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GE Monogram ZSC2200 Oven User Manual

1. 10 2 9 Protection Systems sse 11 2 10 Additional Information 12 Section 12 3 1 Checking the Engine Oil 12 3 2 Changing the Engine Oil and or Oil 12 3 3 Maintaining the Engine Air 13 3 4 Olean Air Intake 13 3 5 Checking the Engine Spark Plug 14 3 6 Fuel Filter Gasoline Only 3 7 Shark Arrestor Muffler 3 8 leaning the 3 9 Battery Maintenance 15 3 10 Major Service 15 Drive erre 15 3 12 Exercising the 15 3 13 Out of Service Procedure 2 2 2 16 Table of Contents TABLE OF Recreational Vehicl t ecreational Vehicle Generator CONTENTS Part Il Installation Instructions Safety 18 Notice to Installer sess 18 Section 1 General Information 20 1 1 Purpose and Scope
2. 56 SAFETY RULES Safety Rules Recreational Vehicle Generator N SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle Safety should be stressed to all operators and potential operators of this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot possibly know of and advise the rec reational vehicle trade of all conceivable methods procedures or techniques by which to perform an installation Nor can the manu facturer anticipate every possible hazard that might result from each installation method procedure or technique The manufactur er has not undertaken any such wide evaluation Therefore people who use a method procedure or technique that the manufacturer
3. GN 410 Single cylinder Cooling Method eese m una am nnns Air cooled Rated 15 4 200 rpm E 407 Cylinder Block Aluminum w Cast Iron Sleeve Type of 2222 Mechanical Fixed Speed Air Cleaner Paper Element w Foam Precleaner MICE ENS 12 volt DC Electric Ignition System Recommended Spark Plug Champion Solid state w Flywheel Magneto Spark Plug Gap 0 030 inch 76 mm Recommended Minimum Battery 400 Cold cranking Amperes Classll Emission Compliant 1 5 6 GENERATOR Rated Maximum Continuous AC Output 4 800 Watts 4 8 kW AC Output LP Fuel 4 500 Watts 4 5 KW Rated Voltage 120 Volts AC Rated Maximum Continuous AC Current Gasoline e 40 Amperes AC Current LP Fue as Rotor RPM Number of Rotor Poles Engine RPM sintetico ends Rated AC Battery Charge Voltage Battery Charge 2 Amperes max Weight 50
4. 009675 0A5649H 0A5646H 073159 031971 009674 0A6529 052858 066386 066849 0A8475 003818 075234 022473 022097 055816 090141 0A1658 074906 0922340SRV 0H3224 022129 027756 086316 053650 004258 075244 094071 094070 075476 022264 065795 090987 086317A 1 1 1 1 1 1 4 4 1 3 3 1 1 2 5 1 2 2 4 1 1 4 4 1 1 1 1 1 1 3 4 1 2 1 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Alternator and Panel Model 04164 3 Drawing No 0D1776 J TY DESCRIPTION LOWER BEARING CARRIER ROTOR ASSEM STATOR ASSEM BALL BEARING BALL BEARING UPPER BEARING CARRIER STUD STATOR M8 1 25 FLANGE LOCK NUT BRUSH HOLDER M5 0 8 X 16 LG TAPTITE SPECIAL LOCK WASHER M5 GENERATOR TOP HOUSING RESISTOR1R 5 25 WLVG v4 M6 FLAT WASHER 74 M6 LOCK WASHER M6 1 0 X 70 LG CAPSCREW GROUND CABLE SPECIAL LOCK WASHER M6 M6 1 0 X 20 LG TAPTITE CONTROLLER PC B DECAL MAINTENANCE SCHEDULE RV 5 16 M8 LOCK WASHER NYLON WASHER PANEL SHEET METAL 4 PIN CONNECTOR CONDUIT ASSEMBLY ASSEMBLY REMOTE CABLE M5 08 X 110 LG PPHMS SPACER PLASTIC 4 0 7 X 16 LG CAPSCREW 8 M4 LOCK WASHER BATTERY CHARGE RECTIFIER M3 0 5 X 12 LG PPHMS PANEL SUPPORT BRACKET ITEM PART NO 35 075235 36 082737 37 049813 38 055440 39 043182 40 045771 41 053623 42 0234848 43 0F9719 44 022152 45 051716 46 090144 47 090145 48 025105 49 086315 50 090734 51 022985 92 0323
5. 198 Pounds neni ees ee 200 Pounds 25 5 inches 648 mm 18 88 inches 479 mm 16 75 inches 425 mm All units are reconnectable to 120 and or 240 volt dual voltage output Units are no longer listed per RVIA ANSI when reconnected for dual voltage output f reconnected for dual voltage the ampere rating for 240 volts is 20 AC amperes for model 05754 0 and 18 8 AC amperes for model 04164 3 Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine condition etc Maximum power decreases about 3 5 for each 1 000 feet above sea level and will also decrease about 1 for each 6 C 10 F above 16 C 60 F ambient temperature 1 6 EVAPORATIVE EMISSIONS INFORMATION This generator is subject to evaporative emission standards which have been implemented by the California Air Resource Board CARB and the Environmental Protection Agency EPA If this generator is offered for sale in the state of California it must be covered by a CARB evaporative Executive Order If this generator is offered for sale to the final consumer in any other state certified low permeation fuel line must be used to supply fuel to the genera tor as required by EPA Anyone who installs or configures a fuel system to supply this generator with gasoline is required to comply with all applicable evaporative emi
6. W TO ROTOR e Sow DIRECT CURRENT M E FROM STATOR 2 EXCITATION WINDING ALTERNATING CURRENT S S The voltage regulator also incorporates voltage surge protection Circuit This circuit prevents troublesome surges in the generator AC output voltage Voltage surge is a common cause of damage to electronic equipment 11 MAINTENANCE S o 2 10 ADDITIONAL INFORMATION 2 10 1 ATTENTION REQUIRED AFTER SUBMERSION If the recreational vehicle generator has been submerged in water it MUST NOT be started and operated Following any submersion in water have an Authorized Service Dealer thoroughly clean and dry the generator Section 3 Maintenance Recreational Vehicle Generator 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 2 10 3 EFFECTS OF MOISTURE AND DIRT Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowe
7. Section 2 Installation Recreational Vehicle Generator 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 standards and regulations The fol lowing general rules apply to rigid fuel lines e Rigid lines should be of annealed seamless drawn aluminum or steel Lines and fittings must comply with SAE J512F Standard Automotive Fittings or with ANSI B126 26 latest edition Route the fuel line so that at least 2 inches 51 mm of clear ance is maintained between the line and any exhaust system parts Do not attach electrical wiring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so if they leak fuel does not drip onto any electrical or exhaust system parts Use nonferrous metal straps without sharp edges to secure fuel lines 24 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 vibration shifting settling or movement The following rules apply The flexible hose must comply with SAE J1737 30R7 Standard for Fuel and Oil Hose It must be approved for use with gasoline and low permeability The hose should be at least 6 inches 152 mm longer than is needed to prevent the hose from rupturing if the generator shifts or set
8. 25 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator DIG A Never use discharged cooling air for heating or permit such air to enter the vehicle interior This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases 2 3 1 GENERATOR AIRFLOW Engine operation drives cooling fans for the two stage cooling air System A pressure fan draws cooling air into the top of the generator Figure 2 9 This airflow cools the engine generator and electronic components The second part of the cooling system a suction fan draws air that is heated from a hot engine into a collector pan at the base of the unit This heated air although cooler than exhaust muf fler is then deflected out the bottom toward the ground Figure 2 9 Airflow Through Engine Generator 2 3 2 COOLING AIR INLET OPENINGS The minimum size of the air inlet opening whether the generator is housed in a conventional compartment or not is at least 100 square inches see Figure 2 10 This rule applies whether inlet air is brought in through an opening in the compartment door an opening in the vehicle skirt through ductwork or by any other means Figure 2 10 Air Inlet in Compartment Door 555566 S 25560 XX SKE KR KY SERRE
9. o 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 Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug to clean 2 Remove the spark plug and check the condition Replace the spark plug if worn or if reuse is questionable 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 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 tight fit Section 3 Maintenance Recreational Vehicle Generator Figure 3 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 030 inch 0 76 mm Cadet V 3 6 FUEL FILTER GASOLINE ONLY Remove and replace the fuel filter Figure 3 5 once each year or every 100 hours of operation whichever comes first Figure 3 5 Fuel Filter Fuel Filter 14 3 7 SPARK ARRESTOR MUFFLER If the generator is not equipped with a spark arrestor exhaust muffler and is to be used on any forest covered brush covered or grass covered unimproved land a spark arrestor may need to be installed The spark arrestor must be maintained in effective work ing order by the vehicle owner
10. Exploded Views and Parts Lists Base and Pulleys Model 05754 0 TY DESCRIPTION O rS ko oi A qOoL BASE MOUNTING GROUND CABLE MOUNT RUBBER CAPSCREW HEX HD 3 8 16 X 1 2 LOCK WASHER 3 8 LOCK WASHER M8 SKID RUBBER MOUNT SAFETY BOLT 5 16 18 X 3 1 2 NUT HEX 5 16 18 NUT FLANGED LOCK M8 1 25 CAPSCR HEX HD M8 1 25 X 60MM SPRING BELT TENSION WASHER SPRING CNTR SLIDE NYLON SUPPORT NYLON SLIDE MANIFOLD EXHAUST GASKET EXHAUST MANIFOLD SOCKET HD CAPSCR M8 1 25 X 20 LG GASKET COLLECTOR PAN SKID RUBBER MOUNT PULLEY ENGINE PULLEY ALT BELT POLY V 4L 40 WASHER PULLEY RETAINER CAPSCR SOCKET HD 3 8 24 X 1 GRADE 5 CAPSCR HEX HD M8 1 25 X 20 CAPSCR HEX HD 3 8 24 X 2 CRIMPTITE 10 24 X 1 2 BRACKET FUEL PUMP HOUSING BLOWER CRIMTITE 8 18 X 1 4 SCREEN SLIDE PAN GASKET BLOWER PAN SPRING GENERATOR SET MT ITEM PART NO 35 004006 36 044456 37 090475 38 087769 39 047695 40 0 6922 41 079246 42 022145 43 023897 44 0A8010A 45 077643 46 075237 47 0D1741A 48 090859 49 0F9176 50 048594 51 0A1658 52 023152 53 0A8475 54 045756 55 022131 56 0480316 57 081105 58 066849 59 001227 60 048010 61 002824 62 0742600131 63 024114 64 001741 65 022152 66 022158 67 048531 68 0 8407 69 022473 70 042110 PARTS LISTS Recreational Vehicle
11. CARBURETOR REGULATOR FUEL LOCKOFF SOLENOID VAPOR WIDTHDRAWAL TANK 2 5 2 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system consider seriously the following items All fittings lines hoses and clamps must be tight and free of leaks Apply a pipe sealant to threads when assembling thread ed connections This reduces the possibility of leakage Test the entire fuel system for leaks using approved test meth ods Optimum gas pressure at the inlet to the gaseous fuel solenoid valve and secondary regulator is 11 inches water column The installer s fuel supply connection point is at the gaseous fuel solenoid valve This is a 3 4 inch female connection Provide a suitable 3 4 inch NPT male connector to attach to the fuel supply line Use a length of approved flexible fuel hose between the gaseous fuel solenoid valve and rigid gas piping The flexible line should be at least six 6 inches longer than necessary 2 5 3 VAPOR WITHDRAWAL LP gas is stored in pressure tanks as a liquid The gas systems used with these generators were designed only for vapor with drawal type systems Vapor withdrawal systems use the gas vapors that form above the liquid fuel in the tank Do NOT attempt to use the generator with any liquid withdrawal type system 2 5 4 PRIMARY REGULATOR Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regulator Mount the primary reg
12. sse IFC ERE AERE IFC Operation and Maintenance sene How to Obtain Service Authorized Service Dealer Locator Number Safety Rules 2 Section 1 General Information 4 11 Generator Identification 4 1 2 Generator 5 19 Safety uu R 5 1 4 Generator AC Connection 5 5 15 ersin a 5 1 6 Evaporative Emissions Information 7 17 Exhaust Emissions Information Gasoline 7 1 8 Exhaust Emissions Information 7 Section 2 Operation 8 2 1 Generator Control 2 2 Optional Remote Start Stop Panel 2 3 Automatic Choke Gasoline 8 24 Before Starting the Engine 2 5 gt Starting the GerleratOr scott titi 2 6 X Stopping the Generator sse 2 Applying Loads to 10 2 8 Summer Winter Heat Riser
13. 11 080308 2 BREATHER GASKET 41 078659 2 THRUST WASHER 12 080309 1 BREATHER COVER 42 0A7628 1 GOVERNOR ARM RC45 13 080338 1 OIL BREATHER SEPARATOR 43 089288C 1 CRANKCASE SUB ASSEMBLY 14 0D4788 1 PIPE PLUG 3 8 44 0E3341 1 BALANCER 15 083897 2 TAPPET SOLID 45 086025 1 SET GEROTOR 16 072694 2 PIVOT BALL STUD 46 0D9853B 2 PUSH ROD 17 003998 2 NUT HEX M8 1 0 G8 47 0 9666 1 CRANKSHAFT ASSEMBLY 18 078672 1 SEAL VALVE STEM 48 090747 1 BREATHER VALVE ASSEMBLY 19 078694 1 PUSH ROD GUIDE PLATE 49 003150 1 ROCKER COVER GASKET 20 083907 2 ROCKER ARM 50 092362 1 ROCKER COVER W FILL 21 066791 1 CYLINDER HEAD W VALVE SEATS 51 068527 4 M6 1 0 X 20MM HEX HEAD AND GUIDES SCREW AND LOCKWASHER 22 0D2274 2 VALVE SPRING RETAINER 52 083921 1 BEARING TUBE SHAFT 23 086515 4 VALVE SPRING KEEPER 53 077158 1 OIL SCREEN PICKUP ASSEMBLY 24 086516 1 EXHAUST VALVE 54 076329 1 OIL FILL PLUG 25 086517 1 INTAKE VALVE 55 0E0057 1 RING 26 089673 2 WASHER VALVE SPRING 56 093064 1 OIL FILL CAP ASSEMBLY 27 004391 2 VALVE SPRING 28 0A9877 1 CAMSHAFT ASSEMBLY 49 LISTS Section 6 Exploded Views and Parts Lists BN Recreational Vehicle Generator Engine Accessories Drawing No 0F1135 E 50 LISTS Recreational Vehicle Generator Engine Accessories Drawing No 0F1135 E OG Section 6 Exploded Views and Parts Lists ee ITEM PART TY DESCRIPTION 1 0 6532 1 MANIFOLD INTAKE 2 091039 1 GASKET MANIFOL
14. 120V SW1 SWITCH START STOP EM SW2 SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL P i 304 TERMINAL CONN 4 TAB E r CONNECTOR NEUTRAL CONNECTION BY CUSTOMER 38 gt 39 WI 2 0 ds F lt QE ZZ __________________ oa 1 3118 023 1 1 3 01 09 912 239918 var NDILOINNDI aiu NULLO3NND2 OV CWNDI LAO a3401sno9 T 7F 7T 7 91W 31713 s8 51 vl ailtm N3335 Tl 81 s 2v18 I 269 SISS ens Pd S 2s u ju go S co r3 183 81 GI SI vl Z a 5 ee 5 sa i slas Dat aa vel YOLIBNNOI e vi vt H2 olss TaNvd ut vl 312 5 awaa 2 NS 119 s3 8l 5 10 40 0 0 at 0 gt 140 AO 30 30 4 A3NOS 91 z GI 99 2 55 11 i s Ta di 99
