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GE 2-9772 Cordless Telephone User Manual

1. ENGINE WIRING scr CONTROL PANEL BOX ui OR A d rp CONTROL ON PRINTED CIRCUIT BOARD Se 56 0 sig J1 mH 4 eh spe 1213 41516171819 4 ae mel RR MB 17 14 85 56 0 4 RED 18 15 86 712 90 18A SP1 nZ IMS 85 0 86 241 0 SW1 amp LED m l ce Ll lt START 184 RED 1 14 BLK 2 0 712 RUN rn ci STDP 184 1 18 13 4 18 zio 86 25 86 16 17 0 3 0 O 0 0 0 18 1735 17 AO Os BO18 712 OF CO 17 14 OE DO 1159 2118 REMOTE PANEL 11 RA 825 225 CONNECTOR 4 4 LI LL 0 1 0 CB2 CB1 6 16 2 12 TIT 0 ee 44 VOLTAGE 416 11 33 REGULATOR CUSTOMER AC CONNECTION CUSTOMER SUPPLIED j NEUTRAL CONNECTION STATOR WIRING LEGEND BY CUSTOMER Ses BA BRUSH ASSEMBLY CB 1 CB2 SEE CHART CH CHOKE HEATER CS CHOKE SOLENOID WHITE GREEN BLACK RED ES EVAPORATIVE PORT SOLENOID F1 FUSE 7 5A FP FUEL PUMP FS FUEL SOLENOID CUSTOMER GRD1 CONTROL PANEL GROUND CONNECT BOX GRD2 UNIT GRO
2. ENGINE WIRING scr 16 CONTROL PANEL BOX 13 LD ZZZZ zZZZZZA 4 2 rn CONTROL CON PRINTED CIRCUIT BOARD 5 560 B J1 mm 0 spe 1121314151617 819 mel BLE KO 17 14 85 5610 4 RED 18 15 86 712 90 18A SP1 nZ IMS 85 0 86 0 e41 0 SW1 amp LED IMI nni ce Ll lt 5 2m RED 1 m PRIME BLK 2 0 712 RUN rn 5 STOP 1843 1 gt 18A 13 4 118 gt 86 25 86 16 17 0 9 35 0 0 W 9 85 4 85 18 0 5 0 9 p 241 6 gt 241 16 7 16 17 90 gt 90 8 gt 90 00 CS 56 Se 56 9 56 15 14 CH 14 gt 3 14 gt 10 gt 14 241 14 77 Fl cd BO18 7121 OF CO 17 14 QOE DO 115 115 REMOTE 33 PANEL ia 2 225 225 CONNECTOR 4 co 0 10 CB1 6 16 2 12 co O a Tae 44 VOLTAGE 4 6 11 33 REGULATOR CUSTOMER n AC CONNECTION Ji EUSTOMER SEE IED jJ NEUTRAL CUNNECTIDN STATOR WIRING LEGEND BY CUSTOMER Ses BA BRUSH ASSEMBLY CB 1 CBe SEE CHART CH CHO
3. Factory installed generator fuel system components include a fuel filter D 12 volt DC electric pump c engine carburetor and d interconnecting lines and fittings e evaporative port Connect a fuel supply line to the fuel filter inlet Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines 24 1 FUEL TANK Either the generator must share the vehicle engine s fuel tank or a separate fuel tank for the generator set must be installed All fuel tanks installed on the vehicle must be constructed installed and restrained so they comply with applicable codes standards and regulations The generator has an evaporative emissions port to evacuate accumulated gasoline vapors 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 Gasoline generators are equipped with an Evaporative Emissions Port that may be used in conjunction with a certified fuel system where required by law A CAUTION Do NOT tee the generator fuel supply li
4. The installer must make certain that the selected location will permit adequate cooling and ventilating airflow to be supplied 2 1 4 GENERATOR RESTRAINT Use four 3 8 16 hardened steel bolts Grade 5 to fasten the generator to the supporting frame or the support tubing These bolts must pass through a the generator mounting base b the compartment floor if a compartment is used and c the support ing framework Figure 2 3 All bolts must be long enough so that when tight at least three threads are visible past the retaining lock nuts Refer to Generator Compartments for the location of the generator mounting holes Torque Bolts to 31 ft Ibs Figure 2 3 Typical Generator Restraint METAL LINED INCH THICK BASE d PLYWOOD HE qa TUBULAR METAL BI SUPPORT FRAME 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
5. 35 Section 5 Electrical 36 Section 6 Exploded Views and Parts Lists 40 Section 7 Warranty 52 Introduction INTRODUCTION READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood contact the near est Authorized Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or care lessly Observe them carefully Their definitions are as follows A DANGER After this heading read instructions that if not strictly complied with will result in personal injury including death and property damage A WARNING After this heading read instructions that if not strictly complied with may result in personal injury or property damage A CAUTION After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the ser
