NUT HEX 5 16 18 STEEL 34 008824 1 TRAY V TWIN RV 5 0C7758 4 VIB MNT 1 5 X 1 38 X 5 16 18 35 081105 2 NUT FLG 5 16 18 LOCK 6 003168 1 WASHER LOCK SPECIAL 5 16 36 073118 1 SCREW 3 8 24 X 2 1 4 G8 7 002417 1 EARTH STRAP 37 046526 1 WASHER LOCK M10 8 077603 2 SCREW HHC 5 16 18 X 3 5 SPC 38 022131 1 WASHER FLAT 3 8 M10 ZINC 9 0 0588 1 SPACER SAFETY BOLT 375 I D 39 002824 T SCREW TAP R 10 32 X 9 1 10 029451 5 FT TAPE ELEC UL FOAM 1 8 X gt 40 01077 1 BLOWER HOUSING GTV760 RV 11 0D8912 1 DUCT AIR OUT 41 042633 1 SCREW HHC 3 8 24 X 1 G5 12 0E0571 2 GASKET AIR OUT DUCT 42 022237 1 WASHER LOCK 3 8 13 0D8911 1 BRACKET MUFFLER SUPPORT 43 049451 1 WASHER FLAT 406ID X 1 620D 14 043107 T SCREW HHC M8 1 25 X 25 G8 8 44 001441 1 SET BLOWER HOUSING GASKET 15 009021 1 MUFFLER GTV760 RV 45 001112 1 BELT V RIB 4LX42 5 16 096289 1 CLAMP EXHAUST 1 25 46 023484T 1 BUSHING SNAP GASOLINE ONLY 17 008940 1 MANIFOLD EXHAUST 0E1534 1 PLUG PLASTIC 0 687 LP ONLY 18 070006 4 WASHER LOCK M8 55 47 007530 1 STUD
98. s for engine emission Model die 50 Load 100 Load 692 1 6 2 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum Institued API Classification SF SG SH or SJ The recommended oil viscosity weights include the following During summer months 40 deg F and higher SAE 30 or SAE 10W 30 During winter months 40 deg F to 20 deg F SAE 5W 30 or SAE5W20 DO NOT USE SAE 10W 40 Crankcase and oil filter capacity is approximately 1 8 L or 1 9 U S quarts DO NOT use special additives See sections Checking the Engine Oil Level and Changing the Engine Oil and or Oil Filter for oil level check and filling procedures 1 6 3 ENGINE SPECIFICATIONS Of Engine etre meter erst rt aga GT 760 Cooling Method seecsesssessseessesssecsssessscssecssecsssessecsseesseesssesneesseeess Air cooled Rated Horsepower 27 at 3600 rpm DiSplaceimieht nte t nieto mius 760 Compression Ratio cssssessseesseesssecstecssessessscsecsessuessueesneesneeseeeseeess 8 6101 Cylinder Aluminum w Cast Iron Sleeve Type of Governor 0 4 29 449 Mechanical Fixed Speed Engine Governor Speed QUIETPAGT B5 tte etti 2200 rpm QUIETPACT 65 75 u nennen 2571 rpm Air
99. sing the generator on any forest covered brush covered or grass covered unimproved land it must equipped with a spark arrestor The spark arrestor must be maintained in good condi tion by the owner operator Clean and inspect the spark arrestor as follows Figure 3 6 Remove the screen retaining bracket by removing the screw Slide the spark arrestor screen out from the tail pipe nspect screen and replace if torn perforated or otherwise damaged DO NOT USE a defective screen If screen is not damaged clean it with commercial solvent Replace the screen and the retaining bracket Figure 3 6 Spark Arrestor TAILPIPE P N 0E0907 RETAINER P N 0D5133A SPARK ARRRESTOR SCREEN P N 0D5133 RETAINING SCREW P N 045764 14 3 7 CLEANING THE GENERATOR 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 moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends
100. ssure tanks as a liquid The gas systems used with these generators were designed only for vapor with drawal type systems Vapor withdrawal systems use the gas vapors that form above the liquid fuel in the tank Do NOT attempt to use the generator with any liquid withdrawal type system 2 5 4 PRIMARY REGULATOR Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regulator Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank The following rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column Do NOT exceed 14 inches water column The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommended MINIMUM gas flow rate for air cooled genera tors is 67 cubic feet per hour If an existing primary gas regulator does not have a sufficient flow capacity for the generator and other gas appliances in the circuit a install a primary regulator with adequate flow rate or b install a separate regulator only and rated at least 67 cubic feet per hour The inlet side of any primary regulator that supplies the generator must connect directly to a gas pressure tank Do NOT tee the generator line into a gas circuit feeding other areas Installation 2 5 5 GASEOUS CARBURETION LP gas va