15. gt 15 14 4 gt 18A IM SP J1 5 m Ji 6 17 ieu START SW1 08 1 7 2 17 dona STOP 2 8 HTO J1 9 4 2 85 0 JI 10 66 1 Te J1 11 gt 85 85 4 0 1 12 0 JI 132 66 REMOTE J1 14 18 4 PANEL J1I 15 18 17 CONNECTOR 01 1 1 17 2 2 14 14 3 3 18 4 4 6 66 15 gt REMOTE PANEL qm S SOPTIONAL gt ES Bid eb EMEN ERE e Ma auc ET uie BATTERY CHARGE WINDING lt 1 1 O 55 START l l R1 ON POWER WINDING 33 44 ON ees 11 i LEGEND 22P BATTERY CHARGE RECTIFIER 11 1 CIRCUIT BREAKER 30 ELECTRONIC 2 CIRCUIT BREAKER 20A VOLTAGE CB3 CIRCUIT BREAKER 2 54 ise GUL ATT 9 CHOKE HEATER GASOLINE MODELS ONLY oi Bem CS CHOKE SOLENOID lt GASOLINE MODELS ONLY gt P ES EVAP SOLENOID GASOLINE FIELD KIT FOR CA TRAILERS F1 FUSE 15 2A ji 4 FUEL PUMP DR LPG SHUT OFF VALVE BLACK GT TERMINAL GROUND 4 CB3 1 HM METER HOUR OPTIONAL ON 9 4 1 HTO SWITCH HIGH TEMP CLOSES ON HIGH TEMP 2 6 IM IGNITION MAGNET n Li LIGHT RUN COPTIONA Cop SWITCH LUW DIL PRESSURE CLOSES ON LOW PRESSURED a DPE WINDING PCB ENGINE CONTROLLER RESISTOR 1 OHM 25W d OF SO OF 4 SC STARTER CONTACTOR ie FIELD BLACK RED SM STARTER MOTOR
16. 090892 091159 091160 091161 049821 086999 0A8584 075281 001085 043182 070185 0 9649 082774 002308 041658 090388 075474 001624 004373 2 5 FT FN 3 E NS eX IN IAS ee ae Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Engine Sheet Metal Drawing No 0D1760 J DESCRIPTION SCROLL FLYWHEEL SCREW TAPTITE M6 1 0 X 10MM FOAM TAPE FLYWHEEL WASHER BELLVILLE M20 X 2 2 NUT M20 X 1 5 FLYWHEEL 3 8 SPECIAL LOCK WASHER SCREW CRIMPTITE 10 24 X 0 5 COVER TOP FLYWHEEL DEFLECTOR EXHAUST PORT ASSEMBLY IGNITION COIL NO ADV V410 RV SCREW TAPTITE M6 1 0 X 25MM GROMMET RUBBER BOOT SPARK PLUG PLUG BUTTON 34 GROMMET RUBBER LOCK WASHER M8 NUT HEX M6 1 0 CAPSCR HEX HD M8 1 25 X 40MM SCREW TAPTITE 3 8 16 X 0 75 ASSY STARTER MOTOR SOCKET HD CAPSCR M8 1 25 X 45MM PLUG BUTTON 1 1 16 ASSEMBLY DIPSTICK amp CAP OIL DRAIN DIPSTICK TUBE OIL DRAIN HOSE ASSEMBLY PIPE NIPPLE 3 8 X 8 LG BRASS STREET ELBOW 3 6 FLAT WASHER 1 4 M6 WRAPPER ENGINE SPARK PLUG WRAPPER STARTER SIDE WRAPPER REAR GEAR CASE WRAPPER CARB SIDE ASSEMBLY WIRE STARTER 16 SUPPORT OIL FILTER BUSHING RUBBER WASHER RUBBER BOLT SHOULDER M6 1 0 X 15MM BOLT SOCKET HD CAPSCR M8 1 25 X 30MM GASKET OIL FILTER
17. 1 1 1 3 4 1 2 1 2 4 4 2 2 LOWER BEARING CARRIER ROTOR ASSEM STATOR ASSEM BALL BEARING BALL BEARING UPPER BEARING CARRIER STUD STATOR M8 1 25 FLANGE LOCK NUT BRUSH HOLDER M5 0 8 X 16 LG TAPTITE SPECIAL LOCK WASHER M5 GENERATOR TOP HOUSING RESISTOR1R 5 25 WLVG v4 M6 FLAT WASHER 74 M6 LOCK WASHER M6 1 0 X 70 LG CAPSCREW GROUND CABLE SPECIAL LOCK WASHER M6 M6 1 0 X 20 LG TAPTITE CONTROLLER PC B DECAL UNIT 5 16 M8 LOCK WASHER NYLON WASHER PANEL SHEET METAL 4 PIN CONNECTOR CONDUIT ASSEMBLY ASSEMBLY REMOTE CABLE M5 08 X 110 LG PPHMS SPACER PLASTIC 4 0 7 X 16 LG CAPSCREW 8 M4 LOCK WASHER BATTERY CHARGE RECTIFIER M3 0 5 X 12 LG PPHMS PANEL SUPPORT BRACKET M5 0 8 X 30 LG CAPSCREW VIBRATION MOUNT M6 1 0 HEX NUT M5 08 X 25 LG HEX HD CAPSCR M3 LOCK WASHER Alternator amp Panel PARTS LISTS ITEM PART NO QTY DESCRIPTION 40 045771 4 HEX NUT M8 41 053623 1 C BREAKER 2 5A ON 42 0234845 1 BUSHING 43 0F9719 1 REGULATOR VOLIAGE 44 022152 5 LOCKWASHER 10 45 051716 3 5 0 8 HEX NUT 46 090144 1 C BREAKER 20 47 090145 1 C BREAKER 30 48 025105 4 6 32 SCREW W LOCK WASHER 49 086315 1 PANEL COVER 086315A 1 PANEL COVER EVAP 05754 ONLY 50 090734 4 4 0 7 X 12 LG CAPSCR W LOCK WASHER amp FLAT WASHER 51 022985 1 6 FLAT WASHER 92 032300 1 FUSE HOLDER 53 022676 1 FUSE AGC 15A 54 087798 1 SWITCH S PD T START STOP 55 092113 1
18. Generator OG Drawing No 001759 TY DESCRIPTION 1 2 1 1 1 1 2 5 3 1 1 4 1 1 6 IN 1 2 2 3 2 1 2 2 5 1 1 7 1 2 2 2 2 1 1 1 2 CABLE BATTERY 3 8 SPECIAL LOCK WASHER FUEL PUMP FUEL FILTER FITTING 1 8 PIPE TO 1 4 TUBE FUEL TUBE METAL CAPSCR HEX HD M6 1 0 X 16 FLAT WASHER M8 5 16 FLAT WASHER 10 GASKET BLOWER HSNG EXHAUST PIPE GASKET WASHER SPRING RETAINER BOOT STARTER CONTACTOR EXHAUST COVER PLATE HOSE FUEL PAN SLIDE SPECIAL LOCK WASHER 1 CAPSCR HEX HD 3 8 16 X 3 4 SPECIAL LOCK WASHER M5 SCREW TAPTITE M6 1 0 X 10 LG FLAT WASHER M10 CLAMP HOSE NUT FLANGE 5 16 18 SPECIAL SCREW 5 0 8 X 16 LG STARTER CONTACTOR GASKET BLOWER HSNG HHS 10 32 X 9 16 LG TAP R STARTER CABLE HEX NUT 5 16 24 BOOT STARTER CONTACTOR LOCK WASHER M4 HEX NUT 10 32 PLATE BLOWER SIDE GASKET BLOWER SIDE FLAT WASHER 1 4 SCREW SWAGE 1 4 28 X 1 2 41 CG Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 0 Base and Pulleys Model 04164 3 Drawing No 0F1124 D 7 8 9 10 D 30 4 39 42 ITEM PART NO 1 0F1126 2 048031M 3 0F7065 4 022145 5 022129 6 045771 7 066849 8 022473 9 062684 10 0A8475 11 077603 12 002368 13 051730 14 029459 15 075215 16 052858 17 073146 18 075209 19 075242 20 075237 21 0A6479 22 046911 23 025017 2
19. RNS RR 5555506 666666656 5 20 555055956660 A RORIS 22 d 100 SQUARE INCHES UNRESTRICTED MINIMUM OPENINGS 06 2 e lt Xx 5 0 2255 2 lt SK 2 e 500 060 SERRE ARRA A ORNARI RRS xx SS QU 9506560 22 0 29 2 2 2 2 x 0 M 5 S NS i xx ut XC xx 5 0 ane 2 9 50 e d 5 5 A 50 22 10 S 25555005 5 559550 22555950 25 MNA MAGN 255550 MM 50505 255050055 55900 ie 2 5 fe 2 Xo sents XX XX 55 XX M 222 d 2 56 55 25 5 T 26 NOTE Screening louvers or expanded metal that cover air open ings restrict airflow Compensate for this by making the actual air opening proportionately larger See the Compensating for Restrictions section NOTE Be sure to meet the minimum clearances illustrated in Figure 2 4 When the unit is installed on a suspended mounting system one of several different methods of supplying airflow may be used as follows Provide a door in the vehicle skirt having an air inlet opening Figure 2 11 Figure 2 11 Suspended Mount Inlet Door Using ductwork Figure 2 12 The ins
20. SWITCH S PD T FUEL PUMP 56 075210A 1 TERMINAL BLOCK 57 0 8475 1 SPECIAL LOCK WASHER 4 58 051715 1 M4 0 7 HEX NUT 59 090157 1 DECAL CB RATING 30 60 090156 1 DECAL CB RATING 20 61 074908 2 5 0 8 X 10 LONG TAPTITE 62 031791 1 CLAMP HOSE 63 023897 2 10 MS FLAT WASHER 64 0D2724 2 ROCKER SWITCH 65 031879 2 WASHER FLAT 4 66 049815 1 HHCS 5 0 8 X 16 67 060247 1 SOLENOID LP NG DC12V 68 007457 1 BARBED EL 90 1 4 NPT X 5 16 69 0G9319 1 WIRE ASSY NOT SHOWN 70 069598 1 BULKHEAD ADAPTER 71 035579 1 BUSHING REDUCER HEX 1 4 TO 1 8 NPT 72 035578 1 NIPPLE PIPE 1 8 X 3 4 73 028740 1 BARBED EL 90 1 8 NPT X 1 4 53 NOTES 54 Section 7 Notes Section 7 Notes NOTES 55 Section 8 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 emis sion control system on your engine for the periods of time listed below provided there has
21. 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 explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery Discharge static electricity 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 Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery Disconnect any charging source prior to connecting or disconnecting battery terminals and Do not use any jumper cables or booster battery to crank and start the generator engine If any battery has discharged remove it for recharging MAINTENANCE Section 3 Maintenance Recreational Vehicle Generator WARNING amp Do not open or mutilate the battery Released electrolyte has been known to be harmtul 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 followin
22. WNOlLd 905 L2Vd3Wleld 21 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator 2 1 LOCATION AND SUPPORT 211 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 reinforce Many recreational vehicles have been factory equipped with an area for the generator set Some vehicles may even have a genera tor compartment provided by the vehicle manufacturer Plan the generator location based on the following The generator set must be installed on a framework that is part of the recreational vehicle as outlined in the Generator 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 underneath the supporting framework The location must provide easy access to frequently serviced components such as filters oil drains spark plugs and other common maintenance parts The location must provide sufficient room to allow minimum clearances as outlined in the Generator Compartment section If sound insulation is to be used on the compartment walls and ceiling the minimum recommended applies to the space between the generator and such insulation The location must provide adequate cooling and ventilating airflow for the
23. applicable exhaust emission levels This generator is certified for use as a mobile engine It is important that you follow the mainte nance specifications listed in this manual to ensure that the engine complies with emission standards for the duration of its life This engine is certified to operate on gasoline The emission control system on the generator consists of the following Fuel Metering System Carburetor assembly Fuel pump and lines Air Induction System Intake pipe manifold Air cleaner Ignition System Spark plug Ignition module Catalytic Converter if equipped Section 1 General Information Recreational Vehicle Generator GENERAL INFORMATION The Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal and California emission requirements See the table below to determine the com pliance period for this generator The displacement of the engine is listed on the Emissions Compliance Label gt 66c0 lt 225ec 250 Hours 1000 Hours 500 Hours 250 Hours gt 225 1 8 EXHAUST EMISSIONS INFORMATION PROPANE The Environmental Protection Agency EPA and the California Air Resource Board CARB require that this generator comply with exhaust emission standards The generator is certified to meet all applicable exhaust emission levels This generator is certif
24. 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 during 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 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 unapproved modifications or the use of counte
25. does not specifically recommend must first completely satisfy themselves that their safety the safety of the vehicle s occupants and the product s safety is not endangered by the method proce dure or technique selected Information illustrations specifications etc contained in these Installation Instructions are based on the latest information avail able at the time of publication Every effort has been expended to be sure that such data is both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time without prior notice DIE A Despite the safe design of this generator operating this equipment imprudently neglect ing its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment A 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 N Generator exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and maintenance of this equipment
26. generator without a great deal of work and expense 2 1 2 GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been 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 tubing OR b 1 1 2 inch 11 gauge angle iron A typical supporting frame with horizontal support tubing is shown in Figure 2 1 The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the generator below the horizontal support tubing by means of suitable structurally sound metal framework The fol lowing general rules apply Vehicle construction MUST be capable of supporting the weight of the generator Whether the generator is mounted above the horizontal support tubing or suspended below the tubing the supporting frame used must be structurally sound If the generator cannot be bolted directly to the supporting frame or support tubing consider using additional tubing angle brackets or other supports to give the supporting frame sufficient strength 22 Figure 2 1 Typical Horizontal Support Frame SUPPORT TUBING 2 1 3 SUSPENDED MOUNTING If the generator will be suspended below the horizontal suppo
27. manufacturer recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of overheating enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate NOTE The installation must be tested especially if air is brought in from below the generator set 2 4 GASOLINE FUEL SYSTEM The installation of a gasoline fuel system Figure 2 14 for a recreational vehicle generator set must comply with applicable codes standards and regulations The entire fuel system must be completely free of leaks There must be no possibility of gasoline vapors entering the vehicle interior INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator Figure 2 14 Generator Fuel System FUEL LINE FUEL PUMP FUEL FILTER Dd A Gasoline is highly flammable and its vapors 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 fu
28. 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 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 1 Fuel Metering System 1 1 Gasoline carburetor assembly and its internal components if so equipped a Fuel filter if so equipped Ignition System including b Carburetor gaskets Spark plug 2 Air Induction System including a b 3 a c Fuel pump if so equipped b Ignition module 4 a b 9 a Intake pipe manifold Air cleaner 1 2 LPG carburetion assembly and its Catalytic Muffler Assembly if so equipped including internal components if so equipped Muffler gasket Exhaust manifold Crankcase Breather Assembly including Breather connection tube a Fuel controller if so equipped b Mixer and its gaskets if so equipped c Carburetor and its gaskets if so equipped d Primary gas regulator if so equipped LP liquid vaporizer if so equipped 57 Section 8 Warranty WARRANTY Recrea
29. of the Manual 1 2 Salos 1 3 Standards Booklets 14 Equipment Description 1 5 Generator Engine Operating 5 20 1 6 Generator AC Connection 20 Section 2 Installation 22 2 1 Location and Support 22 2 2 Generator 23 2 3 Cooling and Ventilating Air 8 25 24 Gasoline Fuel 27 25 LP Gas Fuel System sse 28 2 0 EXHAUST asc ger rit eerte e 30 27 Electrical Connections reete 31 28 Battery Installation eee 32 2 9 Optional Accessories 444241 4 34 Section 3 Post installation Start up Adjustments 34 3 1 Post Installation Tests cse 34 3 2 Before Initial Start up 3 8 Initial 3 4 Testing Under Load 3 5 Installation Checklist Section 4 Troubleshooting 37 Troubleshooting 2 37 Section 5 Electrical 38 Section 6 Exploded Views and Parts Lists 40 Section 7 Notes 54 Section 8 Warranty
30. operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workman ship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and acces sories HOW OBTAIN SERVICE When the generator requires servicing or repairs 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 about parts and service always supply the complete model number and serial number of the unit as given on its data decal which is located on the generator Model No Serial No AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 or locate us on the web at www generac com Part Owner s Manual Introduction Inside Front Cover Read This Manual Thoroughly