6. 11 1115 ees 122 4 14 0 0 10 6 16 e 12 VOLTAGE CUSTOMER REGULATOR AC CONNECTION NEUTRAL CONNECTION BY CUSTOMER 2 4 0 WHITE GREEN RED BLACK POWER WINDINGS DPE WINDING FIELD BA LEGEND BA BRUSH ASSEMBLY CB 1 7 CB 2 SEE CHART CH CHOKE HEATER CS CHOKE SOLENOID ES EVAPORATIVE GAS SOLENOID F1 FUSE 7 SA FP FUEL PUMP S FUEL SOLENOID GRD1 CONTROL PANEL GROUND GRD2 UNIT GROUND STUD HTO HIGH DIL TEMPERATURE SWITCH 4500W IGNITION MODULE CYL 1 CB 1 20A 1 POLE CIRCUIT BREAKER IM IGNITION MODULE CYL 2 CB 2 20 1 POLE CIRCUIT BREAKER IMS IGNITION MODULE STUD LOP LOW DIL PRESSURE SWITCH 55000 SE SINGER CONTACIR 81 91 CIRCUIT MEAE SCR STARTER CONTACTOR RELAY SM STARTER MOTOR E ECL DU SS NN 304 1 POLE CIRCUIT BREAKER SP2 SPARK PLUG CYL 2 5 1 PRIME START RUN OFF SWITCH CB 2 304 1 POLE CIRCUIT BREAKER TB TERMINAL BLOCK 4 TAB 3 7 Electrical Data Wiring Diagram Drawing No 0H3633 A
7. VEHICLE AC DISTRIBUTION PANEL 31 Installation Figure 2 16 Connecting Battery Cables Positive Cable Battery Chasis Ground Negative Cable 2 74 BATTERY COMPARTMENT Install the generator battery in its own vented compartment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compartment The minimum size of openings should be two 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage 2 8 OPTIONAL ACCESSORIES A plug in receptacle Figure 2 17 is provided on the generator set Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit starting and stopping the generator engine from any convenient location inside the vehicle 2 8 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 of this manual 32 Figure 2 17 Remote Panel Plug in Receptacle i WIRE NO WIRE COLOR FUNCTION aa Engine Run Signa ne Brock Post Installation 3 1 POST INSTALLATION TESTS
8. 5 D SS ANN GS lt p gt is eo e o e g e A Base amp Pulley Drawing No 0G7720 B N N X P 022 84 1 AN 0 9 4 amp E Y 7 N N WS v 95 gt o gt 9 o x 44 Base amp Pulley Drawing No 0G7720 B Exploded Views amp Parts Lists ITEM PART NO TY DESCRIPTION 1 063377 1 TRAY 530 RV 2 081105 2 NUT FLANGE 5 16 18 LOCK 3 022259 8 NUT HEX 5 16 18 STEEL 4 022129 12 WASHER LOCK M8 5 16 5 022145 13 WASHER FLAT 5 16 M8 ZINC 6 065217 2 SCREW HHC 3 8 24 1 1 2 G8 7 063748 1 BELT V RIBBED 4L X 43 75 LG 8 046526 2 WASHER LOCK M10 9 022131 2 WASHER FLAT 3 8 M10 ZINC 10 063384 1 ALTERNATOR PULLEY 11 0C7758A 4 VIB MNT 1 5X1 38X5 16 18 DR 45 12 0C1751 1 FAN 7 DIA NYLON 13 002824 11 SCREW HHTR 10 32 X 9 16 14 022473 7 WASHER FLAT 1 4 M6 ZINC 15 022097 7 WASHER LOCK M6 1 4 16 043116 7 SCREW HHC M6 1 0 X 12 G8 8 17 063383 1 ENGINE PULLEY 18 064350 1 FAN ENGINE PULLEY RV 19 063379 2 BRACKET MUFFLER SUPPORT 20 003062 2 BOLT CARR 5 16 18 X 1 21 064429 1 EDGE TRIM W 3 4 HOLLOW CYL 22 003391 1 BLOWER HOUSING WALL 23 0G3742 1 GASKET LOWER BLOWER HOUSING 24 0G7670 1 FRAME GT530 RV MOUNTING 25 0E0588 1 SPACER SAFETY BOLT 375 I D 26 0G4702 2 SCREW HHC 5 16 18 X 3 SPC 27 029451 1 5ft TAPE ELEC UL FOAM 1 8 X 1 2 28 063426 1 DUCT AIR OUT 29 065676 1 GASKET AIR OUT
9. NI o 1 1 1 I 3 em gt D S30vd t na CAIA 91 8 91 L91 AT D 119907 137100 JSnyHX3 1 L91 Z Te 91 6 91 91 2 Ga T091 979 L9I I 26 Installation 6 3 2 TESTING THE INSTALLATION The manufacturer recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of overheating enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate NOTE The installation must be tested especially if bringing in air from below the generator set 2 4 GASOLINE FUEL SYSTEM Gasoline is highly flammable and its vapors are explosive Comply with all codes stan dards 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 The installation of a gasoline fuel system Figure 2 10 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 Figure 2 10 Generator Fuel System
10. 20 1 2 Safely 20 1 3 Standards 20 1 4 Equipment 20 1 5 Generator Engine Operating Speed 20 1 6 Generator AC Connection 20 Section 2 Installation 21 Major Features and Dimensions 21 2 1 Location and 22 2 2 Generator Compartments 23 2 3 Cooling and Ventilating Air 25 2 4 Gasoline Fuel System 27 2 5 Exhaust 28 2 6 Electrical Connections 29 2 7 Battery Installation 30 2 8 Optional Accessories 32 Section Post Installation 33 3 1 Post Installation Tests 33 3 2 Before Initial Start up 33 3 3 Initial SIAR rus eR he bees 33 3 4 Testing Under 33 3 5 Installation Checklist 34 Section 4 Troubleshooting 35 4 1 Troubleshooting Guide
