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Guardian Technologies 004708-0 Portable Generator User Manual

1. SUPPLIED BY CUSTOMER O 07 SUPPLIED BY CUSTOMER D BATTERY 177 SM 16 177 PO 118 4 0K 6 2A ELECTRONIC 4 VOLTAGE 13 REGULATOR o 22S 16 56 O 2A 0 J3 E 15 15 2 L3 14 Jii O 56 0 J12 O 90 JH O 2A a Ji4 O1 18A 4 J5 O As J 6 OL 17 17 PCB J7 O 17 17 J18 O 77 66 33 qup CLOSEST TO BEARING J9 OF 4 4 J10 O 66 44 Ju O 20 55 412 O 0 Jugo 16 A M Jtt4 O 18 15 4 RED d J115 O 2 LJ C FIELD 85 0 oF d 13 J 83 5 gt 7 WP 2 D BCR 33 oop 55 r3 2A 66 Ri 2 OF 44 17 N 66 15 0K 0 o ON 18A 18 0 0 OF I CONN 1 8 18 NN 0 RE Oj ol O O 0 14 GT 1 0 70 2 90 o 14 14 O OMA 33 gt 14 14 4 14 E 18 O O 5 o 17 5 32 14A m REMOTE y 0 con sm PANEL 13 SW2 18 CONNECTOR 15 0B 11P FS FP n Yr 33 er 15 a np po MA 177 13 18 90 14A WHITE LLL 15 BLACK 18 14 18 CB1 18A 14A 14A 85 15 15 85 Jl FILTER MTG LOP T 0 HTO SCREW T2 177 T1 GREEN 17 CUSTOMER AC CONNECTION 0 BLACK WHITE
2. dul WUS d MAILA 21 2 1 2 1 1 NSTALLATION Ps ITED Section 2 Installation Recreational Vehicle Generator LOCATION AND SUPPORT GENERATOR LOCATION 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 rein force Many recreational vehicles have been factory equipped with an area for the generator set Some vehicles may even have a generator compartment provided by the vehicle manufacturer Plan the generator location based on the following The generator set must be installed on a frame work that is part of the recreational vehicle as outlined in the Generator Support section The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from under neath the supporting framework The location must provide easy access to fre quently serviced components such as filters oil drains spark plugs and other common mainte nance parts The location must provide sufficient room to allow minimum clearances as outlined in Generator Compartments If sound insulation is to be used on the compartment walls and ceiling the mini mum recommended applies to the space between the generator
3. 40 Section 6 Exploded Views and Parts Lists CG ts Recreational Vehicle Generator Generator Drawing No 0D8353 M 0 oO A ECON A E CO GD GD CO G2 GD G2 G2 GD G2 PO hD P D p RS DS 29 9 29 N 00 4 O50 O1 CO QC CO CO I O O1 ON CAAN O O1 G5 PS C co 029092 022129 049451 0C8096A 0D8120 066849 066386 0D4217 073159 0D4484H 0D4430H 0D4216 048614 0F9533 022131 027028 0D6832 022145 030231 0C3168 022259 0C8565 0D8048 083512 0D6831 029451 0D6918 0D2558 087680 0D7530 0D9723 0D8451 022097 0G3671 090388 0D7441 081105 089476 022531 0D8981 ine Po an Pa Re AS E AA oo k o mm i pp S S sD BP CO ppp SCREW IHHC 5 16 24 X 11 1 4 G5 WASHER LOCK M8 5 16 WASHER FLAT 406 I D X 1 62 O D FAN 8 CURVE BLADE 16 5MM I D SCREW IHHC M8 1 25 X 260MM SCREW HHTT M5 0 8 X 16 ASSEMBLY BRUSH HOLDER CARRIER REAR BEARING BEARING ROTOR STATOR ADAPTOR ENGINE SCREW HHC 5 16 24 X 3 4 GASKET FRONT DIVIDER WASHER FLAT 3 8 M10 NUT LOCK HEX 5 16 18 NYLON INSERT BRACKET ENGINE MOUNTING WASHER FLAT 5 16 SCREW HHC 5 16 18 X 1 1 2 5 16 SPECIAL LOCK WASHER NUT HEX 5 16 18 SCREW SHC M8 1 25 X 18MM VIBRATION MOUNT SCREW HHTT M8 1 2 X 16MM BRACKET ALTERNATOR MOUNTING TAPE ELEC UL FOAM 1 8 X 1 2 DUCT ALTERNATOR AIR GASKET ALTE
4. eterne 22 2 2 Generator Compartments eee 23 2 3 Cooling and Ventilating Air ssssse 25 2 4 Gasoline Fuel Systeni oe eet ertet 27 2 5 Exhaust System etre conne nodes ee seca codecs 28 2 0 Electrical Connections etit tene 29 2 7 Battery Installation 2 8 Optional ACCESSOTIES cernere ERR raid 32 Section 3 Post installation Start up Adjustments 55 3 1 Post Installation Tests a io 33 3 2 Before Initial Start p eee rennen 33 3 9 Initial Starts u ooo exa eive rouen ud 33 3 4 Testing Under Load ooocccccccnncnnnnnnonononenenennnnaninnnnos 33 3 5 Installation Checklist 34 Section 4 Troubleshooting 35 Section 5 Electrical Data 36 Section 6 Exploded Views and Parts Lists 38 Section 7 Warranty 48 SAFETY RULES Safety Rules Recreational Vehicle Generator SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe A operation be copied and posted in potential hazard areas of the recreational vehicle Safety should be stressed to all operators and potential operators of this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer
5. 2 6 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 installation 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 9 2 6 2 WIRING Wiring should be of stranded copper to reduce the chance that vibration may cause breakage Wire gauge size should be large enough to handle at least 115 percent of the installed generator s rated maximum current Neutral conductors must be the same size as other leg wires Route power supply conductors from generator AC output leads white Black and the green ground wire through approved flexible conduit to the elec trical junction box on the compartment wall If flexible metal conduit is used between the gen erator and the compartment junction box the con duit 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 transfer switch or b approved iso lation receptacle Connecting to a transfer switch or isolation receptacle must prevent vehicle electri cal circuits from being connected to two different power supplies at the same time such
6. EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1997 and later model year engines a Applicability This warranty shall apply to 1997 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment 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 subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a warranted emissions related part to fail to be identical in all material respects to the part as described in the engine manufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or rep
7. PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser 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 engine However Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 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 Califo
8. by Generac Ji Systems Inc 2 VY Owner s Manual and Installation Instructions Air cooled Recreational Vehicle Generators Models 004700 0 004708 0 QUIETPACT 40G This manual should remain with the unit INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc This model is designed and man ufactured to supply electrical power for recreational vehicles 4 READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest 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 person nel to special instructions about a particular opera tion that may be hazardous if performed incorrectly or carelessly Observe them carefully Their defini tions are as follows A DER A After this heading read instructions that if not strictly complied with will result in serious per sonal injury up to and including death or property damage WARNING amp After this heading ead instructions that if not strictly complied with may result in personal injury or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements tha
9. Do not terminate the exhaust system under any opening window or vent that can be opened or is not permanently sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all applicable codes standards and regula tions 2 6 ELECTRICAL CONNECTIONS The following general rules apply to electrical connec tions in a recreational vehicle Qualified electricians who are familiar with appli cable codes standards and regulations should install electrical wiring The wiring should comply with codes standards and regulations The National Electrical Code NFPA 70 and state and local codes apply Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent damage from road shock INSTALLATION Ps lii Section 2 Installation Recreational Vehicle Generator Wiring must be of adequate size have approved insulative qualities and be properly supported Conduit and wire openings into the generator com partment if used must be vapor sealed to prevent entry of flammable explosive or poisonous gases into the vehicle
10. N C 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 COOL ING 33 POST CE Section 3 Post Installation Start up Adjustments INSTALLATION START UP Recreational Vehicle Generator ADJUSTMENTS 3 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT Q Generator is properly located Q Generator is properly supported Q Generator is properly restrained 4 GENERATOR COMPARTMENT Q Compartment construction is proper Q Holes Openings are vapor sealed WU Compartment size is correct OQ Compartment is vapor sealed A Sound insulation is correct A Floor cutouts are properly completed COOLING AND VENTILATING AIR O Airflow is adequate A Air inlet opening is correct Q Compensate for restrictions Q Check that installation has been tested 4 GASOLINE FUEL SYSTEM A Fuel tank complies with all applicable codes Q Fuel system is properly installed and checked for leaks OPTIONAL LP GAS FUEL SYSTEM Q Fuel system is properly installed and checked for leaks Q Pressure at regulator inlet is correct Q Rated flow of primary regulator is correct A All parts are properly installed A Fuel system is properly tested adjusted DATE OF INSTALLATION EXHAUST SYSTEM O Exhaust system complies with all applicable codes O Exhaust system is p
11. BOLT CARR 3 8 16 X 1 3 8 SPECIAL L WASHER NUT HEX M6 X 1 0 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 022237 022131 0C5443 0C7423 029451 074908 0D8717 0D9020 0742600144 0E0724 064933 0742600143 0D8595 0D8627 0D8628 0D8628A 0D8691 0D7176 042115 0D9282 023484E 0F9176 0E0014 0E0017 0C7968 0E0393 0D8981 029451A 0D8628B 0G7366 0A9973 p n2 k k a Qs pan oo al PARTS S LISTS Oo WASHER LOCK 3 8 WASHER FLAT 3 8 M10 BLOCK TERMINAL BATTERY POST STUD 3 8 16 X 2 1 4 BRASS TAPE FOAM 1 8 X Y2 SCREW HHTT M5 0 8 X 10 CUSTOMER CONNECTION HARNESS FOAM AIR OUT COMPARTMENT SIDE CABLE STARTER ASSEMBLY OIL DRAIN SCREW SWT 1 4 20 X 5 8 W W CABLE BATTERY CONNECTION MOUNT FUEL FILTER SUPPORT FOAM AIR INTAKE COMPARTMENT FOAM ROOF AIR OUT COMPARTMENT FOAM BACK COMPARTMENT FOAM DOOR PANEL WASHER SELF LOCKING 1 WASHER NYLON 250 HARDWARE CLOTH COMPARTMENT AIR OUT BUSHING 0 50 SNAP HOSE 1 4 ID BOX MUFFLER TAIL PIPE GASKET MUFFLER TAIL PIPE BOX NUT HEX JAM 3 8 16 BRASS ASSEMBLY CAP amp DIPSTICK FILTER GASKET FOAM TAPE 1 16 X 1 FOAM FRONT AIR OUT COMPARTMENT LOGO QP RIVET POP 39 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Generator Drawing No 0D8353 M o LISTS PARTS 0 q
12. Inside Front Cover Read This Manual Thoroughly IFC CONTENTS asma emana HET IFC Operation and Maintenance IFC How to Obtain Service eec reote pag eee nee IFC Authorized Service Dealer Locator Number IFC Safety Rules Section 1 General Information 1 1 Generator Identification coooocccnnnccnnnncononccnnninnnns 4 1 2 Generator Applicability coooncccnnnccnnnccnnonccnnnncnnns 5 ST 5 1 4 Generator AC Connection System 5 1 5 Specifications sie sccesccceeessseesenenduesacrsecaecadsoaesenners 5 Section 2 Operation 7 2 1 Generator Control Panel u eee 7 2 2 Optional Remote Start Stop Panel fi 2 9 Automatic Choke u e ne 7 2 4 Before Starting the Engine cee 7 2 5 Starting the Generator resres aranean 8 2 6 Stopping the Generator coocccccccooccncnnconaccnnncnonarenen 9 2 7 Applying Loads to Generator 9 2 8 Do Not Overload the Generator 9 2 9 Protection Systems nete tr eta tan tnus 9 2 10 Additional Information eese 10 Section 3 Maintenance 11 3 1 Checking the Engine Oil Level 11 3 2 Changing the Engine Oi