31. out or side out exhaust systems Use the cover plate pro vided with the generator to cover the opening NOT used 2 6 3 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any combustible material such as wood felt cotton organic fibers or other like material If the 3 inch 76 mm clearance cannot be maintained locate insu late or shield the exhaust part s so that the temperature of any combustible material is not raised more than 117 F 65 C above the ambient air temperature Extend 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 recircu lated If there is any possibility of the tailpipe or muffler being dam aged protect these damage prone areas by means of a protec tive device such as a skid bar Install the generator exhaust system according to safe automo tive practices Use enough exhaust system hangers to prevent any part of the system from being dislocated Use exhaust system parts recommended by the manufacturer Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person s installing such unauthor ized parts Do not terminate the exhaust system under any opening win dow or vent that can be opened or is not permanent
32. s fuel tank 2 44 COOLING AND VENTILATING AIR Air inlet and outlet openings in the generator compartment must be open and unobstructed for continued proper operation Without sufficient cooling and ventilating airflow the engine generator quickly overheats which causes it to shut down and may damage the generator 2 45 ENGINE EXHAUST GAS Before starting the generator engine be sure there is no way for Before starting the generator engine inspect for exhaust leaks and ensure there is no way for exhaust gases to enter the vehicle inte rior and endanger people or animals Close windows doors and other openings in the vehicle that if open might permit exhaust gases to enter the vehicle Section 2 Operation OPERATION Recreational Vehicle Generator Dd A AN Generator engine exhaust contains DEADLY carbon Monoxide an odorless colorless poi sonous gas Breathing carbon monoxide can cause dizziness throbbing temples nausea muscular twitching headache vomiting weak ness and sleepiness inability to think clearly fainting unconsciousness or even death If you experience any carbon monoxide poisoning symptoms move into fresh air and immediately seek medical attention Never operate the generator set with the vehicle inside any garage or other enclosed area Adequate unobstructed flow of cooling and ventilating air is critical for expelling toxic car bon monoxide gas and fuel vapors fro
33. 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 warrantable 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
34. the paper filter MAINTENANCE Section 3 Maintenance Recreational Vehicle Generator 8 Installthe cover foam precleaner and paper filter 9 Tighten the two screws to retain the filter in place Figure 3 2 Engine Air Cleaner PAPER AIR FILTER FOAM PRECLEANER AIR CLEANER COVER SCREWS 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 filter 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 1 Follow steps 1 3 in the Cleaning the Foam Precleaner sec tion 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 filter properly 4 Clean the air cleaner cover then reassemble following steps 7 9 in the Cleaning the Foam Precleaner section 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 neces sary Inspect the area around the generator exhaust muffler periodically and remove all grass leaves dirt etc from this area Figure 3 3 Cleaning Air Intake CLEAN THESE AREAS MAINTENANCE
35. vet s s vy 2 5 LL C 82 S A 0 0 e gt 81 091 17 P 1 S 92 91 0 81 17 0 al Ir z 06 I I o 99 O 01 17 v v Oo 6 1 DNI3V38 OL 1535 o8 tr ZI 11 40 9 1 sr O S Ir v8T 0 O Ir 522 ve 06 O 2 1 9S O T Ir vi C r SI ct er 0 9S 9i va I WS 501970934 9991 IDA v 910415373 9 y 0 225 ANBLLVE if 1 2 3I1ddnS el 1 2 Gdridans PARTS dab LISTS o 40 TO ENGINE Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Base and Pulleys Model 05754 0 Drawing No 0D1759 E ITEM PART NO 1 002368 2 053407 3 046911 4 025017 5 022237 6 022129 7 0A6479 8 077603 9 022259 10 052858 11 051730 12 029459 13 075215 14 073146 15 075209 16 0A8341 17 090239 18 040976 19 0A6858 20 0A8614 21 075224B 22 073106B 23 075216 24 049451 25 042633 26 039253 27 0A8250 28 056893 29 0A8615 30 001320 31 063036 32 0A8694 33 0A8726 34 075242 Section 6
36. wattage rating of the bulb If a load does not show its rated wattage multiply that load s rated VOLTS times AMPS to obtain WATTS Induction type motors such as those that run the vehicle s furnace fan refrigerator air conditioner etc need about 2 1 2 time more watts of power for starting than for running for a few seconds during motor starting Be sure to allow for this when connecting electrical loads to the generator First figure the watts needed to start electric motors in the system To that figure add the running wattages of other items that will be oper ated by the generator Do not apply heavy electrical loads for the first two or three hours of operation 2 9 PROTECTION SYSTEMS 2 9 LOW OIL PRESSURE SWITCH This switch Figure 2 4 has normally closed N C contacts that are held open by engine oil pressure during 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 2 9 2 HIGH TEMPERATURE SWITCH This switch Figure 2 4 which has normally open N O contacts is mounted near the oil filter The contacts close if the temperature should exceed approximately 293 F 145 C initiating an engine shutdown Figure 2 4 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE ENGINE OIL PRESSURE FILTER
37. 00 53 022676 54 087798 55 092113 56 075210A 57 0 8475 58 051715 59 090157 60 090156 61 074908 62 031791 63 023897 64 002724 65 031879 66 049815 OH SH BPP BP PARTS TY DESCRIPTION M5 0 8 X 30 LG CAPSCREW VIBRATION MOUNT M6 1 0 HEX NUT 5 08 X 25 LG HEX HD CAPSCR M3 LOCK WASHER HEX NUT M8 C BREAKER 2 5A ON BUSHING REGULATOR VOLTAGE LOCKWASHER 10 M5 0 8 HEX NUT C BREAKER 20A C BREAKER 30A 6 32 SCREW W LOCK WASHER PANEL COVER M4 0 7 X 12 LG CAPSCR W LOCK WASHER amp FLAT WASHER 6 FLAT WASHER FUSE HOLDER FUSE 15 SWITCH S PD T START STOP SWITCH S PD T FUEL PUMP TERMINAL BLOCK SPECIAL LOCK WASHER 4 M4 0 7 HEX NUT DECAL CB RATING 30A DECAL CB RATING 20A M5 0 8 X 10 LONG TAPTITE CLAMP HOSE 10 M5 FLAT WASHER BOOT ROCKER SWITCH WASHER FLAT 4 HHCS M5 0 8 X 16 45 LISTS Section 6 Exploded Views and Parts Lists BN Recreational Vehicle Generator Engine Sheet Metal Drawing No 0D1760 J D 449 e 7 d Im KI MEA s 46 0 4323 045756 029289 091222DSRV 067198N 067890 0A4456 056893 0A6358 091646 063279 063111 022717A 073132 061669 089685 022129 049813 057821 059637 0D9004A 059985 025034 048875 047299 049539 047838 038593 022473 0 6357 0 6360 0A6489 0A6359 0742600131
38. 07 63 0A4456 64 0 9193 65 042110 66 002824 NIP m3 ppp Hw BH l la Q9 la la la la la 2 2a Qn PARTS LISTS TY DESCRIPTION SCREW CRIMPTITE 10 24 X 1 2 GASKET BLOWER SIDE PLATE BLOWER SIDE SCREW HHC M8 1 25 X 20MM HOUSING BLOWER GASKET BLOWER HOUSING GASKET BLOWER HOUSING GASKET BLOWER PAN CAPSCR HEX HD 3 8 24 X 2 WASHER FLAT 3 8 M10 PULLEY ENGINE WASHER FLAT 10 GASKET COLLECTOR PAN SCREW HHC 3 8 24 X 1 BELT POLY V 4L 40 WASHER PULLEY RETAINER PULLEY ALT SCREEN SLIDE PAN SCREW CRIMPTITE 8 18 X 1 4 PAN SLIDE STARTER CONTACTOR WASHER LOCK 10 NUT HEX 10 32 BOOT STARTER CONTACTOR STARTER CABLE NUT HEX 5 16 24 BOOT BATTERY CABLE SCREW HHC 3 8 16 X 3 4 GROUND CABLE WASHER LOCK SPECIAL 3 8 BRACKET LP REGULATOR SCREW SWAGE 1 4 28 X 1 2 SCREW 10 32 X 9 16 43 Exploded Views and Parts Lists Alternator and Panel Model 04164 3 Drawing No 0D1776 J Recreational Vehicle Generator Section 6 LISTS PARTS 0 q Ac 20 32 31 44 ITEM PART NO IND mE L gt PO n2 n5 rS gt O gt CO n5 cO co 4 CO C5
39. 4 022237 25 022259 26 081105 27 0A8614 28 090239 29 040976 30 0A8341 31 077643 32 090859 33 079246 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Base and Pulleys Model 04164 3 Drawing No 0F1124 D TY DESCRIPTION 1 Po po t FS O O5 FS O FS rS r ASSEMBLY REGULATOR 8 HOSE CLAMP HOSE 1 2 1 0 PETROLEOM WASHER FLAT 5 16 8 WASHER LOCK 8 5 16 NUT HEX M8 1 25 SCREW TAPTITE M5 0 8 X 16MM LONG WASHER FLAT 1 4 GROUNDING LUG LOCK WASHER SPECIAL 410 SAFETY BOLT SCREW HHC 5 16 18 X 3 5 BASE MOUNTING SCREW HHC 8 1 25 X 60MM SPRING BELT TENSION WASHER SPRING CENTER NUT TOP LOCK FL M8 1 25 SLIDE NYLON SUPPORT NYLON SLIDE SPRING GENERATOR MOUNT WASHER SPRING RETAINER SKID RUBBER MOUNT MOUNT RUBBER SCREW HHC 3 8 16 X 1 2 WASHER LOCK 3 8 NUT HEX 5 16 18 NUT FLANGE 5 16 18 SKID RUBBER MOUNT GASKET EXHAUST MANIFOLD SCREW SHC M8 1 25 X 20MM MANIFOLD EXHAUST EXHAUST PIPE GASKET EXHAUST COVER PLATE SCREW HHC M6 1 0 X 16MM W LOCK WASHER ITEM PART NO 34 056893 35 048407 36 048531 37 039253 38 001320 39 048010 40 0 8010 41 0 8726 42 0 8250 43 022131 44 075224 45 023897 46 0A6858 47 042633 48 075216 49 049451 50 073106B 51 0A8694 52 063036 53 0A8594 54 001227 55 022152 56 022158 57 001741 58 0742600131 59 024114 60 075763A 61 023152 62 0534
40. ATA DECAL or information decal 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage i Model 05754 0 SSS 1 Generator Air Intake 2 Engine Start Stop Switch 3 Fuse 4 Optional Remote Panel Receptacle en 6 7 8 9 10 11 12 13 14 15 16 17 18 19 behind control panel Generator AC Output Leads behind control panel Fuel Primer Switch Circuit Breaker Circuit Breaker Starter Contactor Fuel Inlet Fuel Pump Fuel Filter Oil Filter Oil Drain Cap Oil Dipstick Data Decal Oil Fill Spark Plug External Vacuum Port i 04164 3 4 CENA Hor 6 15 UU MEE 8 ra lo 8 9 y 10 7 11 12 g E 13 14 Wi 15 16 9 13 12 10 17 1 2 3 4 Generator Air Intake Engine Start Stop Switch Fuse Optional Remote Panel Receptacle behind control panel Generator AC Output Leads behind control panel Fuel Primer Switch Circuit Breaker Circuit Breaker Starter Contactor Fuel Solenoid Demand Regulator Oil Filter Oil Drain Cap Oil Dipstick Data Decal Oil Fill Spark Plug 1 2 GENERATOR APPLICABILITY These generators have been designed and manufactured for sup plying electrical power for recreational vehicles Do not modify the generator or use it for any applica
41. ATIONS 1 5 1 FUEL REQUIREMENTS This generator is equipped with a gasoline fuel system 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 gen erator 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 quality UNLEADED gasoline with the generator Leaded REGULAR grade gasoline is an acceptable substitute NOTE Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits Section 1 General Information Recreational Vehicle Generator caution Ak AA 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 contain ing methanol If using gasoline with alcohol inspect more frequently for fuel leaks and other abnormalities 1 5 2 OPTIONAL PROPANE FUEL SYSTEM This generator is equipped with a liquid propane LP gas fuel sys tem LP gas is usually supplied as a liquid in pressure tanks The generator requires a vap
42. D HEAD 3 051753 1 HHCS M6 1 0 X 40MM 4 0 7585 1 SPARK PLUG CHAMP 5 089228 1 GASKET CARB MANIFOLD 6 0A7336B 1 CARBURETOR GN 410 L P 0 6562 1 CARBURETOR GN410 GAS 7 090970 1 GASKET CARB AIR FILTER 8 0A7660 1 ASSY AIR CLEANER VALVE 0A7660A 1 ASSY AIR CLEANER VALVE W EVAP 02010 3 amp 05754 ONLY 9 056893 3 CRIMPTITE 10 24 X 1 2 10 0A6566 1 DETENT 11 046780 1 SPRING A L BELLCRANK CARB 12 096290 2 STUD CARB MOUNT 90 LG 13 073111 1 FILTER AIR 14 15 0 6563 1 COVER AIR FILTER 16 003633 2 KNOB AIR CLEANER 17 0A6581A 1 BREATHER TUBE 18 002332 1 DECAL AIRBOX QP55 19 092164 1 ASSEMBLY GOV SPRING ADI BRACKET 20 082025 1 NUT HEX LOCK 5 0 8 NYLON 21 0A7029 1 NYLON WASHER 31 X 26 X 13 22 0A6913 1 ROD LINKAGE GOV LEVER BELLCRANK 23 091161 1 BOLT SHOULDER M6 1 0 X 15MM 24 049813 2 NUT M6 1 0 25 092586 2 WASHER FELT 26 083512 2 TAPTITE M8 1 25 X 16MM 27 0A6778 1 SPRING A L GOV LEVER BELLCRANK 28 0A6785 1 ROD LINKAGE BELLCRANK CARB 29 0A6753 1 BELLCRANK GOV RODS 30 0A8222 1 SPRING GOVERNOR 31 086681 1 NUT GOVERNOR LEVER 32 020753 1 HHCS M6 1 0 X 60MM 33 022473 2 M6 FLAT WASHER 34 022097 4 M6 LOCK WASHER 35 046582 1 TUBE WINTER INLET 36 0A6503 1 GROMMET 1 16 1 1 2 37 0A6569 1 GROMMET AIR IN OUT 38 0A7660 1 VALVE WINTER SUMMER 39 0A6568 1 GROMMET WINTER SUMMER VALVE 40 046567 1 SPRING DETENT 41 091916 1 LEVER GOVERNOR ARM 42 083532 1 BOLT HEX HD WASHER LOCK WASHER M6 1 0 X 30MM 43 072683A 1
43. GENERAC ee Guardian Series Owner s Manual and Installation Instructions Air cooled Recreational Vehicle Generators Model 05754 0 PRIMEPACT 50 Model 04164 3 PRIMEPACT 50LP INTRODUCTION Thank you for purchasing this model manufactured by Generac Power Systems Inc This model is designed and manufactured to supply electrical power for recreational vehicles READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the near est Authorized Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or care lessly Observe them carefully Their definitions are as follows A DIE A After this heading read instructions that if not strictly complied with will result in serious per sonal injury including death warninc amp After this heading read instructions that if not strictly complied with could result in serious per sonal injury including death caution A After this heading read instructions that if not strictly complied with might result in minor or moderate injury NOTE After this heading read instructions that if not strictly complied with may result in damage to equipme
44. IES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limita tions 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 BOX 297 WHITEWATER WI 53190 Revision 02 05 Part No 0H3468 Revision A 06 26 09 Printed in U S A