11. 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 5W 30 oil having API classification For Service SJ SL 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 3 132 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Checkthe tag on the engine for oil viscosity and classification Verify that the correct recommended oil is used in the engine see Engine Oil Requirements If necessary drain and refill with the proper oil 2 Check the state of the battery Fill all cells of unsealed batter ies to the proper level with distilled water DO NOT USE TAP WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery 3 Clean and wipe the entire generator 4 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 5 Turn OFF all el
12. 3 Use the 064818 tool supplied with the generator to turn the old filter counter clockwise and remove Let oil drain into the container located directly below 4 Locate the oil drain hose inside and pull the yellow drain plug out of the access hole Figure 3 1 5 Turn the yellow cap counter clockwise to remove and finish draining the old oil 6 After the oil has been drained replace the oil drain plug by tightening it clockwise and return 7 Clean off the oil filter bracket and any old oil that may have spilled while draining 8 Apply a light coating of clean engine oil the gasket of the new oil filter Figure 3 2 9 Screw the new oil filter on by hand until its gasket lightly con tacts the oil filter adapter Then tighten the filter an additional to one turn Replace and secure the round access grom met Figure 3 2 Engine Oil Filter Engine Oil Filter Twist Counter clockwise to Loosen 10 the dipstick valve plug and add new See Engine Oil Requirements to engine DO NOT FILL ABOVE THE FULL MARK 11 Install and tighten plug and dipstick before starting the engine 12 Start engine and check for leaks NOTE Check the oil level and fill to the FULL mark after checking for leaks The filter will retain some oil 3 3 MAINTAINING THE ENGINE AIR CLEANER Replace the paper air filter element after every 200 hours of opera tion
13. As the generator owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your generator but Generac cannot deny warranty solely due to the lack of receipts As the generator owner you should be aware that Generac may deny any and or all warranty coverage or responsibility if your generator or a part component thereof has failed due to abuse neglect improper maintenance or unapproved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer To locate the Generac Authorized Warranty Service Dealer nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California and federal law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac Note t
14. CALIFORNIA PROPOSITION 65 WARNING This product contains or emits chemicals known to the State of California to cause cancer birth defects and other reproductive harm GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and maintenance of this equipment is carried out by an Authorized Service Dealer The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area Shut down the generator and do not operate it until it has been inspected and repaired DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coherently b nausea c vomiting d twitching muscles e throbbing temples f dizzi ness g headaches h weakness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area Keep hands feet clothing etc away fro
15. The air cooled generator set was factory tested and adjusted It should not be necessary to adjust the unit any further except under special circumstances AWARNING 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 3 3 INITIAL START When certain that the unit has been properly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s main circuit breakers to their OFF or open position 2 Refer to Part Starting the Generator for cranking and starting instructions The engine may require more cranking for initial starting since the fuel lines have to be primed use of the primer switch will shorten this time 3 Letthe engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system l