13. STATOR POWER WINDINGS T2 WHITE GROUNDED NEUTRAL The AC connection system on air cooled genera tors uses a GROUNDED neutral A separate green ground wire is connected to the recreational vehicle s junction box NOTE Do NOT connect loads in excess of circuit breaker ratings lt tc uu LLI e INFORMATION Section 1 General Information Recreational Vehicle Generator Figure 1 2 Major Features and Dimensions Drawing No 0D8716 H SNDILO3NNUJS AS3ILV amp E 3O9NVN3INIVW dadindas TIV 3403 SSIIIV JOD INDIA ra 331413 1304 a B O O 1dN v 1 CANO 0 80240 MY RIND 1304 WANIYA TYNSILXI Lest l 1 2 2b gt M LO3NNDO _ Y ENYA 310N38 SSINAVH ANdIND 2v o h Y L6I J t 2 1 62 1 _ TES 86v 38 sas L62 1 v 9El L8 I 2 1 889 96 yl 1 69 T L 91 EI 11 1 O L8 11 J NIVaG IH L 00 62 Leal ese ty ENEZ I l rev gt gt if i L9T Z 11 SOE 7 i 2 LISI 9 1 9941 i L9I S 1 c eg LOTET xa Jdid UVL G8 9I 917 1SnvHX3 Lv T8 MIV 10H 012 ONIN009 SOS C3NInO33 SI I irt 1 v38Y N3d 1Y SNDILINSISAO ANY 30 332 Laaa o f lo 3 38 LShW SI31100 ASNVHXI NV SIVINI NIV 1Y ION pd 1 Le l 1 S30v7d 9 Rr e a rg vEVE SINNATIA 8I 91 6 91 11 91 J dAl L b 1 82 1 LLL
14. 3 12 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 pre pare 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 Note Using a fuel additive such as STA BIL fuel stabi lizer or an equivalent will prevent gum deposits from forming in the engine s fuel system 3 While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 10W 30 oil having API classification For Service SE 4 Attach a tag to the engine indicating the viscosity and classification 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 concrete or earthen floor 7 Clean and wipe the entire generator 4 3 12 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 recom mended 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 batteries to t
15. 4 Replace control board There is no AC output from 1 Main line circuit breaker open 1 Reset circuit breaker the generator to ON or closed 2 Fault with vehicle circuit 2 Reset and replace if necessary breaker and or fuses 3 Transfer switch set to NORMAL 3 Set switch to GENERATOR 4 Start switch not held long 4 Stop then restart the engine enough to flash the field Hold Start switch for at least 2 seconds 5 Generator internal failure 5 Contact aN Authorized Service Dealer 35 Section 5 Electrical Data Recreational Vehicle Generator ELECTRICAL e DATA gt Electrical Schematic and Wiring Diagram Drawing No 0D8063 D BATTERY RED III BLK SC 13 RED 16 G su e s 15 0 elt 14A re e 14 e Fi swe CN 16 14 FS 0 NEL PCB sc 0 15 33 Ji gt 56 LN Je J12 90 cs 0 J3 15 14 H4 gt 18A M SP J15 O J6 gt 17 O START SW1 o 0B JA gt 17 TOP ss gt o Lf so 3 4 HTO 85 7 04 Jo gt 66 L LOP Jt gt 85 85 0 9 J12 X 0 113 2 66 REMOTE J14 gt 18 j PANEL wis gt 18 A CONNECTOR o
16. Gasoline is highly flammable and its vapors are explosive Comply with all codes standards and regulations pertaining to gasoline fuel systems 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 Factory installed generator fuel system components include a fuel filter b 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 INSTALLATION Ps Mi Section 2 Installation Recreational Vehicle Generator 2 4 1 FUEL TANK Either the generator must share the vehicle engine s fuel tank or install a separate fuel tank for the generator set All fuel tanks installed on the vehicle must be constructed installed and restrained so they comply with applicable codes standards and regula tions 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 be 2 to 3 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 caution amp AN Do NOT tee the generator
17. ON electrical loads using the means pro vided such as a main circuit breaker or transfer switch 2 6 STOPPING THE GENERATOR 1 Turn OFF all electrical loads using the means provided such as a main circuit breaker or transfer switch 2 Let generator run at no load for a few minutes to stabilize internal engine generator temperatures 3 Place the Start Stop switch in its STOP position 2 7 APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Before applying electrical loads let the generator stabilize and warm up for a minute or two DO NOT overload the generator 2 71 LETTING THE ENGINE STABILIZE The generator supplies correct rated voltage only at the proper governed speed Some electrical appli ances may be extremely sensitive to voltage Incorrect voltages can damage such appliances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when suf ficient power is not available may shorten engine life Never turn ON electrical loads until after the generator engine has started and stabilized at no load 2 8 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 automati cally shut down To avoid overloading add up
18. This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases 2 3 1 GENERATOR AIRFLOW Engine operation drives cooling fans for the two stage cooling air system A pressure fan draws cooling air into the bottom right side 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 collector compartment at the left side 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 25 INSTALLATION Section 2 Installation Recreational Vehicle Generator Figure 2 8 Compartment Floor Cutout Drawing 0G3723 A 3LY IdW3L NLUIIV I IVISNI 3ZIS Vina v 303 WO 2048us86gs2314 9 dua4 AN vadv N3dU 11y Saws AY NVITAVND LIVINDO DNINODO 3404 TIIINDII SI SNOILONALSEO ANY 30 359313 1d3A 38 LSAW SLIFILAO 1SAVHX3 ANY S AVINI ATV TIV 3LDN L l 62 te Ter LST 21 9 8py Tr SIIVId v 3NI1LnD 8 S y 1 L8 L 8 1 L l v 1 8 NARA em mm 1922 6 0 G 66 Le gos I 1 7 I Lv T 02 L9I E vl Y SIS G 09 N 4 L9I ETI vI SOLE LIVI 9 J YZ 041 N L 91 S1 91 J NI G 62r TYT o _ Y Lv
19. WHITEWATER WI 53190 Revision 02 05 Part No 0D8351A Revision A 08 15 08 Printed in U S A
20. birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this manual and with the unit The gen erator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique uti lized does not render the generator unsafe A DIE A A 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 N 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 a
21. energy In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury SAFETY RULES Safety Rules Recreational Vehicle Generator FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations 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 installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on t
22. the filter until saturated with clean oil 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 Remove the dipstick and wipe it dry with a clean lint free cloth This will be used later to check the oil level Remove the oil fill cap on the oil fill tube and slowly add the proper type and amount of rec ommended oil see Engine Oil Requirements Periodically use the dipstick to check the oil level and continue to fill the crankcase until the oil reaches the dipstick Full mark DO NOT FILL ABOVE THE FULL MARK Install and tighten the oil fill cap and the dipstick before operating the engine 10 Start the engine and check for leaks Figure 3 1 Oil Maintenance Features Oil Dipstick Oil Fill Oil Drain Oil Filter 11 MAINTENANCE 20 Section 3 Maintenance Recreational Vehicle Generator NOTE Check the oil level and fill to the FULL mark after checking for leaks The filter will retain some oil 3 3 MAINTAINING THE ENGINE AIR CLEANER 3 3 1 CLEANING THE FOAM PRECLEANER Clean and re oil the foam precleaner every three months or every 25 hours of operation whichever occurs first S
23. while other vehicles may use an isolating receptacle Some vehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads To start the generator from either the generator con trol panel or from the optional remote panel proceed as follows 1 Turn OFF electrical loads using the means pro vided in the vehicle such as a main line circuit breaker or transfer switch NOTE If starting from the generator control panel turn OFF loads by setting the generator s main 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 stabi lized 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 to 15 seconds to prime the fuel system However if the engine is warm skip Step 2 3 Hold the engine Start Stop switch in the START position to crank the engine Release the switch when the engine starts caution AN If the engine does not start after it has been cranking for 15 seconds release the Start Stop switch wait one minute and try again Holding the switch for longer than 15 seconds can dam age the starter motor 4 Letthe engine run at no load for a few minutes to stabilize and warm up 5 Turn
24. wrench and tighten the rocker arm jam nut with a crows foot Tighten the jam nut to 65 85 inch pounds torque After tightening the jam nut recheck valve clearance to make sure it did not change Figure 3 8 Figure 3 8 Tightening Jam Nut CROW S FOOT 3 14 RV GENERATOR SERVICE INTERVAL DO HOUS ss veses csamerena es caavevensy Clean Spark Arrestor 100 TOU Granon Change Engine Oil filter 100 Hors rite Clean Air Pre filter 100 Hours etes Inspect Spark Plugs 250 Hours Replace Paper Air Filter Element 400 HOUrS rtr eene Replace Fuel Filter HOO HOUT Sica dsd Replace Spark Plugs 1st 50 Hours then every 500 HIS csssussesssenssuca sensor Adjust Valve Lash 15 NOTES 16 Section 4 Notes Recreational Vehicle Generator PART II INSTALLATION INSTRUCTIONS SAFETY RULES Safety Rules Recreational Vehicle Generator 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 manufacturer to aid in the installation of the products described in this manual The manufac turer assumes that inst
25. 3 SPARK ARRRESTOR SCREEN P N 089680 RETAINING SCREW P N 056892 Figure 2 12 Spark Arrestor Installation T 27 411 pm LD 4011 58 5 5 7 32 DRILL BOTTOM SIDE ONLY 9 2 5 2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any combus tible material such as wood felt cotton organic fibers or other like material If the 3 inch 76 mm clearance cannont be maintained locate insulate or shield the exhaust part s so that the tempera ture of any combustible material is not raised more than 117 F 65 C above the ambient air temperature Extend the 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 recirculated If there is any possibility of the tailpipe or muffler being damaged protect these damage prone areas by means of a protective device such as a skid bar Install the generator exhaust system according to safe automotive practices Use enough exhaust system hangers to prevent any part of the system from being dislocated Use exhaust system parts recommended by the manufacturer Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person s installing such unauthorized parts