45. ION Ps Section 2 Installation Recreational Vehicle Generator 2 1 8 GENERATOR AC CONNECTIONS Generator AC output leads T1 red T2 white and T3 black come out of the generator as shown in Figure 2 17 Leads T1 red and T3 black are hot while T2 white is the grounded neutral lead There is also a green lead that connects to ground in the junction box of the recreational vehicle Figure 2 17 Generator AC Output Leads Line T1 red to T2 white is protected against overload 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 Line T3 black to T2 white also is protected against overload by a 20 amp circuit breaker CB2 Use this line to neutral connection separately to operate similar loads However be sure the total unit load does not exceed the maximum rating of the generator The neutral line T2 white on all units is a grounded neutral caution Do NOT connect electrical loads in excess of any circuit breaker rating or problems with circuit breaker tripping will develop which causes a loss of AC output Also do NOT exceed the genera tor 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 amperag
46. Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 20 Section 1 General Information 1 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to air cooled generators These generators are designed specifically for install ing in recreational vehicles They operate 120 volt single phase 60 Hertz AC electrical loads that require 40 0 amps gasoline or 37 5 amps LP fuel at 120 volts 1 5 GENERATOR ENGINE OPERATING SPEED The generator s revolving field rotor is driven by a single cylinder four cycle engine through a pulley and drive belt arrangement The generator supplies 120 volts AC at 60 Hertz when the rotor is oper ating at 3 600 rpm The drive belt arrangement allows the engine to operate at a lower speed than the rotor 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 STATOR POWER WINDINGS GROUNDED NEUTRAL The AC connection system on all air cooled generators uses a GROUNDED neutral A separate green ground wire is connected to the recreational vehicle s junction box For these units loads connected across T1 red to T2 white MUST NOT exceed 30 amperes or 3 600 watts and loads con nected across T3 black and T2 white MUST NOT exceed 20 amperes or 2 400 watts each at 120 volts The combined load ing of the two breakers shou
47. PLUG 1 8 NPTF 02010 3 ONLY 028414A 1 BARBED STRAIGHT 1 8 NPT X 1 4 05754 0 ONLY 44 0A6239 1 ASSEMBLY CHOKE SOLENOID 02010 3 amp 05754 ONLY 45 0A6584 1 LINKAGE CHOKE 02010 3 amp 05754 ONLY 46 036544 1 PIN COTTER 3 32 X 5 02010 3 amp 05754 ONLY 47 089473 1 ASSEMBLY CHOKE HEATER 02010 3 amp 05754 ONLY 48 0A7094 2 PPHMS 4 40 X 25 02010 3 amp 05754 ONLY 51 Exploded Views and Parts Lists Alternator amp Panel Drawing No 0H3636 A Recreational Vehicle Generator Section 6 LISTS PARTS 0 q Eo a 35 32 31 52 ITEM PART NO made mii cO gt n2 n5 n2 PPS gt gt cO ON orm www CO CO oon 009675 0A5649H 0A5646H 073159 031971 009674 0A6529 052858 066386 066849 0A8475 003818 075234 022473 022097 055816 090141 0A1658 074906 0922340SRV 0H3224 022129 027756 086316 053650 004258 075244 094071 094070 075476 022264 065795 090987 086317A 075235 082737 049813 055440 043182 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Drawing No 0H3636 A TY DESCRIPTION 1 1 1 1 1 1 4 4 1 3 3 1 1 2 5 1 2 2 4 1 1 4 4 1 1 1
48. SUPPORT SWITCH OIL PRESSURE 10 PSI SWITCH OIL TEMPERATURE SCREW PHILIPS PAN MACH M3 0 5 X 8MM LOCK WASHER M3 FILTER OIL ENGINE LONG BLOCK GN410VSRV KEY WOODRUFF 4 X 19 DIA COVER CARB SPECIAL LOCK WASHER M6 TAPTITE M6 1 00 X 12MM BOOT TEMPERATURE SWITCH BOOT OIL PRESSURE SWITCH SPACER ENDFRAME PARTS viia 47 2 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator GN 410 Engine Drawing No 0E9615 B 48 PARTS Section 6 Exploded Views and Parts Lists LISTS Recreational Vehicle Generator GN 410 Engine Drawing No 0E9615 B OG ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 062565 1 RING SET PISTON DIA 90 29 0E3812 2 CRANKSHAFT SEAL 2 0E3221 1 CONNECTING ROD 30 076361 1 THRUST WASHER 3 0E1466 1 PISTON PIN 31 0A5776 1 PRESSURE RELIEF BALL 4 071983 2 PISTON PIN RETAINER 32 0A7811 1 GOVERNOR SPOOL 5 021713B 1 CYLINDER HEAD GASKET 33 078645 1 GOVERNOR RETAINER C RING 6 0A1442 8 FLANGED HEX HD CAPSCREW 34 078691 1 COVER OIL PRESSURE RELIEF M8 1 25 X 42 35 074908 1 M5 0 8 X 10MM TAPTITE 7 021742 4 M10 1 5 X 105MM HHFL 36 0A7975 1 GOVERNOR GEAR ASSEMBLY 8 002751 1 PISTON FLAT TOP DIA 90 COATED 37 0A5771 1 OIL PRESSURE SPRING 9 076701 1 CRANKCASE GASKET 38 0B2104 1 SPRING WASHER 10 045756 2 M6 1 0 X 10 TAPTITE THD 39 0 9667 1 OIL SUMP ASSEMBLY FORMING 40 078658 1 GOVERNOR ARM PIN
49. SWITCH 5 2 0 Section 3 Maintenance Recreational Vehicle Generator 2 9 8 FIELD BOOST The Controller Circuit Board houses a field boost diode and resistor that are not part of the automatic choke circuit These two compo nents are part of a field boost circuit Figure 2 5 During engine cranking only a positive DC battery voltage is delivered through the diode resistor brushes and slip rings and the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Figure 2 5 Field Boost Circuit CONTROLLER IRCUIT CLOSEST 0 BOARD BEARING 0 N FIELD GRND 2 9 4 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 6 controls the generator s AC output voltage This regulator supplies an excitation current to the rotor By regulating the rotor s excitation current the strength of its magnetic field is regulated and in turn the voltage delivered to connected electrical loads is controlled When the AC frequency is 60 Hertz voltage is regulated at 120 volts voltage to frequency ratio is 2 to 1 Figure 2 6 Solid State Voltage Regulator Or j SENSING
50. ain circuit breaker or transfer switch 2 Let generator run at no load for a few minutes to stabilize inter nal 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 11 LETTING THE ENGINE STABILIZE The generator supplies correct rated voltage only at the proper governed speed Some electrical appliances may be extremely sensitive to voltage Incorrect voltages can damage such appli ances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when sufficient power is not available may shorten engine life Never turn ON electrical loads until after the generator engine has started and stabilized at no load 10 28 SUMMER WINTER HEAT RISER SYSTEM Under certain weather conditions it is possible for ice to form in the venturi area of the carburetor This condition can be very dangerous because it can prevent the governor system from func tioning properly which results in a runaway engine The most common weather conditions leading to this problem are temperatures in the range of 25 F to 35 F 4 C to 1 7 C along with high humidity This ice formation also can be attributed to the load being applied during
51. and ventilating air into or out of the compart ment In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise levels Such a compartment might be constructed as follows Figure 2 7 Use 5 8 inch thick or 3 4 inch thick plywood in the compart ment Construct the compartment floor of a double thickness of 5 8 inch or 3 4 inch plywood Line the compartment interior walls and floor as well as the underside of the floor with 26 gauge galvanized steel Vapor seal all compartment seams and joints Over the galvanized steel lining install a combination of acousti cal materials as mentioned in the Sound Insulating Materials section DX A To prevent fire or explosion do not install any insulation or other absorbent materials on the interior or underside of the compartment floor Seal all compartment door edges to prevent noise leakage around the door perimeter Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 inch 25 mm thick fiberglass with a 2 pound density Figure 2 7 Typical Noise Abatement PLYWOOD EXTERIOR 5 8 OR 3 4 THICK SOUND INSOLATION MATERIAL PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION 2 2 5 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items Figure 2 8 E
52. arting a cold engine if it has not been started in more than two weeks this switch must be pressed 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 It is not necessary to press the primer switch for LP units 2 1 2 START STOP SWITCH To crank and start the engine hold this switch in the START posi tion Release the switch when the engine starts To stop an operat ing engine press and hold the switch in the STOP position until the engine shuts off The switch center position is the RUN position 23 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 replaxed use only an identical replacement 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 120 240 volt AC output to the vehicle circuits The generator has one 20 amp breaker and one 30 amp breaker NOTE If the generator has been reconnected for dual voltage AC out put 120 240 volts install line breakers having an amperage rating that is different than that stated in the Generator AC Connection System section The replacement line breakers consist of two separate breakers one 20 amp and one 30 amp with a connect
53. bber base sealant f flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartment s electrical junction box NOTE Flexible metal conduit due to its unique construction is NOT vapor tight along its entire length e Seams and joints of the galvanized steel whether used as a liner or forthe 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 23 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator Figure 2 6 Types of Lock Seams T Tu ACME LOCK FOLD LOCKED STANDING OFF SET DOUBLE LOCK DOUBLE SEAM EL TEN GORDON SEAM LOCK SEAM STANDARD LAP JOINT After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material See the Sound Insulating Materials section DIG A Do not install any flammable material directly above or around the compartment Heat trans ferred through the compartment structure may be sufficient to ignite char o
54. bility of connecting the different power sources to the vehicle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operating Failure to isolate the vehicle circuits from the dockside power supply when the generator is running may result in damage to the generator or serious injury or death to dockside utility power workers due to backfeed of electrical energy In case of accident caused by electric shock immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a rope or board to free the victim from the live conduc tor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury Safety Rules SAFETY RULES Recreational Vehicle Generator A FIRE HAZARDS A 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
55. connected 18 wire 2 Reconnect or close wire continues to run between Start Stop switch and engine control board 3 Open Disconnected 0 wire 3 Reconnect or close wire between Start Stop switch and engine control board 4 Defective engine control board 4 Replace 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 two 2 seconds 5 Generator internal failure 5 Contact an Authorized Service Dealer 37 Section 5 Electrical Data Recreational Vehicle Generator ee ia gt Electrical Schematic and Wiring Diagram Drawing 001754 BATTERY RED BLK sc 13 RED 4 16 e 5 5 Poa Ss T Crete OMCs nae ee 15 15 lt OPTIONAL 1 14 E L Swe sc 0 4 15 K J3 21 1 gt 56 lt X Je Ji 2 2 90 cs 0 e J1 3
56. d DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER 36 Fuel system is properly installed and checked for leaks Fuel system is properly installed and checked for leaks EXHAUST SYSTEM Exhaust system complies with all applicable codes Exhaust system is properly and safely installed ELECTRICAL CONNECTIONS Q 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 Generator is properly bonded to the vehicle D BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Q Cables are clean and tight Q Cables are connected properly Proper ventilation is provided Terminals coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES Q Check that remote start stop panels if used installed properly Check that hourmeter kit if used is installed properly Check that any other options and accessories if used are installed properly POST INSTALLATION TESTS Check that all tests are completed properly Section 4 Troubleshooting TROUBLESHOOTING Recreational Vehicle Generator TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank 1 Fuse blown Replace
57. d 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 section Engine Oil Requirements Check the engine crankcase oil level at least every eight hours of operation or before use To check the engine oil level proceed as follows see Figure 3 1 1 Be sure the generator is as level as possible 2 Remove the dipstick and wipe it dry with a clean lint free cloth 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 dipstick Full mark DO NOT FILL ABOVE THE FULL MARK caution Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 5 Install and tighten the oil fill cap and the dipstick before oper ating the engine 3 2 CHANGING THE ENGINE OIL AND OR OIL FILTER caution Hot oil may ca
58. e capacity 2 1 4 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The following general rules apply Cut wiring to the required length and allow extra wire for junc tion box connections Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation 31 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator Route conduit so it does not interfere with generator move ment f using metallic conduit vapor seal the end of the conduit where it enters the junction box Do this because flexible metal lic conduit is not vaporproof along its entire length 2 7 5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 2 18 An alternate method for isolating different power sources is by using an isolat ing receptacle Figure 2 19 Whichever method is use be certain that both power sources are NOT connected at the same time 276 POWER SUPPLY CORD The power supply cord must comply with all applicable codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected 27 7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code NFPA 70 551 7 requires that ground fault circuit interrupters GFCIs on all external and some internal electrical r