101. t size is correct O Compartment is vapor sealed Q Sound insulation is correct Floor cutouts are properly completed COOLING AND VENTILATING AIR Airflow is adequate Q Air inlet opening is correct CQ Compensate for restrictions Q Check that installation has been tested GASOLINE FUEL SYSTEM C Fuel tank complies with all applicable codes Fuel system is properly installed and checked for leaks OPTIONAL LP GAS FUEL SYSTEM Fuel system is properly installed and checked for leaks Pressure at regulator inlet is correct O Rated flow of primary regulator is correct a All parts are properly installed Fuel system is properly tested adjusted DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER 38 EXHAUST SYSTEM Exhaust system complies with all applicable codes Q Exhaust system is properly and safely installed ELECTRICAL CONNECTIONS O Connections comply with local code requirements and all National Electrical Codes Q Junction box is properly installed Q Wiring meets all standards All connections are correct O Conduit is properly installed and sealed O Generator is properly bonded to the vehicle BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Cables are clean and tight Cables are connected properly Proper ventilation is provided Terminals are coated with anti corrosion grease and terminal covers ar
102. t system parts Use nonferrous metal straps without sharp edges to secure fuel lines Flexible Fuel Line Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines This prevents breaking of the line caused by vibration shifting settling or movement The following rules apply The flexible hose must comply with SAE J30R7 Standard for Fuel and Oil Hose It must be approved for use with gasoline and low permeability 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 29 Installation 2 5 LP GAS FUEL SYSTEM fa LP gas is highly EXPLOSIVE The gas is heavier pa than air and tends to settle in low areas Even the slightest spark can ignite it and cause and explosion Only competent qualified people should be allowed to install test adjust or service an LP gas fuel system Install the optional fuel system in compliance with appli cable codes standards and regulations After the installation do not do anything that might render the system in noncompliance with appli cable codes and standards 2 5 1 PARTS NOT INCLUDED IN FUEL SYSTEM The propane fuel system does NOT include such items as a gas tank b gas piping c fittings d valves and e primary regula tor used to store the gaseous fuel and deliver it to the gaseous fuel solenoid Figure 2 11 A DANGER Use only
103. tarting problems For the best cold weather starting the voltage drop between battery ter minals and the generator connection point should not exceed 0 12 volts per 100 amperes of cranking current These generators are rated at about 100 DC amperes of cranking current Select battery cables based on a cable length and b prevail ing 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 110 0103 111015 84045 0 180704500 Q9 For warm weather use No 2 cable up to 20 feet 2 8 3 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or to the lug on the starter contactor Figure 2 17 NOTE Check to be sure the battery cable boot for the starter cable has been installed 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connection Figure 2 17 3 Connect cables so the connectors are clean and tight Figure 2 17 Connecting Battery Cables o o o C Positive Cable L s LA Battery o P P Chassis Ground Installation Figure 2 15 Transfer Switch Isolation Method 2ND AIR FROM 20 AMP CONDITIONER HACR BREAKER JUNCTION BOX VEHICLE WIRING FLEXIBLE CONDUIT
104. tch Figure 2 15 An alternate method for isolating different power sources is by using an isolat ing receptacle Figure 2 16 Whichever method is used be certain that both power sources are NOT connected at the same time 2 7 6 POWER SUPPLY CORD The power supply cord must comply with all applicable codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected 2 7 7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code NFPA 70 article 551 requires that ground fault circuit interrupters GFCIs on all external and some internal electrical receptacles be installed Contact the manufac turer or dealer for recommendations 2 8 BATTERY INSTALLATION 2 8 1 RECOMMENDED BATTERY Install a battery that meets the following requirements The battery must be a 12 volt automotive type storage bat tery For prevailing ambient temperatures above 32 F 0 C use a battery rated 70 amp hours and capable of delivering 400 cold cranking amperes For prevailing ambient temperatures below 32 F 0 C use a battery rated 95 amp hours and capable of delivering 400 cold cranking amperes NOTE If the battery is to be used to power other vehicle accessories as well as start the generator a battery with a larger capacity may be needed 34 2 8 2 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes s