26. 3 5 WASHER FLAT 1 4 24 022097 4 WASHER LOCK M6 1 4 25 049813 4 NUT HEX M6 1 0 26 055440 2 SCREW HHC M5 0 8 X 25mm 27 049815 1 SCREW HHC M5 0 8 X 16mm 28 038750 2 SCREW HHC M6 1 0 X 30mm 29 051714 2 NUT HEX M3 0 5 30 0D8794 1 PANEL CONTROL 31 025105 2 SCREW RHM 6 32 X 1 4 SIMS 32 028739 2 TIE WRAP UL 4 NOT SHOWN 33 0D8308 1 DECAL NOT SHOWN 34 0D8418 1 HARNESS NOT SHOWN 35 023484S 1 BUSHING SNAP 1 09 36 043182 2 WASHER LOCK M3 37 031879 2 WASHER FLAT M3 38 0D6575D 1 DEUTSCH MOUNTING CLIP 39 0A9973 1 RIVET POP 0 125 LARGE FLANGE as Drawing No 0D8355 AD Part 1 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator GN 220 H SH Engine PARTS q A INO 60L 0 LHOd WONOVA TVNYALXA TANVd MOVE TANSO TONH A INO 60110 YI 100 TIO E OL LZ i x A INO 60Lv0 YH TOOD TIO 44 ITEM PART NO QTY DESCRIPTION 1 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 0D8433 0C1069 0C1069 090965F 0G6468 081810 083312 0D8400 0C8917A 0C8798A 045756 082774 022129 081990 0D9004A 0E7585 0G3111 0G3231 0D7666A 0D7666B 090051 080316 090948 078631 0D8332 091846 0D7558 078643 0D8372 0C2756 0D7458 0C3979 085953 0D8739 2 pope o a N msi Si Sak ak SE k TRES S ek E M om E a Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator PARTS LISTS GN 220 H SH Engi
27. 3 8 STUD M8 1 25 10MM X 30MM 47 Section 7 Warranty WARRANTY Recreational Vehicle Generator 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 engine New utility and lawn and garden equipment 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 engine for the periods of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition and exhaust systems Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility
28. 47637 0E3811 0D1303 078645 0A7811 072683A 0A9878 089096 088156 0A8822 078691 0A5772 0A5776 074908 078606 076361 0D2414 099922 003733 004390 084186 083192 0E0057 078699B 021705B 0C3590 0C3591 0D9853A 083235 080336 0C8754 077161 077160 076307 088403 026073A 0D1411A 076329 0C3592 049340A 045761A E E sk sk eek NS NDOT ek AS IO es E aD NA o SS SS cL AA A a NO E ek Sek a AS ie ks A LONG BLOCK ASSEMBLY CONNECTING ROD ASSEMBLY PISTON PIN PISTON RING SET DIA 75 PLATEAU HONED GEAR COVER ASSEMBLY M8 X 56MM HEAD BOLT PISTON COATED DIA 75 PIN RETAINER RING ASSY CRANKSHAFT GH220 TAPER GOVERNOR R PIN WASHER FLAT 1 4 015 THK CRANKCASE ASSEMBLY GOVERNOR ARM OIL SEAL GOVERNOR GEAR ASSEMBLY GOVERNOR GEAR C RING GOVERNOR SPOOL 1 8 NPT PIPE PLUG CAMSHAFT ASSEMBLY CRANKCASE GASKET VALVE STEM SEAL CYLINDER HEAD GASKET OIL PRESSURE RELIEF COVER OIL PRESSURE SPRING 11 32 BALL M5 FORM SCREW M6 1 0 X 12MM SCREW GOVERNOR GEAR THRUST WASHER SCREW HHFC M8 1 25 X 35MM SPRING WASHER VALVE RETAINER VALVE SPRING VALVE SPRING WEAR WASHER GEROTER SET O RING SLEEVE SEAM DWL CYLINDER HEAD ASSEMBLY EXHAUST VALVE INTAKE VALVE PUSH ROD TAPPET OIL PICK UP ASSEMBLY ROCKER COVER GASKET PIVOT BALL STUD GN 191 220 ROCKER ARM ROCKER ARM JAM NUT PUSH ROD GUIDE PLATE 1 4 NPT PIPE PLUG ROCKER COVER ASSEMBLY PLASTIC OIL FILL PLUG VALVE SPRING KEEPER BARBED ELBOW 90 1 4 NPT X
29. 5 0 8 LOCK TOP WRAPPER PLUG EXPANSION LOWER WRAPPER GASKET OIL PSI PAD 04709 ONLY ADAPTER OIL FILTER SCREW SHC M6 1 0 X 20MM G12 9 SCREW SHC M6 1 0 X 35MM G12 9 04709 SWITCH OIL 5 PSI FILTER OIL SWITCH THERMAL 305F WASHER LOCK M3 SCREW PPHM M3 0 5 X 6MM ELBOW 90D STREET 1 8NPT RHMS 44 40 X 5 16 SEMS COTTER PIN ROD CHOKE CONTROL BOOT CHOKE SOLENOID PLASTIC SCREW TAP R 1410 32 X 9 16 RHMS 44 40 X 1 4 SEMS ASSEMBLY BI METAL HEATER SOLENOID CHOKE FUEL HOSE 3 8 LO PERM BARBED TEE 1 2X3 8X1 2 BARBED EL 90 1 4NPT X 3 8 BULKHEAD ADAPTOR FITTING PLUG STD PIPE 1 4 COUNTERSUNK SCREW HHTT M4 0 7 X 8 BP OIL COOLER 220 CLAMPHOSE OETIKER STEPLESS 17 HOSE 3 8 X 16 25 BRAID WRAP BARBED EL 90 1 8NPT X 3 8 OIL FILTER SPACER 220RV 45 Section 6 Exploded Views and Parts Lists GN 220 H SH Engine Drawing No 0D8355 AD Part 2 Recreational Vehicle Generator PARTS q 46 Section 6 Exploded Views and Parts Lists LISTS Recreational Vehicle Generator GN 220 H SH Engine Drawing No 0D8355 AD Part 2 0 N A oO A G PS O1 O1 OC 4 4 gt gt d E P d CO G CO Q2 CO CO Q2 CO CO CO lO D D lO O ID D S lO S o FO O do Oo O Oi G IO O X Oi ON u c 0 lt l O Oi Q IO O cO 0 lt O O1 amp c Io O 0E8804 078621 076389 0G4379 0A8897B 077168 064331 076390 0G5827 078658 0F0967 089213E 0
30. 8 American Wire Gauge AWG copper wire minimum In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury SAFETY RULES Safety Rules Recreational Vehicle Generator FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations 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 installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection A
31. AP 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 24 A Dd A Do not install any flammable material directly above or around the compartment Heat trans ferred through the compartment structure may be sufficient to ignite char or discolor seat cush ions fiberboard and other flammable materials Use approved nonflammable insulating materi als 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 seal ant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a nonflam mable type One excellent insulating material is a 1 inch 25 mm thick fiberglass having a 2 pound den sity When fiberglass is used its coated side should face toward the compartment interior A Dd A Do not install sound insulation or any absorbent material on the compartment floor interior Such materials will become soaked with combustible or explosive vapors and liquids and will become a fire hazard Using a combination of sound insulating materials can often reduce noise more effectively than a single material For example a sheet of lead or visco e
32. ARK caution Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine Install and tighten the oil fill cap and the dipstick before operating the engine 3 2 CHANGING THE ENGINE OIL AND OR OIL FILTER Change the engine oil after the first 25 hours of operation Thereafter change the oil every 100 operating hours Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures 9 MAINTENANCE 20 Section 3 Maintenance Recreational Vehicle Generator Change the engine oil filter after the first 25 hours of operation and every 100 operating hours there after To change the oil and or oil filter proceed as fol lows see Figure 3 1 Run the engine until it is thoroughly warmed up at least five minutes then shut OFF the engine Immediately after the engine shuts OFF pull the oil drain cover free of the base Remove the plug from the tube with a 5 16 allen wrench and drain the oil into a suitable container Loosening the oil fill cap will allow the crankcase to drain faster After the oil has drained replace the plug onto the end of the oil drain tube Retain the cover in the base With the oil drained remove the old oil filter by turning it counterclockwise Place a towel under neath to catch excess oil Apply a light coating of clean engine oil to the gas ket of the new filter Fill
33. Fuel consumption is in gal hr 4 1 5 3 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum Institute API Service Classification SE SG or SH The recommended oil weights include the following During summer months SAE 30 An acceptable substitute is SAE 10W 30 During winter months SAE 5W 30 DO NOT USE SAE 10 W40 Crankcase and oil filter capacity is approximately 800 mL or 84 U S quarts Do NOT use special addi tives See sections Checking the Engine Oil Level and Changing the Engine Oil and or Oil Filter for oil level check and fill procedures 1 5 4 ENGINE Type of Engine aeoiee GN 220 Single cylinder Cooling Method usina dais seed Air cooled Rated HorsepowWer asia d entend 7 8 4 200 rpm Displacement osie nes aus astasqa ya piskaq qas 220cc Cylinder Block gt u a noe Aluminum w Cast Iron Sleeve Type of Governor Mechanical Fixed Speed Air Cleaner iio otis Paper Element w Foam Precleaner E CARR RINDO NR AR TR RA O Na etes 12 volt DC Electric Ignition System Solid state w Flywheel Magneto Recommended Spark Plug Champion evacrisa RC14YC AG os cons p ua ene ari Ea Satay asda i n R45S Fram Autolite eter e natacion ainda oa ae 65 Spark Plug Gap 0 030 inch 76 mm Recommended Minimum Battery 400 Cold cranking Amperes Section 1 General Information 4 1 5 5 GENERATOR Rated Ma
34. GREEN 90 cs NEUTRAL CONNECTION 14 CH BY CUSTOMER 37 PARTS dab LISTS Oo 38 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Enclosure Drawing No 0D8352 M TO CARB 55 31 ITEM PART NO QTY DESCRIPTION _ OQ G PS 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 0D6822 0D6942 0D6939 0D6943 0D6941 0D6941A 0D6940 0D6940A 0D6945 0G7329 0D8254 0C5644 0D7513 087769 0D7613 0D7614 040173 047411 022473 023484S 022097 086729 0D3700 022129 022259 075763A 0D7293 064113 0C7561 0A4456 049813 a M NNNN n nNNnNN p Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Enclosure Drawing No 0D8352 M TRAY ENCLOSURE PANEL ENCLOSURE SIDE PANEL REAR DIVIDER PANEL ENCLOSURE ROOF PANEL ENCLOSURE BACK PANEL ENCLOSURE BACK EXTERNAL PORT 04709 ONLY PANEL FRONT DIVIDER PANEL FRONT DIVIDER EXTERNAL PORT 04709 ONLY COMPARTMENT AIR INTAKE PANEL ENCLOSURE DOOR SHIELD MUFFLER SLIDE LATCH FLUSH PUMP FUEL FILTER FUEL FUEL LINE FILTER TO PUMP FUEL LINE PUMP TO CARB CLAMPHOSE WORM GEAR SCREW HHC M6 1 0 X 16 WASHER FLAT 14 BUSHING 1 09 SNAP WASHER LOCK M6 1 4 CONTACTOR STARTER NUT FLANGE M6 1 0 NYLOK WASHER LOCK M8 5 16 NUT HEX 5 16 18 BOOT BATTERY CABLE PANEL AIR BOX COVER SCREW M6 1 00 X 20MM WING
35. MPERATURE SWITCH This switch Figure 2 2 which has normally open N O contacts is mounted near the oil filter The contacts close if the temperature should exceed approximately 284 F 140 C initiating an engine shutdown Figure 2 2 Low Oil Pressure and High Temperature Switches High Temperature Switch Low Oil Pressure Switch OPERATION Section 2 Operation ix Recreational Vehicle Generator 2 9 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 components are part of a field boost circuit Figure 2 3 During engine cranking only a positive DC battery voltage is delivered through the diode resistor brushes and slip rings to the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Figure 2 3 Field Boost Circuit Crer 9 16 CONTROLLER CIRCUIT CLOSEST TO BOARD BEARING 4 N FIELD GRND i 2 9 4 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 4 controls the generator s AC output voltage This regulator sup plies an excitation current to the rotor By regulating the rotor s excitation current the strength of its mag
36. PG carburetion assembly and its 4 Catalytic Muffler Assembly if so equipped including internal components if so equipped a Muffler gasket a Fuel controller if so equipped b Exhaust manifold b Mixer and its gaskets if so equipped 5 Crankcase Breather Assembly including c Carburetor and its gaskets if so equipped a Breather connection tube d Primary gas regulator if so equipped e LP liquid vaporizer if so equipped Generac engine types covered by this warranty statement include the following 1 Utility 2 Lawn and Garden Equipment 3 Recreational Vehicle RV Generator 4 Industrial Mobile IM Generator Part 2 49 Section 7 Warranty WARRANTY Recreational Vehicle Generator GENERAC POWER SYSTEMS THREE YEAR LIMITED WARRANTY FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS NOTE ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES For a period of 3 three years of operation from the date of original sale Generac Power Systems Inc Generac will at its option repair or replace any part which upon 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 trans