59. ea planned for installa tion of the generator NOT on the generator Route the generator s AC output leads into this junction box through approved flexible conduit This is the point of first termination for generator AC output leads 2 1 2 WIRING Wiring should be of stranded copper to reduce the chance that vibration may cause breakage Wire gauge size should be large enough to handle at least 115 percent of the installed generator s rated maximum current If neutral conductors are used they must be the same size as other leg wires Route power supply conductors from generator AC output leads T1 red T2 white T3 black and the green ground wire through approved flexible conduit to the electrical junction box on the compartment wall If flexible metal conduit is used between the generator and the compartment junction box the conduit end that terminates the compartment junction box must be vapor sealed Flexible metal conduit is NOT vapor tight along its entire length From the junction box route power supply wires through approved conduit to either a double pole double throw transfer switch or b approved isolation receptacle Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being connected to two different power supplies at the same time such as generator and dockside power Conductors must be rated 221 F 105 C or must be of a larger conductor size INSTALLAT
60. eceptacles be installed Contact the manufacturer or dealer for recommendations 2 8 BATTERY INSTALLATION 2 8 1 RECOMMENDED BATTERY Install a battery that meets the following requirements The battery must be a 12 volt automotive type storage bat tery For prevailing ambient temperatures above 32 F 0 C use a battery rated 70 amp hours and capable of delivering 400 cold cranking amperes For prevailing ambient temperatures below 32 F 0 C use a battery rated 95 amp hours and capable of delivering 400 cold cranking amperes NOTE If the battery is to be used to power other vehicle accessories as well as start the generator a battery with a larger capacity may be needed 2 8 2 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes 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 Figure 2 18 Transfer Switch Isolation Method FROM 20 AMP 2ND AIR CONDITIONER HACR BREAKER DOUBLE DOUBLE JUNCTION BOX FLEXIBLE CONDUIT VEHICLE WIRING VEHICLE AC DISTRIBUTION PANEL SWITCHING 30 AMP MAIN BREAKER HACR BREAKERS FOR AIR CONDITIONERS BREAKERS POWER SUPPLY CORD 32 INSTALLATION Ps Section 2 Installation Recreational V
61. ed or if you have experienced carbon monoxide poisoning symptoms during use Shut down the generator and do not operate it until it has been inspected and or repaired Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector Z ELECTRICAL HAZARDS A The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and bar riers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mounting to the vehicle frame or chas sis or by means of an approved bonding conductor DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum If the vehicle electrical circuits can be powered by any other source of electricity such as a dockside power receptacle there must be no possi
62. ehicle Generator Figure 2 19 Installation With Isolation Receptacle BOX FLEXIBLE CONDUIT These generators are rated at about 100 DC amperes of cranking current Select battery cables based on a cable length and b prevail ing ambient temperatures Generally the longer the cable and the colder the weather the larger the cable size must be as shown in the chart CABLE SIZE 2 CABLE LENGTH in Feet meters 0 to 10 0 to 3 11 to 15 3 4 to 4 5 16 to 20 4 5 to 6 For warm weather use No 2 cable up to 20 feet 2 8 3 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or to the lug on the starter contactor Figure 2 20 JUNCTION DOCKSIDE POWER RECEPTACLE C power SUPPLY pemg CORD VEHICLE AC DISTRIBUTION PANEL 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 20 3 Connect cables so the connectors are clean and tight Figure 2 20 Connecting Battery Cables SIDE VIEW OF GENERATOR STARTER CONTACTOR GROUND LUG NEGATIVE CABLE BATTERY 33 POST Section 3 Post installation Start up Adjustments INSTALLATION START UP ADJUSTMENTS Recreational Vehicle Generator 2 8 4 BATTERY COMPARTMENT Insta
63. einstallation 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 043369 and inverter if applicable with regard to the generator Oylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Manifolds Generac RV generators manufactured prior to December 31 1997 DO NOT have a transferable warranty Generac RV generators manufactured after January 1 1998 have a transferable warranty to the second owner ONLY for the remainder of the three year limited warranty Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any warranty service 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 Fa
64. el filter inlet Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines 2 41 FUEL TANK Either the generator must share the vehicle engine s fuel tank or a separate fuel tank must be installed 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 regulations The generator has an evaporative emissions port to evacuate accumulated gasoline vapors when necessary If the generator is to share the vehicle engine s tank separate fuel pickup tubes are required for the engine and the generator The manufacturer recommends that the fuel pickup tube be two to three inches 51 to 76 mm shorter than the vehicle engine s pickup tube This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods caution Do NOT tie the generator fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not run ning generator operation may drain the vehicle engine supply line making it difficult to start the vehicle engine Gasoline generators are equipped with an evaporative emissions vacuum port that may be used in conjunction with a certified fuel system where required by law 27 INSTALLATION Ps
65. empt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a rope or board to free the victim from the live conduc tor If the victim is unconscious apply first aid and get immediate medical help Safety Rules SAFETY RULES Recreational Vehicle Generator Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury A FIRE HAZARDS A For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installation do noth ing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regulations Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining
66. entially 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 AN Generator exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death 18 N GENERAL HAZARDS N For safety reasons the manufacturer recommends that the installation initial start up and maintenance of this equipment is carried out by an Authorized Service Dealer Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement Before performing any maintenance on the generator discon nect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its par
67. er attached to the diaphragm opens a valve to permit gas glow through the carburetor Figure 2 16 LP Gas Carburetion Diagram GAS FLOW POSITIVE 4 PRESSURE R GAS AT LOW PRESSURE ZERO PRESSURE AREA INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator The greater the airflow through the carburetor venturi the lower the pressure at the venturi throat The lower the pressure at the venturi throat the greater the diaphragm movement and the greater the movement of the regulator valve The more the regulator valve opens the greater the gas flow that is proportional to airflow through the generator The following facts about the secondary regulator must be empha sized The regulator must be sensitive to venturi throat pressure changes throughout the operating range The regulator must be properly adjusted so it will stop the flow of gas when the engine is not running no air flow through the carburetor The slightest airflow and vacuum in the venturi throat should move the regulator valve off its seat and permit gas to flow 25 6 FUEL SUPPLY LINES LP gas lines must be accessible but protected against possible damage Do NOT connect electrical wiring to any LP gas fuel line or run wiring alongside the lines Route gas lines away from hot engine exhausts Retain gas lines with metal clamps that do not have sharp edges Install an approved length of flexible
68. erating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mounting to the vehicle frame or chas sis or by means of an approved bonding conductor DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum If the vehicle electrical circuits can be powered by any other source of electricity such as a dockside power receptacle there must be no possibility of connecting the different power sources to the vehicle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operating Failure to isolate the vehicle circuits from the dockside power supply when the generator is running may result in damage to the generator or serious injury or death to dockside utility power workers due to backfeed of electrical energy In case of accident caused by electric shock immediately shut down the source of electrical power If this is not possible att
69. esh air and immediately seek medical attention Never operate the generator set with the vehicle inside any garage or other enclosed area Adequate unobstructed flow of cooling and ventilating air is Critical for expelling toxic carbon monoxide gas and fuel vapors from the generator compartment and for proper genera tor operation Without sufficient cooling airflow deadly carbon monoxide gas can accumulate and the engine generator may quickly overheat causing serious damage to the generator Do not operate the genset in any confined space The exhaust system must be installed in accordance with the genset installation manual Do not alter the installation or permit even partial blockage of ventilation systems as this can seri ously affect the safe and proper operation of the generator Do not operate the generator if the exhaust system is leaking or has been damaged or if you have experienced carbon monoxide poisoning symptoms during use Shut down the generator and do not operate it until it has been inspected and or repaired Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector Z ELECTRICAL HAZARDS A The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and bar riers are in place before op
70. free cloth This will be used later to check the oil level 8 Remove the oil fill cap on the rocker cover and slowly add the proper type and amount of recommended oil see section 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 9 Install and tighten the oil fill cap and the dipstick before oper ating the engine 10 Start the engine and check for leaks 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 Service the foam precleaner more frequently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 2 1 Turn the two screws counterclockwise to loosen 2 Remove the cover foam precleaner and paper filter 3 Remove the foam precleaner from the cover 4 Wash the foam precleaner in liquid detergent and water 5 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 distrib ute oil DO NOT TWIST 7 Install the foam precleaner into the cover followed by
71. fuse 2 Loose corroded or defective x lt Tighten clean or replace battery cables as necessary 3 Defective engine Start Stop 3 Replace Start Stop switch switch 4 Defective starter contactor 4 Replace contactor 5 Defective starter motor 5 Replace starter motor 6 Low or defective battery 6 Charge or replace battery The engine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel pump 2 Replace fuel pump e 3 Open 14 wire from 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 Fuelline 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 Dis
72. g procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek 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 or go to www generac com Make sure to identify the MODEL NUMBER and SERIES 3 11 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement The drive belt and pulleys are warranted for the life of the generator Drive belt tension was properly adjusted before the unit was shipped from the factory If suspecting that the drive belt tension is incorrect contact an Authorized Service Dealer 3 12 EXERCISING THE GENERATOR The manufacturer recommends starting and operating the genera tor at least once every seven days Let the unit run for at least 30 minutes to exercise the engine 15 Section 3 Maintenance MAINTENANCE Recreational Vehicle Ge
73. g includes a use of common hand tools b use of special tools and c use of any tools and or equipment from other suppliers The manufacturer cannot possibly know of and advise the rec reational vehicle trade of all conceivable methods procedures or techniques by which to perform an installation Nor can the manu facturer anticipate every possible hazard that might result from each installation method procedure or technique The manufactur er has not undertaken any such wide evaluation Therefore people who use a method 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 proce dure or technique selected Information illustrations specifications etc contained in these Installation Instructions are based on the latest information avail able at the time of publication Every effort has been expended to be sure that such data is both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time without prior notice A Despite the safe design of this generator operating this equipment imprudently neglect ing its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment Pot
74. g 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 following address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC BOX 297 WHITEWATER WI 53190 Part 1 56 Section 8 Warranty Recreational Vehicle Generator WARRANTY 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 equip ment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subse quent 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
75. he generator engine Also water from one engine can damage the other engine 2 6 1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U S Forest Service Use only mufflers and parts approved by the manufacturer Any person s installing an unapproved muffler an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable for any damage injury or warranty expense that might be caused by such unapproved installation or modification 30 Failure to provide and maintain a spark arrestor may be in violation of the law If this generator is used on any forest covered brush covered or grass covered unimproved land a spark arrestor must be installed The vehicle owner or operator must maintain this device in good condition In the state of California the preceding is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands 2 6 2 TYPE OF EXHAUST SYSTEM Two types of exhaust systems for these generators are available from the manufacturer They include the following e Qut the bottom exhaust system dimensions 15 16 O D model 9742 e Qut the side exhaust system dimensions are 1 1 4 O D 18 gauge model 4172 NOTE No matter what type of exhaust kit best fits the recreational vehicle the mounting base has openings for either bottom