105. the Air Box Cover turn the plastic wing screw counter clockwise to loosen 2 Remove the Air Box Cover by pulling up and left to clear the three locating tabs 3 Turn the exterior steel wing nut on the left side of the Air Box Compartment counterclockwise and remove 4 Pullthe Air Filter Assembly to the right and out of the front of the compartment 5 Twist the steel wing nut counterclockwise while holding the offset stud Set aside and save all this hardware for use with the new air filter and pre cleaner 6 Discard old air filter and pre cleaner safely 7 Insert the flanged end of the Offset Stud into the new air filter and through the hole in the end plate 8 Install the gasket flat washer lock washer and wing nut in that order Tighten the wing nut clockwise while aligning the Offset Stud as in Figure 3 3 9 Saturate the foam pre cleaner in clean engine oil Gently squeeze it in a clean cloth to remove excess oil and to distrib ute the oil evenly DO NOT TWIST 10 Slide the foam pre cleaner onto the air filter 11 With your right hand on the air filter end angle the assembly into the compartment and insert the Offset Stud into the hole on the left side of the Air Box Compartment Before the air filter gasket contacts the sheet metal wall ensure the rubber snout of the carburetor intake adapter is captured within the footprint of the Air Filter 12 Replace the steel wing nut onto the Offset Stud and tighten clockw
106. the engine is inspected by a Generac Authorized Warranty Service Facility the purchaser owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such parts 8 Any Generac authorized and approved emission related replacement parts may be used in the performance of any ECS warranty maintenance or repairs and will be provided without charge to the purchaser owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of Generac equipment caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING IF EQUIPPED 1 FUEL METERING SYSTEM 4 AIR INJECTION SYSTEM A CARBURETOR AND INTERNAL PARTS A PULSE AIR VALVE B PRESSURE REGULATOR 5 EXHAUST SYSTEM 2 AIR INDUCTION SYSTEM A CATALYST A INTAKE MANIFOLD B THERMAL REACTOR B AIR FILTER C EXHAUST MANIFOLD 3 IGNITION SYSTEM A SPARK PLUGS B IGNITION COILS MODULE Part 2 Part No 0H1912 Rev A 05 09
107. the product s installation requirements Give seri ous consideration to all information and instructions in the manual both for safety and for continued reliable operation of the equip ment Because of the different recreational vehicle models and the variations between the models it would be extremely difficult if not impractical to provide detailed instructions for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all applicable codes standards and regulations 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 precedence over the manual 1 22 SAFETY Before handling installing operating or servicing this equipment carefully read the Notice to Installer and Safety Rules 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 3 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The following standards booklets latest revi sion a
108. the sale to the original purchaser owner 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 297 WHITEWATER WI 53190 Part 1 Part No 0H1912 Rev A 05 09 52 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS warranty for equipment using small spark ignited engines a Applicability This warranty shall apply to equipment that uses small off road engines The ECS Warranty period shall begin on the date the new equip ment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each sub sequent purchaser owner that the ECS when installed was 1 Designed built and equipped so as to conform with all applicable regulations and 2 Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS Warranty Period c The warranty on emissions related parts will be interpreted as follows 1 Any warranted part that is not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it sha