37. RNATOR DUCT NUT WING M6 1 0 STUD M6 1 0 OFFSET ELEMENT AIR FILTER WASHER FLAT 281 1 D X 1 50 O D WASHER LOCK M6 1 4 MUFFLER W CATALYST SCREW HHTT M6 1 0 X 12MM BOLT CARR 5 16 18 X 2 NUT FLANG 5 16 18 LOCK GASKET EXHAUST SCREW HHC 5 16 18 X 1 3 4 FILTER GASKET RV 41 CG urs Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Control Panel Drawing No 0D8354 H 25 24 25 23 14 Section 6 Exploded Views and Parts Lists CG srs Recreational Vehicle Generator Control Panel Drawing No 0D8354 H 0 1 0F9719 1 REGULATOR VOLTAGE 2 075210A 1 TERMINAL BLOCK 3 092234 1 CONTROLLER P C B 4 065795 1 BATTERY CHARGER RECTIFIER 5 023484F 1 BUSHING SNAP 1 023484F 2 BUSHING SNAP 1 04709 ONLY 6 023484R 1 BUSHING SNAP 1 1 4 F 075234 1 RESISTOR 1 OHM 25W 8 057159 1 CIRCUIT BREAKER 2 0 Amp 60Hz 054502 1 CIRCUIT BREAKER 3 0 Amp 50Hz 9 087798 1 SWITCH S P D T 10 092113 1 SWITCH S P D T ON MOM ON 11 032300 1 HOLDER FUSE 12 0A9611 1 FUSE 7 5A 13 090145 1 CIRCUIT BREAKER 30 X 1 60HZ 0E2314 1 CIRCUIT BREAKER 15A 2 POLE 50HZ 14 0A1658 2 LOCK WASHER SPECIAL 15 075235 2 SCREW HHC M5 0 8 x 30mm 16 047411 2 SCREW HHC M6 1 0 X 16mm 17 049226 5 WASHER LOCK M5 18 051716 1 NUT HEX M5 0 8 19 075476 2 SCREW PPHM M4 0 7 x 16mm 20 022264 2 WASHER LOCK 8 M4 21 051715 4 NUT HEX M4 0 7 22 0A2053 1 SCREW HHC M6 1 0 x 65mm 23 02247
38. Replace starter motor 6 Low or defective battery 6 Charge or replace battery The engine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel pump 2 Replace fuel pump 3 Open 14 wire from 3 Check connections and engine control board insulation of 14 wires 4 Flooded engine 4 Wait 5 10 minutes before trying 5 Defective spark plug s 5 Clean re gap or replace plug s 6 Fuel line shut off closed 6 Open fuel line shut off 7 Plugged fuel filter 7 Clean or replace fuel filter The engine starts hard 1 Air cleaner 1 Check clean or replace air cleaner and runs rough plugged or damaged 2 Defective spark plug s 2 Clean re gap or replace plug s The engine starts but shuts 1 Engine oil level low 1 Check oil and add oil as needed down when the Start Stop 2 Defective low oil 2 Replace pressure switch switch is released pressure switch 3 Defective high temperature 3 Replace temperature switch switch 4 Defective engine control board 4 Replace control board 5 Overheated engine 5 Check that the airflow openings are adequate The Start Stop switch is 1 Defective Start Stop switch 1 Replace switch set to Stop but the engine 2 Open Disconnected 18 wire 2 Reconnect or close wire continues to run between Start Stop switch and engine control board 3 Open Disconnected 0 wire 3 Reconnect or close wire between Start Stop switch and engine control board 4 Defective engine control board
39. TERRUPTERS The National Electrical Code NFPA 70 551 7 requires that ground fault circuit interrupters GFCIs be installed on all external and some internal electri cal receptacles Contact the dealer for recommenda tions 2 7 BATTERY INSTALLATION 4 2 71 RECOMMENDED BATTERY Install a battery that meets the following require ments The battery must be a 12 volt automotive type storage battery 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 bat tery with a larger capacity may be needed DOCKSIDE POWER RECEPTACLE POWER SUPPLY CORD VEHICLE AC DISTRIBUTION PANEL 2 72 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes starting problems For the best cold weather starting the voltage drop between battery terminals and the generator connection point should not exceed 0 12 volts per 100 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 prevailing ambient temperatures Gene
40. TION 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 workmanship 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 accessories 4 HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact an Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting an Authorized Service Dealer or the factory about parts and service always supply the complete model number and serial number of the unit as given on its data label which is located on the generator Model No Serial No AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 or locate us on the web at www guardiangenerators com Part Owner s Manual Introduction
41. URE AND DIRT Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor 3 1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements see Engine Oil Requirements Check the engine crankcase oil level at least every eight hours of operation or before each use To check the engine oil level proceed as follows see Figure 3 1 1 2 3 5 Be sure the generator is as level as possible Remove the dipstick and wipe it dry with a clean lint free cloth Install and tighten the dipstick cap then remove it again The oil level should be at the dipstick Full mark If necessary remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dip stick Full mark DO NOT FILL ABOVE THE FULL M
42. allation 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 sup pliers The manufacturer cannot possibly know of and advise the recreational vehicle trade of all conceiv able methods procedures or techniques by which to perform an installation Nor can we anticipate every possible hazard that might result from each installa tion method procedure or technique The manufac turer has not undertaken any such wide evaluation Therefore people who use a method procedure 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 procedure or technique selected Information illustrations specifications etc con tained in these Installation Instructions are based on the latest information available at the time of publica tion Every effort has been expended to be sure that such data 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 DG A A D
43. 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 compart ment 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 sur rounding 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 gauge steel tub ing OR b 1 1 2 inch 11 gauge angle iron A typical S S upporting frame with horizontal support tubing is hown in Figure 2 1 The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the genera tor below the horizontal support tubing by means of suitable structurally sound metal framework The following general rules apply Vehicle construction MUST be capable of support ing the weight of the generator Whether the generator is mounted above the hori zonta
44. as genera tor and dockside power Conductors must be rated 221 F 105 C or must be of a larger conductor size 4 2 6 5 GENERATOR AC CONNECTIONS Generator AC output leads BLACK hot and WHITE grounded neutral come out of the generator as shown in Figure 2 13 There is also a green lead that connects to ground in the junction box of the recreational vehicle Leads BLACK to WHITE are protected against over load by a 30 amp circuit breaker CB1 Use this line to neutral connection separately to operate 120 volt single phase 60 Hertz AC loads requiring up to 3 600 watts 3 6 kW of power INSTALLATION E Section 2 Installation Figure 2 13 Generator AC Output Leads REMOTE PANEL CONNECTOR AC OUTPUT HARNESS FUEL FILTER CONNECTIONS caution N 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 gener ator s rated wattage capacity Add the watts or amperes of all lighting appliance tool and motor loads the generator will operate at one time This total should be less than the unit s rated wattage amperage capacity Recreational Vehicle Generator 4 2 6 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 allo
45. cked This should be done with an automotive type bat tery hydrometer NOTE Servicing of the battery is to be performed or supervised by personnel knowledgeable of batter ies and the required precautions Keep unauthor ized personnel away from batteries Damage will result if the battery connections are made in reverse A DI A Do not dispose of the battery in a fire The battery is capable of exploding Storage batter ies give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explo sion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing 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 pre cautions are to be observed when working on batteries e 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 bo
46. d 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 ae or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC PO BOX 297
47. d warranty Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any warranty service All warranty expense allowances are subject to the conditions defined in Guardian s Warranty Policies and Procedures Guide THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Guardian generators that utilize non Generac replacement parts Costs of normal maintenance adjustments installation and start up Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as 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 cause
48. dd up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one time This total should not be greater than the wattage capacity of the generator If an electri cal device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of current for starting than for continuous operation 1 3 SAFETY Before attempting to use the generator set care fully read the Safety Rules section of this manual Comply strictly with these rules to prevent accidents and damage to equipment and or property We sug gest copying and posting the Safety Rules in poten tial hazard areas of the vehicle Stress safety to all operators and potential operators of this equipment Section 1 General Information GENERAL Recreational Vehicle Generator INFORMATION 1 4 GENERATOR AC CONNECTION SYSTEM This generator set is equipped with dual stator AC power windings These two stator windings sup ply electrical power to customer electrical loads by means of a two wire connection system Note how ever that the neutral is bonded to the frame of the engine generator The generator may have been installed so that it pow ers 120 volt AC loads Figure 1 1 It can be wired to connect 120 volt AC electrical loads This procedure should be done by an Authorized Service Dealer or other qualif
49. de 5 to fasten the generator to the supporting frame or the support tubing These bolts must pass through a the generator mounting base b the compartment floor if a compartment is used and c the support ing framework Figure 2 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 METAL LINED Ya INCH THICK BASE PLYWOOD A TUBULAR METAL SUPPORT FRAME gt i lt lt GRADE 5 BOLTS METAL LINED VEHICLE BOTTOM CHASSIS 2 22 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compartment that the installer constructs the compartment must meet certain spec ifications as outlined in the following sections 2 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a mini mum clearance of 1 2 inch 13 mm on the front and top one 1 inch 25 mm on the sides and one 1 inch 25 mm from the back for air circulation AFTER the compartment has been lined with metal and sound insulation Figure 2 4 INSTALLATION he Sectio