76. hose between the gaseous fuel solenoid valve and rigid fuel supply lines The flexible line must be nonmetallic nonorganic and nonconductive It must be approved for use with LP gas 2 5 7 EXCESS FLOW VALVE LP gas tanks should have an excess flow valve according to NFPA 501C Paragraph 3 4 4 This valve and the gas lines must be carefully sized so the valve will close when a fuel line is severed or broken Consult the Natural LP Gas Association for information and limitations of excess flow valves Manual shutoff valves on the supply tank and elsewhere in the sys tem must be fully open when operating the generator The excess flow valve functions properly only if all valves are fully open 25 8 LEAKAGE TESTS Do not place the generator into service until the gas system has been properly tested for leaks To test the system a separate source of 12 volts DC is needed to open the gaseous fuel solenoid valve The leak test must comply fully with NFPA Paragraph 318 All con nections hoses valve regulators fittings and other fuel system parts must be tested under gas or air pressure of not less than 90 psi 620 kPa while using soap and water or an equivalent solution to check for leaks Other approved methods of testing for leaks may be used if appropriate DO NOT USE ANY FLAME TO TEST FOR LEAKS 29 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator DIG A Gaseous fue
77. ied for use as a mobile engine It is important that you follow the mainte nance specifications listed in this manual to ensure that the engine complies with emission standards for the duration of its life This engine is certified to operate on propane fuel LP The emission control system on the generator consists of the following Fuel Metering System Mixer assembly Fuel regulator and lines Air Induction System Intake pipe manifold Air cleaner Ignition System Spark plug Ignition module Catalytic Converter if equipped The Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal and California emission requirements See the table below to determine the com pliance period for this generator The displacement of the engine is listed on the Emissions Compliance Label Displacement Category Compliance Period 500 Hours 8 250 Hours gt 225 OPERATION Section 2 Operation ix Recreational Vehicle Generator 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 Figure 2 1 Generator Control Panel FUSE MAIN START 15A BREAKER STOP FUEL PRIMER 211 FUEL PRIMER Before st
78. ilures 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 oollision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit war ranty 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 WARRANT
79. ing piece between the breaker handles so that both breakers will operate at the same time If the unit is reconnected for dual voltage it is no longer RVIA listed 2 2 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel Figure 2 2 is available that allows starting and stopping the generator engine conveniently from inside the vehicle The remote panel includes a Start Stop switch hourmeter generator run lamp and a wire harness The Prime switch is not connected it must be used with jumper wire 007666 Figure 2 2 Optional Remote Panel Models 0H3068 STOP PRIME 9 9 Helds Seconde M 2 2 3 AUTOMATIC CHOKE casotine ONLY The engine is equipped with an automatic choke that consists of two main components a choke solenoid and prechoke 2 31 CHOKE SOLENOID During engine cranking Start Stop switch at START a solid state choke module signals the choke solenoid to activate and cycle choke on choke off until the engine starts The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking When the engine starts the choke stops cycling 2 3 2 PRECHOKE The choke system also has a temperature sensitive metal strip that adjusts choke valve angle according to ambient temperatures 1 6 in cold ambient temperatures choke valve closes more Once the engine starts an element heats the tempe
80. is installed in accordance with the manufacturer s instructions and recommendations Following proper installation do noth ing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regulations Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extin guishers 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 combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Gasoline is extremely FLAMMABLE its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws governing the storage and handling of gasoline Fuel lines must be properly installed and fastened and free of leaks There must be no possibility of gasoline vapors entering the vehicle interior It is required that an approved flexible nonconductive fuel line between the generator fuel connection point and rigid f
81. is carried out by an Authorized Service Dealer Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement Before performing any maintenance on the generator discon nect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dan gerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc A ENGINE EXHAUST HAZARDS Generator engine exhaust contains DEADLY carbon monox ide an odorless colorless poisonous gas Breathing carbon monoxide can cause dizziness throbbing temples nausea muscular twitching headache vomiting weakness and sleepi ness inability to think clearly fainting unconsciousness or even death If you experience any carbon monoxide poisoning symptoms move into fr
82. l lines between the tank and the secondary regulator are under a positive pres sure about 11 inches water column Gas pres sure at the outlet side of the secondary regula tor however is a negative pressure and can draw flame inside a line or fitting and cause an explosion 2 6 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used A properly installed exhaust system must be vapor tight quiet and completely safe A A The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concen trations 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 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 Ak AN Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on t
83. ld not exceed 5 500 watts NOTE Do NOT connect loads in excess of circuit breaker ratings om E Oo CSSHONI J 14 11 4 x LATINO 15 9 WDLLDS NI 44 SNUIS 1 IV NOILOANNDO 710 p NOILOSNNOO AN3LIVE 137470 15 3015 o 1 e Z E i 5 LL EJ 9 9 pa OF Ss Nec 0 s VW 3E L89l 92v o s e LT 0 98 9 0 8 2 b 1113 110 224 3sn3 IE Ww 1 3 9312 IY 3SDH Nivad 710 T Figure 1 2 Major Features and Dimensions Drawing 0F1127 A 0299 ID EH 9 mm Y NOLLOANNOO INIT 1303 3 1105 9 g O 1504 WANIYA TYNAILXI 0 saavaa 1109919 e 9 L681 008v asn4 j N3NV312 MIV 2911541 710 a WILSAS 1404 n o 4 105959
84. ll the generator battery in its own vented compartment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compartment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid support ing structure where leaks and spills of battery fluid will not cause damage 2 9 OPTIONAL ACCESSORIES A plug in receptacle Figure 2 21 is provided on the generator set above the muffler enclosure Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit starting and stoping the generator engine from any convenient location inside the vehicle Figure 2 21 Remote Panel Plug in Receptacle CFE NSS Iw LL WOON 7 os we WIRE 18 WIRE 0 STOP d b GROUND WIRE 14 WIREH ENGINE RUN CRANK SIGNAL 2 9 1 REMOTE PANEL MODELS The remote panels mount a rocker type start stop switch a Generator Run advisory lamp and an hourmeter The hourmeter should be used in conjunction with the maintenance operations found in Part 1 of this manual The Prime switch is not connected it must be used with jumper wire 0G7666 e Model 0F0429 includes the remote panel and a 10 foot long 5 wire harness e Model 0F0430 includes the remote panel and a 30 foot long 5 wire harness 34 3 1 POST INSTALLATION TESTS The ai
85. ly sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all appli cable codes standards and regulations 2 7 ELECTRICAL CONNECTIONS Be sure to read the Generator AC Connection System section The following general rules apply to electrical connections in a recreational vehicle Qualified electricians who are familiar with applicable codes standards and regulations should install electrical wiring The wiring should comply with codes standards and regula tions The National Electrical Code NFPA 70 and state and local codes apply Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent damage from road shock Wiring must be of adequate size have approved insulative qualities and be properly supported Conduit and wire openings into the generator compartment if used must be vapor sealed to prevent entry of flammable explosive or poisonous gases into the vehicle 271 ELECTRICAL JUNCTION BOX Install an approved square electrical junction box with a blank cover on the interior or exterior wall of the ar
86. m the generator compartment and for proper genera tor operation Without sufficient cooling airflow deadly carbon monoxide gas can accumulate and the engine generator may quickly overheat causing serious damage to the generator Do not operate the genset in any confined space The exhaust system must be installed in accor dance with the genset installation manual Do not alter the installation or permit even partial blockage of ventilation systems as this can seriously affect the safe and proper operation of the generator Do not operate the generator if the exhaust sys tem is leaking or has been damaged or if you have experienced carbon monoxide poisoning symptoms during use Shut down the generator and do not operate it until it has been inspected and or repaired Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector 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 while other vehicles may use an isolating receptacle Some vehicles may be equipped with a DC converter which allows the generator to power cer tain DC lighting and other DC loads To start the generator from either the generator control panel o
87. nerator S o 3 13 OUT OF SERVICE PROCEDURE 3 13 1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days and it is to be out of service longer than 30 days prepare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 While the engine is still warm from running drain the oil com pletely Refill the crankcase with SAE 10W 30 oil having API classification For Service SF 4 Attach a tag to the engine indicating the viscosity and clas sification of the oil in the crankcase 5 Remove the spark plug and pour two or three tablespoons of clean fresh engine oil into the spark plug threaded openings Reinstall and tighten the spark plug 6 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor 7 Clean and wipe the entire generator 16 3 13 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Check the tag on the engine for oil viscosity and classification Verify that the correct recommended oil is used in the engine see the Engine Oil Requirements section If necessary drain and refill with the proper oil Check the state of the battery Fill all cells of unsealed batteries to the proper level with distilled water DO NOT USE TAP WATER IN THE BATTERY Recharge
88. ngine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts See the Generator Restraint section DIG A Fuel lines and exhaust piping must not penetrate into the vehicle living area INSTALLATION he Section 2 Installation Recreational Vehicle Generator 1 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 available to the generator for cooling ventilat ing and combustion The installer also must provide for a path for exhausting the cooling air to the exterior of a compartment if so equipped Figure 2 8 Compartment Floor Cutout 348 13 77 9 THIS HOLE IS OPTIONAL __ FOR MOUNTING GENERATOR 586 23 17 32 1 37 564 22 2 1 l 213 MOUNTING HOLES 5 PLACES 85 3 47 ee ee n mam m Y 1 263 10 37 85 3 3 117 4 67 96 3 87 178 7 0 1 480 118 9 eB N 211 18 377 EM 1 mi 642 25 37 gt THIS IS THE MINIMUM OPENING NEEDED IN THE COMPARTMENT FLOOR FOR OUTLET AIR
89. nt and or property These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the service are essential to prevent ing 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 per sonal safety and or property of others This symbol points out potential explosion haz ard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator driver is responsible for proper and safe use of the vehicle and its equipment and the safety of all vehicle occupants We strongly recommend that the operator read this manual and thoroughly understand all instructions before using this equipment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for this generator model In addition the latter portion of this manual contains information necessary for the proper installation of these generators OPERATION AND MAINTENANCE It is the
90. operator For assistance in ordering installing and maintaining spark arrestor exhaust mufflers contact the nearest Authorized Service Dealer Exhaust mufflers supplied by the manufacturer are spark arrestor types The manufacturer s exhaust mufflers for recreational vehicle generators do not have a spark arrestor screen but are of the more efficient toroid or swirl type To remove carbon and combus tion deposits from such mufflers remove the plug from the muffler and run the engine for approximately 15 minutes Shut down the engine let the muffler cool and install the plug warninc amp Be sure to reinstall the muffler plug tightly Engine vibration could cause a loose plug to fall out Without the plug in place hot engine exhaust is directed out the opening This hot exhaust depending on the installation could be directed to areas not able to withstand the extreme heat such as wooden floor boards or other flammable material This could result in a fire 3 8 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a