109. ting the generator s main circuit breaker to the OFF or open position If starting from a remote panel turn OFF loads using the means provided in the vehicle such as a main circuit breaker Electrical load circuits will be turned ON after the generator has started stabilized and warmed up 2 If the engine has not been started in more than two weeks press the Fuel Pump Primer switch and hold it for about 10 seconds However if the engine is warm skip Step 2 3 To crank and start the engine hold the start stop switch at START Release the switch when the engine starts 10 A CAUTION If the engine does not start after it has been cranking for 15 seconds release the Start Stop switch and wait 1 minute before trying again Holding the switch for longer than 15 seconds can damage 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 provided such as a main circuit breaker or transfer switch 2 6 STOPPING THE GENERATOR Turn OFF all electrical loads using the means provided such as a main circuit breaker or transfer switch 2 Let generator run at no load for a few minutes to stabilize internal engine generator temperatures 3 Place the Start Stop switch in its STOP position The engine will come to a complete stop 2 7 APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Befo
110. to neutral connection separately to operate similar loads However be sure the total unit load does not exceed the maximum rating of the generator The neutral line T2 white on all units is a grounded neutral Figure 2 14 Generator AC Output Leads Green Ground A CAUTION Do NOT connect electrical loads in 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 generator s rated wattage capacity Add the watts or amperes of all lighting appli ance tool and motor loads the generator will operate at one time This total should be less than the unit s rated wattage amperage capac ity 33 Installation 2 7 4 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The following general rules apply Cut wiring to the required length and allow extra wire for junction box connections Carefully prepare conduit ends to prevent sharp edges from cut ting through wiring insulation Route conduit so it does not interfere with generator move ment If using metallic conduit vapor seal the end of the conduit where it enters the junction box Do this because flexible metallic con duit is not vaporproof along its entire length 2 7 5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer swi
111. ucted compartments typically utilize a standard lap joint After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material See Sound Insulating Materials 26 Figure 2 6 Types of Lock Seams n ACME LOCK FOLD LOCKED STANDING OFF SET DOUBLE LOCK DOUBLE SEAM EL GORDON SEAM LOCK SEAM STANDARD LAP JOINT A DANGER Do not install any flammable material directly above or around the Heat transferred through the compartment structure may be sufficient to ignite char or discolor seat cushions fiberboard and other flammable materials Use approved nonflammable insulat ing materials in high temperature areas 2 2 3 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 sealant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a nonflammable type One excellent insulating material is a 1 inch 25 mm thick fiberglass having a 2 pound density When fiberglass is used its coated side should face toward t
112. wer If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a rope or board to free the victim from the live conduc tor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installation do noth ing that might alter a safe 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 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 pertaining to fire extin guishers
113. y 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 3 INSTALLATION This Owner s Manual has been prepared under the assumption that a competent qualified technician installed the generator into a recreational vehicle We also assume the installer complied with all applicable codes standards and regulations pertaining to installation An INSTALLATION MANUAL was shipped with the generator That Manual contains manufacturer s instructions and recommenda tions for installing the unit into an industrial vehicle After installa tion installers should forward the Installation Manual to Owners Operators for their information Owners Operators have the responsibility to make sure that noth ing is done that might render the installation unsafe or in non compliance with applicable codes standards and instructions 1 4 SAFETY Before using the generator set carefully read GENERAL SAFETY RULES inside the cover Comply with these RULES to prevent accidents and damage to equipment and or property The manu facturer suggests copying and posting the GENERAL SAFETY RULES to potential operators of this equipment 1 5 GENERATOR AC CONNECTION SYSTEM These air cooled generator sets are equipped with dual stator AC power windings These two stator windings supply electrical power to customer electrical loads by means of a dua

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