50. derside of the compartment floor Seal all compartment door edges to prevent noise leakage around the door perimeter Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 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 on page 26 Engine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts see Generator Restraint A DIG A Fuel lines and exhaust piping must not pen etrate into the vehicle living area INSTALLATION he Section 2 Installation Recreational Vehicle Generator 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 air is avail able to the generator for cooling ventilating and combustion The installer also must provide for a path for exhausting the cooling air to the exterior of a compartment if so equipped A DEH A A Never use discharged cooling air for heating or permit such air to enter the vehicle interior
51. e 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the purchaser owner Such use shall not reduce Generac s 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 a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 2 Air Induction System including 1 1 Gasoline carburetor assembly and its a Intake pipe manifold internal components if so equipped b Air cleaner a Fuel filter if so equipped 3 Ignition System including b Carburetor gaskets a Spark plug c Fuel pump if so equipped b Ignition module 1 2 L
52. e into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can dam age the other engine 2 5 1 SPARK ARRESTOR This spark arrestor assembly meets code and stan dard requirements of the U S Forest Service Use only mufflers and parts approved by the manufactur er Any person s installing an unapproved muffler or an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable for any damage injury or warranty expense that might be caused by such unapproved installation or 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 provide a spark arrestor The vehi cle owner or operator must maintain this device in good condition In the state of California the preced ing is required by law Section 4442 of the California Public Resources Code Other states may have simi lar laws Federal laws apply on federal lands When installing replacing the tailpipe or spark arres tor components verify that the tailpipe has a hole to securely fasten the spark arrestor components see Figures 2 11 and 2 12 Use only manufacturer supplied hardware Substitution of parts may cause damage to the screen or a loose fit to the tailpipe Figure 2 11 Spark Arrestor TAILPIPE P N 0E068
53. e on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc ZN ELECTRICAL HAZARDS A The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle have the generator properly grounded bonded either by solid mounting to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT disconnect the bonding conductor if so equipped DO NOT reconnect the bonding conduc tor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No
54. er properly 4 Clean the air cleaner cover then reassemble fol lowing steps 7 9 in section Cleaning the Foam Precleaner 3 4 CLEAN AIR INTAKE Clean all foreign material from the air intake Figure 3 3 at least once every 100 hours of operation Clean more often if necessary Inspect the area around the generator exhaust muf fler periodically and remove all grass leaves dirt etc from this area Figure 3 3 Cleaning Air Intake 3 5 CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine Remove the spark plug and check the condition Replace the spark plug if worn or if reuse is question able 2 Clean spark plug by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug to clean 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 030 inch 0 76 mm by carefully bending the ground electrode Figure 3 4 Figure 3 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 030 inch 0 76 mm E caution Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end If nec essary re form the wire terminal to obtain a tigh
55. ermit exhaust gases to enter the vehicle A BENI A N The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coher ently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weakness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired A Dd A AN Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installa tion manual Make sure there is ample fresh air when operating the genset in a confined area 2 5 STARTING THE GENERATOR NOTE Read the vehicle manufacturer s instructions The owner operator should become familiar with the vehicle in which this generator is installed Differences exist between vehicles For example some vehicles may use a transfer switch to isolate dockside power from the generator
56. ervice the foam precleaner more fre quently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 2 Turn the two screws counterclockwise to loosen Remove the cover foam precleaner and paper filter Remove the foam precleaner from the cover Wash the foam precleaner in liquid detergent and water Wrap the foam precleaner in a clean cloth and gently squeeze it dry 6 Saturate the foam precleaner in clean engine oil Gently squeeze it in a clean cloth to remove excess oil and to distribute oil DO NOT TWIST 7 Install the foam precleaner into the cover fol lowed by the paper filter 8 Install the cover foam precleaner and paper filter 9 Tighten the two screws to retain the filter in place gt Ne 9 Figure 3 2 Engine Air Cleaner 3 3 2 CLEANING OR REPLACING THE PAPER FILTER Once each year or every 100 hours of operation whichever comes first clean or replace the paper filler The new replacement filter must be flame retardant Service the paper filter more frequently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 2 12 1 Follow steps 1 3 in Cleaning the Foam Precleaner service the foam precleaner if necessary 2 Remove the paper filter 3 Clean the air filter by tapping it gently on a solid surface If the filter is too dirty replace it with a new one Dispose of the old filt
57. espite 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 DA 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 18 N GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and main tenance of this equipment is carried out by an Authorized Service Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust system must be installed properly in strict com pliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards The generator com partment must be completely vapor sealed from the vehicle interior There must be no possibility of exhaust fumes entering the vehicle interior Never operate this equipment with a leaking or defective exhaust system Keep hands feet clothing etc away from drive belts fans and other moving or hot parts N
58. ever remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ven tilating air is critical to correct generator opera tion and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or permit even partial blockage of ventilation provi sions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Before performing any maintenance on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc Never insert any tool or other object through open ings in the generator interior even if the unit is not running Serious injury or damage to the equip ment may occur A ELECTRICAL HAZARDS N The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires
59. fficient concentrations can cause unconsciousness or even death This exhaust system must be installed properly in strict com pliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards The generator com partment must be completely vapor sealed from the vehicle interior There must be no possibility of exhaust fumes entering the vehicle interior Never operate this equipment with a leaking or defective exhaust system Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ven tilating air is critical to correct generator opera tion and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or permit even partial blockage of ventilation provi sions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement Before performing any maintenanc
60. fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not run ning generator operation may drain the vehicle engine supply line making it difficult to start the vehicle engine 2 4 2 GENERATOR FUEL SUPPLY LINE 2 4 2 1 Rigid Fuel Lines Those lines used to supply fuel from a tank to the generator must comply with applicable codes stan dards and regulations The following general rules apply to rigid fuel lines Rigid lines should be of annealed seamless drawn aluminum or steel Lines and fittings must comply with SAE J512E Standard Automotive Fittings or with ANSI B126 26 latest edition Route the fuel line so that at least 2 inches 51 mm of clearance is maintained between the line and any exhaust system parts Do not attach electrical wiring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so if they leak fuel does not drip onto any electrical or exhaust system parts Use nonferrous metal straps without sharp edges to secure fuel lines 27 INSTALLATION Ps ITED Section 2 Installation Recreational Vehicle Generator 2 4 2 2 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 vibrati
61. he proper level with dis tilled water DO NOT USE TAP WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery 3 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 neces sary and then start the engine 6 Allow the unit to run for several minutes to warm up 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 13 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation adjust the valve clearance in the engine When adjusting valve clearance the engine should be at room temperature and the piston should be at Top Dead Center TDC of its compression stroke both valves closed Correct clearance is 0 001 0 003 inch 0 03 0 07mm Adjust valve clearance as follows 1 Loosen the rocker arm jam nut Use an allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Figure 3 7 MAINTENANCE Section 3 Maintenance Recreational Vehicle Generator Figure 3 7 Adjusting Valve Clearance FEELER GAUGE ome ALLEN WRENCH 2 When valve clearance is correct hold the pivot ball stud with the allen
62. he recreational vehicle generator electrical sys tem Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS A Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning 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 to install an approved flexible non conductive fuel line between the generator fuel con nection point and rigid fuel lines 19 Recreational Vehicle Generator 1 1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product s installation requirements Give serious consideration to all information and instructions in the manual both for safety and for continued reliable ope