91. or Restraint METAL LINED Y INCH THICK BASE 1 PLYWOOD F TUBULAR METAL SUPPORT FRAME I GRADE 5 BOLTS METAL LINED VEHICLE BOTTOM CHASSIS 2 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compart ment that the installer constructs the compartment MUST meet certain specifications as outlined in the following sections 2 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a minimum clearance of 1 2 inch 13 mm on the front 1 1 2 inches 38 mm on the top and 1 inch 25 mm on the sides and back for air circulation AFTER the compartment has been lined with metal and sound insulation Figure 2 4 NOTE Refer to Figure 1 2 Major Features and Dimensions Figure 2 4 Clearances Plywood Compartment 1 1 2 Clearance on Top 1 Clearance in Back Insulation 2 22 COMPARTMENT CONSTRUCTION The generator compartment should be either constructed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum s low melting point INSTALLATION he Section 2 In
92. or withdrawal type fuel system This type of gaseous fuel system uses the vapors forming above the liq uid fuel in the storage tank Air temperature around the storage tank must be high enough to sustain adequate fuel vaporization In colder climates it may be necessary to use an independent heat source to be sure the fuel sufficiently vaporizes in the storage tank LP gas may consist of propane butane or a mixture of the two gases Propane vaporizes at temperatures as low as 20 F 29 C but butane returns to its liquid state when the temperature drops below about 32 F 0 C For that reason a higher ratio of propane is desired in the gas mixture when temperatures drop below freezing 1 5 3 FUEL CONSUMPTION Model Noload i 2load Fullload Gasoline is in gal h LP is in gal h and cf h 1 5 4 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum Institute API Service Classification SF SG or SH The recom mended 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 1 400 mL or 1 5 U S quarts Do NOT use special additives See Checking the Engine Oil Level and Changing the Engine Oil and or Oil Filter sections for oil level check and fill procedures 15 5 ENGINE OF
93. r from the optional remote panel proceed as follows 1 Turn OFF electrical loads using the means provided in the vehicle such as a main line circuit breaker or transfer switch OPERATION Section 2 Operation ix Recreational Vehicle Generator 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 stabilized and warmed up 2 Ifthe 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 Ak A If the engine does not start after it has been cranking for 15 seconds release the Start Stop switch and try again Holding the switch for longer than 15 seconds can damage the starter motor 4 Letthe engine run at no load for a few minutes to stabilize and warm up 5 ON electrical loads using the means provided such as a main circuit breaker or transfer switch 2 6 STOPPING THE GENERATOR Turn OFF all electrical loads using the means provided such as a m
94. r cooled generator set was factory tested and adjusted It should not be required to adjust the unit any further except under special circumstances warninc amp Do not make any unnecessary adjustments Factory settings are correct for most applica tions When making adjustments however be careful to avoid overspeeding the engine 3 2 BEFORE INITIAL START UP Before starting complete the following 1 Check the engine crankcase oil level and if necessary fill to the dipstick FULL mark cross hatched area with the rec ommended oil Do not fill above the FULL mark 2 Check the fuel supply Gas fuel lines must have been properly purged and leak tested in accordance with applicable fuel codes All fuel shutoff valves in the fuel supply lines must be open DIG A 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 per mitted Be sure no gasoline fuel vapors enter the vehicle interior 3 3 INITIAL START When absolutely certain that the unit has been properly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s main circuit breakers to their OFF or open position 2 Refer to Part section Starting the Generator for cranking and starting instructions The engine may require more c
95. r discolor seat cushions fiberboard and other flammable mate rials Use approved nonflammable insulating materials in high temperature areas 2 2 3 SOUND INSULATING MATERIALS Once installers have determined that a compartment is properly constructed and metal lined they can add acoustical material This may include additional sealant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a nonflammable type One excellent insulating material is a 1 inch 25 mm thick fiberglass having a 2 pound density When fiberglass is used its coated side should face toward the compartment interior DIG A Do not install sound insulation or any absorbent material on the compartment floor interior Such materials will become soaked with combustible or explosive vapors and liquids and will become a fire hazard Using a combination of sound insulating materials can often reduce noise more effectively than a single material For example a sheet of lead or visco elastic material along with a layer of other acoustical material is more effective than when a single material is used 24 2 24 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement compartment NOTE Any method used to reduce noise must not adversely affect the flow of cooling
96. rank ing for initial starting since the fuel lines have to be primed use of the primer switch will shorten this time 3 Letthe engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load See the Testing Under Load section Run the unit at least 30 minutes with loads applied 6 Turn off all electrical loads by setting the generator 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 Section 3 Post installation Start up Adjustments NOTE The generator set was thoroughly tested and adjusted at the factory before shipping No additional adjustment should be necessary Only qualified service technicians who have been trained should perform adjustments outlined in this manual 3 4 TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 percent of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling airflow is available Do not allo
97. rature sensitive strip to a normal operating condition opening the choke valve This may take about three minutes in cooler weather 2 4 BEFORE THE ENGINE NOTE Instructions and information in this manual assume the genera tor has been properly installed connected serviced tested and adjusted by a qualified installation technician or installation contractor 2 41 INSTALLATION Generator installation must have been properly completed so it complies with all applicable codes standards and regulations and with the manufacturer s recommendations NOTE Be sure the installation complies with all standards and codes listed in the Standards Booklets section of this manual 2 4 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recom mended oil before starting Refer to the Engine Oil Requirements section and Checking the Engine Oil Level and Changine the Engine Oil and or Oil Filter sections for oil servicing procedures and recommendations Any attempt to crank or start the engine before it hase been properly serviced with the recom mended oil may result in an engine failure 2 43 FUEL SUPPLY The engine must have an adequate supply of proper fuel to oper ate Before starting it check that sufficient fuel is available NOTE Depending on the installation the generator may have either a separate fuel tank or it may share the vehicle engine
98. 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 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 3 9 BATTERY MAINTENANCE All lead acid batteries will discharge when not in use The genera tor battery should be inspected as follows 3 0 1 WEEKLY nspect the battery posts and cables for tightness and corro sion Tighten and clean as necessary Check the battery fluid level of unsealed batteries and if nec essary fill with Distilled Water Only Do not use tap water in batteries 3 9 2 EVERY SIX MONTHS Have the state of charge and condition checked This should be done with an automotive type battery hydrometer NOTE Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precau tions Keep unauthorized personnel away from batteries Damage will result if the battery connections are made in A Do not dispose of the battery in a fire The battery is capable of exploding Stored batteries give off explosive hydrogen gas
99. 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 replaced 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
100. rfeit 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 California and federal law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac 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 service evidence must be presented showin
101. rt tubing the suspension method used with the vehicle frame mem bers 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 generator is adequately protected road test the installation through mud water and slush Figure 2 2 Typical Suspended Mounting System GENERATOR MOUNTING HOLES FOR 3 8 16 BOLTS BOTH SIDES SUPPORT P VEHICLE GENERATOR FRAME SUPPORT FRAME e The installer must make certain that the selected location will permit adequate cooling and ventilating airflow to be supplied 2 1 4 GENERATOR RESTRAINT Use four 3 8 16 hardened steel bolts Grade 5 to fasten the genera tor 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 supporting 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 the Generator Compartment section for the location of the generator mounting holes Figure 2 3 Typical Generat
102. s standards or regulations must take precedence over the manual 1 2 SAFETY Before handling installing operating or servicing this equipment carefully read the Notice to Installer and Safety Rules on pages 18 and 19 Comply with all safety rules to prevent death personal injury or damage to equipment and or property Stress safety to all installers operators and service technicians who work on this equipment 1 3 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The following standards booklets latest revi sion are available from the sources indicated 1 Standard 501C Standard for Recreational Vehicles available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 NFPA 70 NFPA Handbook of the National Electric Code available same as Item 1 3 ANSI C1 1975 and ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI A119 2 NFPA 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 Box 1015 North Highlands CA 95660 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions
103. ssion regulations If this generator is configured such that it shares the primary fuel system of a vehicle in which it is installed reduced certification requirements may apply See the CARB guidance document MAC 05 05 located at http www arb ca gov msprog macs mac0505 mac0505 pdf for further details If this generator is installed such that it uses a dedicated fuel system detailed evaporative emission requirements apply contact a repu table fuel system manufacturer to purchase a complete fuel sys tem certified for use with this generator or consult the California Code of Regulations if you wish to obtain certification on your own See the installation instructions in this manual for connecting fuel system vapor lines to the engine This generator is not legal for sale in the state of California unless all CARB evaporative emission requirements are adhered to and is not legal for sale in any other state unless certified low permeation fuel line is used to supply the generator with gasoline Contact the California Air Resource Board or the Environmental protection agency for further information CARB regulations can be found in 13 CCR 2750 2773 EPA regulations can be found in 40 CFR Part 90 1 7 EXHAUST EMISSIONS INFORMATION GASOLINE The Environmental Protection Agency EPA and the California Air Resource Board CARB require that this generator comply with exhaust emission standards The generator is certified to meet all
104. stallation Recreational Vehicle Generator 1 f the compartment is lined with galvanized steel it may be constructed of any material The manufacturer recommends that the compartment be constructed of 1 2 inch thick plywood not strandboard with the floor made of a double thickness of 1 2 inch plywood with the grain of the wood at cross section for added strength Figure 2 5 Figure 2 5 Typical Compartment Construction l CROSS SECTION VIEW METAL LINING i 1 FIREPROOF 1 EIN RM SOUND INSULATION METAL VAPOR SEALED PLYWOOD AT ALLTIMES METAL LINING f e If constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel seams splices and joints of the compart ment walls unless vapor tight by design should be caulked to prevent poisonous flammable or explosive vapors from entering the vehicle interior NOTE Caulking must be done so that the caulking material 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 living area must be sealed vapor tight with silicone ru
105. taller must be sure air is available to the top of the generator since air inlets are located at the top By providing an opening in the vehicle skirt and space behind the generator for cooling airflow Figure 2 13 Recommended clearance behind the back of the generator is at least 1 2 inch 13 mm Figure 2 12 Air Inlet Using Ductwork ANTI SPLASH BAFFLE V ET oS Ss GENERATOR AIR OUT AIR IN Figure 2 13 Air Inlet in Vehicle Skirt VEHICLE FLOOR VEHICLE SKIRT AIR INLET MINIMUM CLEARANCE 1 1 2 2 3 3 COMPENSATING FOR RESTRICTIONS Such materials as screening louvers or expanded metal can restrict the free flow of air Compensate for this restriction by mak ing the actual air opening proportionately larger Some materials may offer only a 60 percent free air inlet area Other more efficient materials may provide up to a 90 percent free air inlet area The percentage of free air inlet opening is usually available from the material supplier or manufacturer To determine the actual air inlet opening size required divide 100 square inches by the percentage of free air inlet area for the material being used For example If planning to use screening with an 80 percent free air inlet area divide 100 by 0 8 which results in 125 square inches Minimum actual size of air inlet opening in this case is 125 square inches 2 3 4 TESTING THE INSTALLATION The