63. ied installer Figure 1 1 Connections for 120 Volts Only STATOR POWER WINDINGS T2 WHITE GROUNDED NEUTRAL 1 5 SPECIFICATIONS 4 1 5 1 FUEL REQUIREMENTS This generator is equipped with a gasoline fuel sys tem Depending on the installation the generator may have either a separate fuel tank or it may share the vehicle engine s fuel tank NOTE Some installations using a shared fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine s pickup tube Such an arrangement causes the generator engine to run out of gas while adequate fuel for the vehicle remains in the tank To reduce lead and carbon deposits use high qual ity 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 GENERAL Recreational Vehicle Generator INFORMATION cauroN AN The manufacturer does not recommend using any gasoline containing alcohol such as gaso hol If using any gasoline containing alcohol it must not contain more than 10 percent ethanol and it must be removed from the generator dur ing storage Do NOT use any gasoline containing methanol If using gasoline with alco hol inspect more frequently for fuel leaks and other abnormalities No Load 1 2 Load Full Load 004700 0 0 24 0 35 0 55 004708 0
64. itch and an hourmeter The hourmeter provides a continuous indication of engine generator operating time Use the hourmeter for checking off periodic maintenance requirements on the unit 2 3 AUTOMATIC CHOKE The engine is equipped with an automatic choke that consists of two main components a choke solenoid and prechoke 2 3 1 CHOKE SOLENOID During engine cranking Start Stop switch at START a solid state choke module signals the choke sole noid 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 temperatures i e in cold ambient tem peratures 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 NOTE Instructions and information in this manual assume the generator has been properly installed connected serviced tested and adjusted by a qualified installation technician or installation contractor 9 2 4 1 INSTALLATION Generator installation must have been properly com pleted so it complies with all applicable codes stan da
65. ks press this switch for approximately 10 to 15 seconds to bring fuel from the tank to the carburetor This rocker type switch springs back into its original position when released 4 2 1 2 START STOP SWITCH To crank and start the engine hold this switch in the START position Release the switch when the engine starts To stop an operating engine press and hold the switch in the STOP position until the engine shuts off The switch center position is the RUN position 2 1 3 FUSE The fuse protects the engine s DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine cannot be cranked If the fuse must be replaced use only an identical replacement 4 2 1 4 MAIN BREAKER The main breaker protects the generator s AC output circuit against overload and provides a method of turning OFF the generator s 120 volt AC output to the vehicle circuits This generator has 30 amp breaker Section 2 Operation OPERATION Recreational Vehicle Generator ix 2 2 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel is available that allows starting and stopping the generator engine conveniently from inside the vehicle Order part number 0F0429 or OF0430 a remote panel that includes a Start Stop switch a generator run lamp a fuel prime sw
66. l 1 1 17 2 2 14 14 3 3 18 4 4 BCR 15 5 5 z Z y 6 o tls Ub laibgdi 5 E 8 8 d 5 E LS 1 7 66 14A 15 18 14 17 O BATTERY CHARGE WINDING 55 R1 ON 4 VA LAS POWER WINDING O SN ND tf 3 ON 44 228 11S HP j FUEL 22P PRIME ELECTRONIC nm gt REMOTE PANEL VOLTAGE OPTIONAL ESRB REGULATOR OK BCR BATTERY CHARGE RECTIFIER l CB1 CIRCUIT BREAKER 30A 2A CB3 CIRCUIT BREAKER 2 5A b i CH CHOKE HEATER GASOLINE ONLY CB3 CS CHOKE SOLENOID ON F1 FUSE 7 5A 9 4 Ti FP FUEL PUMP OR LPG SHUT OFF VALVE 2 6 FS FUEL SOLENOID GASOLINE ONLY L AAA ASA GT TERMINAL GROUND 4 TAB DPE WINDING HM METER HOUR OPTIONAL HTO SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP OF OA A OO 4 IM IGNITION MAGNETO 177 FIELD L1 LIGHT RUN OPTIONAL WHITE BLACK LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE PCB ENGINE CONTROLLER R1 RESISTOR 1 OHM 25W T2 SC STARTER CONTACTOR p 120V 30A SM STARTER MOTOR SW1 SWITCH START STOP NEUTRAL CONNECTION SW2 SWITCH FUEL PRIMER BY CUSTOMER SP SPARK PLUG TC TERMINAL CONN 4 TAB 36 Section 5 Electrical Data Recreational Vehicle Generator ELECTRICAL Electrical Schematic and Wiring Diagram Drawing No 0D8063 D b DATA
67. l and or Oil Filter 11 3 3 Maintaining the Engine Air Cleaner 12 3 4 Clean Air Intake erg rales 12 3 5 Checking the Engine Spark Plug 12 36 JB el Filtros DSO RR RR deceret tup ebus RENA 13 3 7 Clean Spark ArrestOr 5 eterne te eeu eo 13 3 8 Cleaning the G emerato r s assssssedusassssse 13 3 9 Battery Maintenance eeeseeeeee 14 3 10 Major Service Manual see 14 3 11 Exercising the Generator sssesssss 14 3 12 Out Of Service Procedure nee erreet ennt 14 3 13 Adjusting Valve Clearance 15 3 14 RV Generator Service Interval 15 Section 4 Notes u u uuu 16 Table of Contents AE F CONTENTS Recreational Vehicle Generator Part II Installation Instructions Safety Rules m 18 Section 1 General Information 20 1 1 Purpose and Scope of the Manual 20 I2 20 1 3 Standards Booklets eee teen 20 1 4 Equipment Description 20 15 Generator Engine Operating Speed 20 1 6 Generator AC Connection System 20 Section 2 Installation 22 2 1 Location and Support
68. l support tubing or suspended below the tub ing the supporting frame used must be structur ally sound If the generator cannot be bolted directly to the supporting frame or support tubing consider using additional tubing angle brackets or other supports to give the supporting frame sufficient strength Figure 2 1 Typical Horizontal Support Frame SUPPORT TUBING 2 1 3 SUSPENDED MOUNTING If the generator will be suspended below the hori zontal support tubing the suspension method used with the vehicle frame members must a be able to support the weight of the generator AND b provide sufficient restraint for the generator One typical sus pended mounting system is shown in Figure 2 2 The location of a suspended mounting system must be carefully planned keeping the following general rules in mind Protect the generator against road splash and debris Baffles or splash guards may be required to protect certain areas of the generator To make sure the gen erator is adequately protected road test the installa tion through mud water and slush The installer must make certain that the selected location will permit adequate cooling and ventilat ing airflow to be supplied Figure 2 2 Typical Suspended Mounting System GENERATOR SUPPORT FRAME MODEL 004718 0 GENERATOR MOUNTING HOLES FOR 5 16 18 BOLTS 6 PLACES 2 1 4 GENERATOR RESTRAINT Use four 5 16 18 hardened steel bolts Gra
69. l v 1 i 1 rgo L9UV I1 1 Lv E 21 644 6 69 D0p d0 X04 JINVaVITO EN o As N K x s TEN L9VILT 4 Il dioptds SOS 39NVSV319 WNBILIGIV vey Le7T I 1 8 2 2 18 S1nU 1n2 SEL dTOr do SOS CV 8 1 82 1 _ LEV LI LIE 3 ro OT 2 8 Ti d10v dO SOS TY CSSHINI WW NI 38V SNOISNINIO W Ad MAIA 9 2 3 2 TESTING THE INSTALLATION The manufacturer recommends testing the installa tion to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of overheating enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate NOTE Test the installation especially if bringing in air from below the generator set 2 4 GASOLINE FUEL SYSTEM The installation of a gasoline fuel system Figure 2 10 for a recreational vehicle generator set must comply with applicable codes standards and regula tions 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 m amn TONE gt i Fuel Pump amp Fuel Filter Behind Access Panel amp Air Filter A DG A A
70. laced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related 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 such written instructions 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 emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the 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 ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantabl
71. lastic material along with a layer of other acoustical mate rial is more effective than when a single material is used 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 com partment NOTE Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compartment In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise levels Such a compartment might be constructed as follows Figure 2 7 Use 5 8 inch thick or 3 4 inch thick plywood in the compartment Construct the compartment floor of a double thick ness of 5 8 inch or 3 4 inch plywood Figure 2 7 Typical Noise Abatement PLYW00D EXTERIOR 5 8 OR 3 4 THICK SOUND INSOLATION MATERIAL PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION 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 steel lining install a combi nation of acoustical materials as mentioned in Sound Insulating Materials A DIG A To prevent fire or explosion do not install any insulation or other absorbent materials on the interior or un
72. le Generator 3 Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step 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 minutes with loads applied 6 Turn off all electrical loads by setting the gener ator s main circuit breakers to their OFF 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 addi tional adjustment should be necessary Only quali fied 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 per cent 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 tem perature switch The switch has normally closed
73. le or explo sive vapors from entering the vehicle interior NOTE Caulking must be done so that the caulking mate rial will stay in place permanently Pressing such materials as putty tape onto joints and seams is NOT acceptable A high quality silicone rubber base sealant is recommended Holes and openings made in the compartment walls to allow for the passage of electrical conduit conductors hoses cables etc into the vehicle liv ing area must be sealed vapor tight with silicone rubber base sealant If flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartments electrical junction box NOTE Flexible metal conduit due to its unique construc tion is NOT vapor tight along its entire length 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 constructed compartments typically utilize a standard lap joint Figure 2 6 Types of Lock Seams TL a ACME LOCK FOLD LOCKED STANDING OFF SET DOUBLE LOCK DOUBLE SEAM ET GORDON SEAM LOCK SEAM STANDARD L
74. n 2 Installation Recreational Vehicle Generator Figure 2 4 Clearances Plywood Compartment 1 2 Clearance on Top Insulation NOTE Refer to Figure 1 2 Major Features and Dimensions 2 2 2 COMPARTMENT CONSTRUCTION The generator compartment should be either con structed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum s low melting point If the compartment is lined with galvanized steel it may be constructed of any material The manu facturer recommends that the compartment be constructed of 1 2 inch thick plywood not strand board with the floor made of a double thickness of 1 2 inch plywood with the grain of the wood at cross section for added strength Figure 2 5 Figure 2 5 Typical Compartment Construction CROSS SECTION VIEW METAL LINING Bar FIREPROOF ie SOUND INSULATION Bh 2 q al kahi METAL LINING t a ii ei VAPOR SEALED ES PLYWOOD ATALLTIMES gt METAL LINING E d 23 INSTALLATION Ps ITED Section 2 Installation Recreational Vehicle Generator If constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel All seams splices and joints of the compartment walls unless vapor tight by design should be caulked to prevent poisonous flammab
75. n 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 501C 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 20 Section 1 General Information 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 1 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to air cooled generators This generator is designed specifically for installing in recreational vehicles This generator operates 120 volts single phase 60 Hertz AC electrical loads that require 30 0 amps 1 5 GENERATOR ENGINE OPERATING SPEED The generator s revolving field rotor is driven by a single cylinder four cycle engine The generator sup plies 120 volts AC at 60 Hertz when the rotor is oper ating at 3 600 rpm 1 6 GENERATOR AC CONNECTION SYSTEM The generator is equipped with dual stator power windings as shown in Figure 1 1 Figure 1 1 120 volt Single Voltage Connection
76. ne Drawing No 0D8355 AD Part 1 0 GUARD FAN SCREW HHTT M6 1 0 X 8MM 04709 ONLY BLOWER HOUSING BLOWER HOUSING 220RV 04709 ONLY NUT HEX M16 1 5 WASHER M16 CONICAL ASSEMBLY CHOKE SOLENOID BRACKET FLYWHEEL WITH RING GEAR BACKPLATE ELECTRIC START SCREW HHTT M6 1 0 X 10MM KEY WOODRUFF 4 X 19D 5 16 M8 LOCK WASHER SCREW SHC M8 1 25 X 40MM ASSY STARTER SPARK PLUG CHAMPION RC14YC TAPTITE M6 1 0 X 25 ZINC ASSEMBLY IGNITION COIL ADV W DIODE BREATHER TUBE BREATHER TUBE 04709 ONLY GASKET MANIFOLD HEAD SCREW HHFC M6 1 0 X 30MM INTAKE MANIFOLD GASKET CARBURETOR MANIFOLD CARBURETOR GASKET CARB ADAPTOR ADAPTOR CARB BOLT CARB MOUNT M6 1 0 X 75MM GASKET CARB TO AIRBOX ASSEMBLY GOVERNOR LEVER ROD GOVERNOR SPRING ANTI LASH WASHER CARB WEAR ASSEMBLY BRACKET GOVERNOR ADJUST 34 35 36 37 38 39 40 41 42 43 44 45 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 0D8398 091638A 067967 082025 092984 094820 089739 091848 091848 0D8778 040945 040946 BONS e RECS Si Gul IDE VE 0D9235 070185B 0G6437 043182 0C4739 0D9689 0A7095 077091 0D8397 077075 0C2824 047094 0D8590 0D8591 0G6277A 2 066273 0G7458 069598 050873 045764 0E9406A 063662 0G4695B 046344 0G6502 E ANS BO SS ES INS ENO JM Eddie ard NOUNS qu sss NG EIL ROD CHOKE LINKAGE SPRING GOVERNOR SCREW HHTT 5 16 X SEMI GIMLET NUT M
77. netic field is regulated and in turn the voltage deliv ered to connected electrical loads is controlled When the AC frequency is 60 Hertz voltage is regulated at 120 volts voltage to frequency ratio is 2 to 1 Figure 2 4 Solid State Voltage Regulator JD e 8 LE SENSING te TO ROTOR 00 DIRECT CURRENT e 5 FROM STATOR EXCITATION WINDING ALTERNATING CURRENT 9 S O 10 The voltage regulator also incorporates a voltage surge protection circuit This circuit prevents trou blesome surges in the generator AC output voltage Voltage surge is a common cause of damage to elec tronic equipment 2 10 ADDITIONAL INFORMATION 4 2 10 1 ATTENTION REQUIRED AFTER SUBMERSION If the recreational vehicle generator has been sub merged in water it MUST NOT be started and oper ated Following any submersion in water have an Authorized Service Dealer thoroughly clean and dry the generator 4 2 10 2 OPERATION IN HIGH GRASS OR BRUSH Never operate the generator while the vehicle is parked over high grass weeds brush leaves or any other combustible substance Such materials can ignite and burn from the heat of the exhaust system The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down 4 2 10 3 EFFECTS OF MOIST
78. ny 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 nec essary fill to the dipstick FULL mark cross hatched area with the recommended oil Do not fill above the FULL mark 2 Check the fuel supply Gas fuel lines must have been properly purged and leak tested in accor dance with applicable fuel codes All fuel shutoff valves in the fuel supply lines must be open A EI A N If a liquid propane LP gas fuel system has been installed it must be properly tested for leaks before operating the system in compliance with ANSI A119 2 NFPA 501C No leakage is permit ted Be sure that no gasoline fuel vapors enter the vehicle interior 3 3 INITIAL START When absolutely certain that the unit has been prop erly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s main circuit breakers to their OFF or OPEN position 2 Refer to Part I 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 2 INSTALLATION START UP ADJUSTMENTS Recreational Vehic
79. o 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 32 Figure 2 17 Remote Panel Plug in Receptacle m 9 wR DOD ell allal 7 12 00 pus Mud LENGTH mm FUNCTION 0 WHITE 12 0 305 GROUND 14 RED 12 0 305 ENGINE RUN SIGNAL 15 ORANGE 12 0 305 12 VDC 17 YELLOW _ 12 0 305 START 18 BROWN 12 0 305 STOP 14A BLUE 12 0 305 PRIME P N 0D9099 B 4 2 8 1 REMOTE START STOP PANEL A remote mounted Start Stop panel Figure 2 18 is available that allows the user to start and stop the generator engine conveniently from inside the vehicle The remote panel includes a Start Stop switch hour meter generator run lamp a fuel prime switch and a wire harness The hourmeter should be used in conjunction with the maintenance operations found in Part I of this manual Figure 2 18 Optional Remote Panel Section 3 Post Installation Start up Adjustments POST 3 1 POST INSTALLATION TESTS The air cooled generator set was factory tested and adjusted It should not be required to adjust the unit any further except under special circumstances WARNING amp Do not make a
80. on shifting settling or movement The follow ing 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 perme ability The hose should be at least 6 inches 152 mm longer than is needed to prevent the hose from rupturing if the generator shifts or settles 2 5 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 DIG A AN The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coher ently b vomiting c twitching muscles d throbbing temples e dizziness f headaches g weakness and h sleepiness IF FEELING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Do not operate the generator until its exhaust system has been inspected and properly repaired caution Never tee the generator engine exhaust pip
81. oster battery to crank and start the generator engine If any battery has discharged remove it for recharging 14 WARNING amp Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed e 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 medical 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 10 MAJOR SERVICE MANUAL To obtain a service manual for the generator contact the nearest Authorized Service Dealer Make sure to identify the MODEL NUMBER and SERIES 3 11 EXERCISING THE GENERATOR The manufacturer recommends that the generator be started and operated at least once every seven days Let the unit run for at least 30 minutes to exercise the engine 3 12 OUT OF SERVICE PROCEDURE 4
82. portation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac generators sold and rated for Recreational Vehicle RV applications as Generac has defined Recreational Vehicle generator applications The factory recommends exercising the unit one half hour every month WARRANTY SCHEDULE COMMERCIAL APPLICATIONS YEAR ONE 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components WARRANTY SCHEDULE CONSUMER PERSONAL APPLICATIONS YEARS ONE AND TWO 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components YEAR THREE 100 one hundred percent only on selected part s and labor listed Any labor and part s not listed and removal and reinstallation are the owner s responsibility Rotor Stator Computer Control Board part numbers 0A6060 and 0A3369 and inverter if applicable with regard to the generator Cylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Manifolds Generac RV generators manufactured prior to December 31 1997 DO NOT have a transferable warranty Generac RV generators manufactured after January 1 1998 have a transferable warranty to the second owner ONLY for the remainder of the three year limite
83. rally the longer the cable and the colder the weather the larger the cable size must be as shown in the chart CABLE LENGTH CABLE SIZE 16 to 20 4 5 to 6 For warm weather use No 2 cable up to 20 feet INSTALLATION Ps TED Section 2 Installation Recreational Vehicle Generator 2 7 5 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 16 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 16 3 Connect cables so the connectors are clean and tight Figure 2 16 Connecting Battery Cables POS FUEL NEG a O a A 2 14 BATTERY COMPARTMENT Install the generator battery in its own vented com partment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage 2 8 OPTIONAL ACCESSORIES A plug in receptacle Figure 2 17 is provided on the generator set Use this receptacle t
84. ration of the equipment Because of the different recreational vehicle mod els and the variations between the models it would be extremely difficult if not impractical to provide detailed instructions for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all appli cable codes standards and regulations pertaining to the installation and use of this product If any portion of this manual appears to be in conflict with such codes standards or regulations the applicable codes standards or regulations must take prece dence over the manual 1 2 SAFETY Before handling installing 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 equip ment 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 revision are available from the sources indicated 1 NFPA Standard 501C Standard for Recreational Vehicles available from the National Fire Protectio
85. rds and regulations and with the manufacturer s recommendations OPERATION Section 2 Operation ix Recreational Vehicle Generator 4 2 4 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommended oil before starting Refer to sections Engine Oil Requiremtents Checking the Engine Oil Level and Changing the Engine Oil and or Oil Filter for oil servicing procedures and recommendations caution Ak Any attempt to crank or start the engine before it has been properly serviced with the recom mended oil may result in an engine failure 2 4 3 FUEL SUPPLY The engine must have an adequate supply of proper fuel to operate Before starting it check that suffi cient fuel is available NOTE Depending on the installation the generator may have either a separate fuel tank or it may share the vehicle engine s fuel tank 2 4 4 COOLING AND VENTILATING AIR Air inlet and outlet openings in the generator com partment must be open and unobstructed for con tinued proper operation Without sufficient cooling and ventilating airflow the engine generator quickly overheats which causes it to shut down and may damage the generator 2 4 5 ENGINE EXHAUST GAS Before starting the generator engine be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals Close windows doors and other openings in the vehicle that if open might p