106. the battery to 100 percent state of charge or if defective replace the battery Clean and wipe the entire generator Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly Turn OFF all electrical loads Add fuel if necessary and then start the engine Allow the unit to warm up thoroughly Apply electrical loads to at least 50 percent of the unit s rated wattage capacity When the engine is thoroughly warmed up shut it down The generator is now ready for service PART Il INSTALLATION INSTRUCTIONS AFETY RULE Safety Rules Recreational Vehicle Generator DANGER For fire safety installation of generator into a recreational vehicle must comply strict AN ly 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 com ply with the manufacturer s instructions and recommendations NOTICE TO INSTALLER These nstallation Instructions have been published by the manu facturer to aid in the installation of the products described in this manual The manufacturer assumes that installation personnel are familiar with the procedures for installing such products or similar products manufactured The manufacturer also assumes that personnel have been trained in the recommended installation procedures for these products and that such trainin
107. these weather conditions Generators running with no load or light loads applied usually have the most problems The Summer Winter Lever Figure 2 3 should be in the WINTER position for ambient temperatures below 40 F 4 4 C and in the SUMMER position for ambient temperatures above 40 F 4 4 C Figure 2 3 Heat Riser System WINTER POSITION SUMMER POSITION ul When the heat riser is in the SUMMER down position Figure 2 2 air is drawn into the air cleaner from the upper intake tube When the heat riser is in the WINTER up position air is drawn from the lower intake tube which is positioned to draw the heated air near the exhaust manifold To prevent carburetor icing the owner operator should physically position the heat riser to the proper position dependent on the temperature 2 8 1 NOT OVERLOAD THE GENERATOR Read the rated wattage amperage capacity of the generator on the generator data decal see Generator Identification Applying electrical loads in excess of the unit s rated capacity will cause the engine generator to automatically shut down To avoid overloading add up the wattage of all connected electrical lighting appliance tool and motor loads This total should not be greater than the generator s rated wattage capacity Most lighting appliance tool and motor loads indicate their required watts on their nameplate or data plate For light bulbs simply note the
108. time This total should not be greater than the wattage capacity of the generator If an electrical device nameplate gives only volts and amps multiply volts times amps to obtain watts 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 carefully read the Safety Rules section of this manual Comply strictly with these rules to prevent accidents and damage to equipment and or property We suggest copying and posting the Safety Rules in potential hazard areas of the vehicle Stress safety to all operators and potential operators of this equipment Section 1 General Information s GENERAL Recreational Vehicle Generator INFORMATION 1 4 GENERATOR CONNECTION SYSTEM This generator set is equipped with dual stator AC power windings These two stator windings supply electrical power to customer electrical loads by means of a dual two wire connection system Note however that the neutral is grounded The generator may have been installed so that it powers 120 volt AC loads Figure 1 1 It can be wired to connect both 120 and or 240 volt AC electrical loads This procedure should be done by an Authorized Service Dealer or other qualified installer Figure 1 1 Connections for 120 Volts Only 30 STATOR POWER WINDINGS GROUNDED NEUTRAL 1 5 SPECIFIC
109. tion other than for what it was designed If there are any questions pertaining to its application write or call the factory Do not use the unit until advised by a competent authority 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 120 240 volt single phase 60 Hertz AC electrical loads These loads can require up to 4 800 watts 4 8 kW of power but cannot exceed 40 AC amperes of current at 120 volts or 20 AC amperes at 240 volts for model 05754 0 For model 04164 3 the loads can require up to 4 500 watts 4 5 kW of power but cannot exceed 37 5 amperes of current at 120 volts or 18 8 amperes at 240 volts caution A Do not overload the generator Some installations may require that electrical loads be alternated to avoid overloading Applying excessively high electrical loads may damage the generator and may shorten its life Add up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one
110. tional 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 pur chaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac generators sold and rated for Recreational Vehicle RV applications as Generac has defined Recreational Vehicle generator applications The factory recommends exercising the unit one half hour every month WARRANTY SCHEDULE COMMERCIAL APPLICATIONS YEAR ONE 10026 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 r
111. tles 2 5 LP GAS FUEL SYSTEM DINE A LP gas is highly EXPLOSIVE The gas is heavier than air and tends to settle in low areas Even the slightest spark can ignite it and cause and explosion Only competent qualified people should be allowed to install test adjust or ser vice an LP gas fuel system Install the optional fuel system in compliance with applicable codes standards and regulations After the installation do not do anything that might render the system in noncompliance with applicable codes and standards The LP powered range of generators are fitted with a nonadjust able factory set system These systems are tamper proof to meet 1997 California Air Resources Board requirements for engine emission 28 2 51 PARTS NOT INCLUDED IN FUEL SYSTEM The propane fuel system does NOT include such items as a gas tank b gas piping c fittings d valves and e primary regula tor used to store the gaseous fuel and deliver it to the gaseous fuel solenoid Figure 2 15 Dd A Use only approved components in the fuel sup ply system All components must be properly installed in accordance with applicable codes Improper installation or use of unauthorized components may result in fire or an explosion Follow approved methods to test the system for leaks No leakage is permitted Do not allow fuel vapors to enter the vehicle interior Figure 2 15 Typical Propane Gas Fuel System
112. to fire extin guishers 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 combustible materials are left in the generator compartment or on or near the generator as FIRE or EXPLOSION may result Keep the area surrounding the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws governing the storage and handling of gasoline Fuel lines must be properly installed and fastened and free of leaks There must be no possibility of gasoline vapors entering the vehicle interior It is required that an approved flexible nonconductive fuel line between the generator fuel connection point and rigid fuel lines be installed If the generator is equipped with a liquid propane LP gas fuel system install the unit so it complies with all codes standards and regulations pertaining to such systems LP gas is highly explosive The gas tends to settle in low areas where even the slightest spark can ignite it and cause an explosion Do not allow gas vapors to enter the vehicle Section 1 General Information GENERAL INFORMATION Recreational Vehicle Generator 1 1 GENERATOR IDENTIFICATION Please record the following information from the generator D
113. ts as a step Stepping on the unit can stress and break parts and may result in dan gerous operating conditions from leaking exhaust gases fuel leakage oil leakage etc N ENGINE EXHAUST HAZARDS Generator engine exhaust contains DEADLY carbon monox ide an odorless colorless poisonous gas Breathing carbon monoxide can cause dizziness throbbing temples nausea muscular twitching headache vomiting weakness and sleepi ness inability to think clearly fainting unconsciousness or even death If you experience any carbon monoxide poisoning symptoms move into fresh air and immediately seek medical attention Never operate the generator set with the vehicle inside any garage or other enclosed area Adequate unobstructed flow of cooling and ventilating air is critical for expelling toxic carbon monoxide gas and fuel vapors from the generator compartment and for proper genera tor operation Without sufficient cooling airflow deadly carbon monoxide gas can accumulate and the engine generator may quickly overheat causing serious damage to the generator Do not operate the genset in any confined space The exhaust system must be installed in accordance with the genset installation manual Do not alter the installation or permit even partial blockage of ventilation systems as this can seri ously affect the safe and proper operation of the generator Do not operate the generator if the exhaust system is leaking or has been damag
114. uel lines be installed If the generator is equipped with a liquid propane LP gas fuel system install the unit so it complies with all codes standards and regulations pertaining to such systems LP gas is highly explosive The gas tends to settle in low areas where even the slightest spark can ignite it and cause an explosion Do not allow gas vapors to enter the vehicle 19 Recreational Vehicle Generator GENERAL INFORMATION 11 PURPOSE AND SCOPE OF THE MANUAL These nstallation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product s installation requirements Give seri ous consideration to all information and instructions in the manual both for safety and for continued reliable operation of the equip ment Because of the different recreational vehicle models and the variations between the models it would be extremely difficult if not impractical to provide detailed instructions for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all applicable codes standards and regulations pertaining to the installation and use of this product If any portion of this manual appears to be in conflict with such codes standards or regulations the applicable code
115. ulator at the gas tank outlet or in the supply line from the gas tank The following rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column Do NOT exceed 14 inches water column The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommended MINIMUM gas flow rate for all air cooled gen erators is 67 cubic feet per hour If an existing primary gas regulator does not have a sufficient flow capacity for the generator and other gas appliances in the circuit a install a primary regulator with adequate flow rate or b install a separate regulator only and rated at least 67 cubic feet per hour The inlet side of any primary regulator that supplies the generator must connect directly to a gas pressure tank Do NOT tee the generator line into a gas circuit feeding other areas 2 5 5 _ GASEOUS CARBURETION LP gas vapors should be supplied to the secondary regulator inlet at about 11 inches water column positive pressure The engine pistons draw air in during the intake stroke Figure 2 16 This air passes through a carburetor venturi which creates a low pressure that is proportional to the quantity of air being pumped The low pressure from the carburetor venturi acts on the regulator dia phragm to pull the diaphragm toward the source of low pressure A lev
116. use burns Allow engine to cool before draining oil Avoid prolonged or repeated skin exposure with used oil Thoroughly wash exposed areas with soap Change the engine oil after the first 25 hours of operation Thereafter change the oil every 100 operating hours Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures SB Figure 3 1 Oil Maintenance Features 12 OIL DRAIN CAP Change the engine oil filter after the first 25 hours of operation and every 100 operating hours thereafter To change the oil and or oil filter proceed as follows see Figure 3 1 1 Run the engine until it is thoroughly warmed up at least five minutes then shut OFF the engine 2 mmediately after the engine shuts OFF pull the oil drain hose free of its retaining clip Remove the cap from the hose and drain the oil into a suitable container Loosening the oil fill cap will allow the crankcase to drain faster 3 After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip 4 With the oil drained remove the old oil filter by turning it counterclockwise 5 Apply a light coating of clean engine oil to the gasket of the new filter 6 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn 7 Remove the dipstick and wipe it dry with a clean lint
117. w the unit to overheat during prolonged operation NOTE The generator engine is equipped with a high temperature switch The switch has normally closed N C contacts When the engine temperature is too high switch contacts close and the engine shuts down automatically THE MANUFACTURER RECOMMENDS TESTING THE GENERA TOR FOR ADEQUATE COOLING Recreational Vehicle Generator 2 POST Oo INSTALLATION START UP ADJUSTMENTS 35 POST Section 3 Post installation Start up Adjustments INSTALLATION STARTUP Recreational Vehicle Generator ADJUSTMENTS 3 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT Generator is properly located Q Generator is properly supported Generator is properly restrained GENERATOR COMPARTMENT 9 Compartment construction is proper Holes Openings are vapor sealed Compartment size is correct 9 Compartment is vapor sealed Q Sound insulation is correct Q Floor cutouts are properly completed COOLING AND VENTILATING AIR Airflow is adequate Air inlet opening is correct 9 Compensate for restrictions Q Check that installation has been tested GASOLINE FUEL SYSTEM Fuel tank complies with all applicable codes C OPTIONAL LP GAS FUEL SYSTEM Rated flow of primary regulator is correct All parts are properly installed Pressure at regulator inlet is correct Fuel system is properly tested adjuste

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