86. re rotating and or hot during operation Exercise care near running generators N GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and main tenance 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 concentra tions can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coherently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weak ness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired Never sleep in the vehicle while the genset is run ning unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in su
87. rnia 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 The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period 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 ser vice evidence must be presented showing the date of the sale to the original purchaser owner The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and or transportation of the product to from the inspection or repair facilities The purchaser owner also shall be responsible for any and or all damages or losses incurred while the engine is being transported shipped for inspection or warranty repairs If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 as Section 7 Warranty Recreational Vehicle Generator WARRANTY
88. roperly and safely installed 4 ELECTRICAL CONNECTIONS A Connections comply with local code requirements and all National Electrical Codes Junction box is properly installed Wiring meets all standards All connections are correct Conduit is properly installed and sealed D LD Generator is properly bonded to the vehicle 4 BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Cables are clean and tight Cables are connected properly Proper ventilation is provided D LD O Terminals are coated with anti corrosion grease and terminal covers are positioned 4 OPTIONAL ACCESSORIES Q Check that remote start stop panels if used are installed properly A Check that hourmeter kit if used is installed properly A Check that any other options and accessories if used are installed properly 4 POST INSTALLATION TESTS Check that all tests are completed properly NAME OF INSTALLER SIGNATURE OF INSTALLER sa Section 4 Troubleshooting TROUBLESHOOTING Recreational Vehicle Generator TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank 1 Fuse blown 1 Replace fuse 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defective engine Start Stop 3 Replace Start Stop switch switch 4 Defective starter contactor 4 Replace contactor 5 Defective starter motor 5
89. rrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor which can be damaging to the generator windings caution Do NOT use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also con taminate the generator fuel system 13 MAINTENANCE 20 Section 3 Maintenance Recreational Vehicle Generator 3 9 BATTERY MAINTENANCE All lead acid batteries will discharge when not in use The generator battery should be inspected as follows 3 9 1 WEEKLY Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary Check the battery fluid level of unsealed batteries and if necessary fill with Distilled Water Only Do not use tap water in batteries 3 9 2 EVERY SIX MONTHS Have the state of charge and condition che
90. ssociation are appropriate for use on the recreational vehicle generator electrical sys tem Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS A Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline Section 1 General Information Recreational Vehicle Generator 1 1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage 1 Generator Air Intake 11 Fuel Filter Side View 2 Engine Start Stop Switch 12 Oil Filter 3 Fuse 13 Oil Drain Cap 4 Optional Remote Panel Receptacle Side View 14 Oil Dipstick 5 Generator AC Output Leads Side View 15 Air Filter Behind Access Panel 6 Fuel Primer Switch 16 Oil Fil 7 Circuit Breaker 17 Spark Plug 8 Starter Contactor 18 External Vacuum Por
91. t model 004708 0 only 9 Fuel Inlet 10 Fuel Pump Behind Access Panel Ir EN i d i pes Im ao 1 2 GENERATOR APPLICABILITY These generators have been designed and manufac tured for supplying 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 application contact an Authorized Service Dealer Do not use the unit until advised by a competent authority A DIG A 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 After installation do nothing that might render the unit in noncompliance with such codes stan dards and instructions Use this generator to supply electrical power for operating 120 volt single phase 60 Hertz AC electri cal loads These loads can require up to 3 600 watts 3 6 kW of power but cannot exceed 30 AC amperes of current at 120 volts caution Do not overload the generator Some installa tions may require that electrical loads be alter nated to avoid overloading Applying excessively high electrical loads may damage the generator and may shorten its life A
92. t fit 3 6 FUEL FILTER Remove and replace the fuel filter Figure 3 5 once each year or every 400 hours of operation whichever comes first Fuel filter is removed with a 15 16 deep well socket Figure 3 5 Fuel Filter POS FUEL NEG a O 2A 3 7 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 using 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 condition by the owner operator MAINTENANCE 20 Section 3 Maintenance Recreational Vehicle Generator Clean and inspect the spark arrestor as follows Remove the screen retaining bracket by removing the screw Slide the spark arrestor screen out from the tail pipe Inspect screen and replace if torn perforated or otherwise damaged DO NOT USE a defective screen If screen is not damaged clean it with com mercial solvent Replace the screen and the retaining bracket Figure 3 6 Spark Arrestor TAILPIPE P N OE0683 V SPARK ARRRESTOR SCREEN P N 089680 RETAINING SCREW P N 056892 3 8 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt co
93. t require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows This symbol points out important safety informa tion that if not followed could endanger person al safety and or property of others A This symbol points out potential explosion hazard 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 recom mend that the operator read this manual and thor oughly 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 for generator model numbers 004700 0 and 004708 0 In addition the latter portion of this manual contains information necessary for the proper installation of these genera tors 4 OPERA
94. ter minals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mount ing to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper 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 vehi cle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operat ing 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
95. the wattage of all con nected electrical lighting appliance tool and motor loads This total should not be greater than the generator s rated wattage capacity Most lighting appliance tool and motor loads indicate their required watts on their nameplate or data plate For light bulbs simply note the wattage rating of the bulb If a load does not show its rated wattage multiply that load s rated VOLTS times AMPS to obtain WATTS Section 2 Operation OPERATION Recreational Vehicle Generator J Induction type motors such as those that run the vehicle s furnace fan refrigerator air conditioner etc need about 2 1 2 time more watts of power for starting than for running for a few seconds dur ing 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 watt ages of other items that will be operated by the generator Do not apply heavy electrical loads for the first two or three hours of operation 2 9 PROTECTION SYSTEMS 2 9 1 LOW OIL PRESSURE SWITCH This switch Figure 2 2 has normally closed N C contacts that are held open by engine oil pressure dur ing cranking and operating Should oil pressure drop below a preset level switch contacts close and the engine automatically shuts down The unit should not be restarted until oil is added 4 2 9 2 HIGH TE
96. w extra wire for junction box connections Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation Route conduit so it does not interfere with genera tor movement If using metallic conduit vapor seal the end of the conduit where it enters the junction box Do this because flexible metallic conduit is not vaporproof along its entire length 2 6 5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 2 14 An alternate method for isolating different power sources is by using an isolating receptacle Figure 2 15 Whichever method is used be certain that both power sources are NOT connected at the same time 2 6 6 POWER SUPPLY CORD The power supply cord must comply with all appli cable codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected Figure 2 14 Transfer Switch Isolation Method JUNCTION BOX FLEXIBLE CONDUIT DOUBLE VEHICLE WIRING VEHICLE AC DISTRIBUTION PANEL SWITCHING 30 AMP MAIN BREAKER HACR BREAKERS FOR AIR CONDITIONERS GFCI BREAKERS POWER SUPPLY CORD 30 INSTALLATION Ps Iii Section 2 Installation Recreational Vehicle Generator Figure 2 15 Installation With Isolation Receptacle JUNCTION BOX FLEXIBLE CONDUIT 4 2 6 7 GROUND FAULT CIRCUIT IN
97. ximum Continuous AC Output Gasoline 3 600 Watts 3 6 kW Rated Voltage e booa Eres 120 Volts AC Rated Maximum Continuous AC Current Gasoline eeeeuss 30 Amperes A Single ROWE REM ee iO 3 600 Number Of Rotor Poles oerte eer qoo 2 Engine RPM M 3 600 Rated AC Frequency ses ce eire erect eite tet e eb ii 60 Hz Battery Charge Voltage eet tette 14 Volts DC Battery Charge Currentl 2 Amperes max Gasoline Weight s a ette re erp tena 170 Pounds Length us asua US externe 749 8 mm 29 52 in A n 483 1 mm 19 02 in Height osise iiris 342 2 mm 13 47 in 4 1 5 6 EMISSIONS COMPLIANCE PERIOD For non handheld engines 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 emission requirements For engines less than 225 cc displacement Category C 125 hours B 250 hours and A 500 hours For engines of 225 cc or more Category C 250 hours B 500 hours and A 1000 hours 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 Figure 2 1 Generator Control Panel B H CONTROL CENTER gt START FUEL 30A A lle STOP PRIME HI Ow 4n 2 1 1 FUEL PRIMER Before starting a cold engine if it has not been started in more than two wee

Guardian Technologies 004708-0 Portable Generator User Manual

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