16. 2 5 Starting the 10 2 6 Stopping the 10 2 7 Applying Loads to 10 2 8 Protection Systems 11 Section 3 Maintenance 12 3 4 Checking the Engine Oil Level 12 3 2 Changing the Engine Oil and or Oil Filter 12 3 3 Maintaining the Engine Air Cleaner 13 3 4 Checking the Engine Spark Plug 13 3 5 Fuel Filter Gasoline ONIY 0 a 13 3 6 Clean Spark 14 3 7 Cleaning the 14 3 8 Battery Maintenance 14 3 9 Adjusting Valve Clearance 15 3 10 Major Service 16 3 11 Drive BOs 16 3 12 Exercising the 16 3 13 Out of Service Procedure 16 3 14 RV Generator Service Interval 16 Part Il Installation Instructions 18 Notice to Installer uu eee 18 Section 1 General Information 20 1 1 Purpose and Scope of the Installation
17. Standard for Fuel and Oil Hose It must be approved for use with gasoline and low permeability The hose should be at least 6 inches 152 mm longer than is needed to prevent the hose from rupturing if the generator shifts or settles 27 Installation 2 5 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used A properly installed exhaust system must be vapor tight quiet and completely safe A DANGER The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentrations can cause uncon sciousness 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 twitch ing 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 A CAUTION Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the gen erator engine Also w
18. era FIREPROOF e SOUND INSULATION Bh eh METAL LINING n E VAPOR SAL PLYWOOD AT ALL TIMES oe METAL LINING e p NOTE Caulking must be done so that the caulking material will stay in place permanently Pressing such materials as putty tape onto joints and seams is not acceptable A high quality silicone rub ber base sealant is recommended Holes and openings made in the compartment walls to allow for the passage of electrical conduit conductors hoses cables etc into the vehicle living area must be sealed vapor tight with silicone rubber base sealant If flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartment s electrical junction box NOTE Flexible metal conduit due to its unique construction is NOT vapor tight along its entire length e Seams and joints of the galvanized steel whether used as a liner or for the compartment itself must be lapped and mechanically secured Such seams may be manufactured welded bolted riveted or screwed Manufactured lock seams are shown in Figure 2 6 Installer constructed compartments typically utilize a standard lap joint After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material See Sound Insulating Materials 24 Figure 2 6 Types of Lock Seams n A
19. 53 48 49 54 24 27 28 29 30 31 32 33 34 35 36 39 41 55 24 27 28 29 30 31 32 33 34 35 39 41 46 530 RV Engine Drawing No 0G7719 B 530 RV Engine Drawing No 0G7719 B Exploded Views amp Parts Lists ITEM PART NO TY DESCRIPTION 1 0E3812 2 SEAL D 35 X 48 2 2 0D4788 1 3 8 SQUARE HEAD PLUG 3 073144 9 SCREW 8 1 25 X 45 4 0G7260A 1 GEAR COVER 5 078699B 6 SLEEVE DOWEL PIN 6 0A5776 1 11 32 DIAMETER PRESSURE RELIEF BALL 7 0E9482 1 OIL PRESSURE SPRING 8 0C5315A 1 GEAROTOR OUTER 9 0C5314A 1 GEAROTOR INNER 10 0E9379 1 SCREEN OIL PICK UP 11 0E9382 1 COVER GEROTOR 12 0G0919 3 SCREW HHFCS M6 1 0 x 12 13 0E3372A 1 BREATHER SEPARATOR 14 0E9345 1 GEAR GEAROTOR 15 076390 4 RETAINER RING 16 064379 2 PISTON RING SET 17 064331 2 PISTON 18 076389 2 PISTON PIN 19 061054 2 CONNECTING ROD ASSEMBLY 20 0G1063G 1 CRANKSHAFT 21 093064 1 OIL FILL CAP 22 0E9334F 1 COVER ROCKER W FILL 23 080318 8 SCREW HHFC M6 1 0 X 25 24 0E9352 2 GASKET VALVE COVER 25 0E9368 2 SPARK PLUG 26 077168 12 SCREW HHC M8 1 25 X 56 27 084186 4 WASHER VALVE SPRING 28 088156 2 SEAL VALVE STEM 29 004390 4 VALVE SPRING 30 003733 4 VALVE RETAINER 31 003592 8 KEEPER VALVE SPRING 32 077161 4 STUD ROCKER ARM 33 077160 4 ROCKER ARM 34 076307 4 JAM NUT ROCKER ARM 35 0 9353 2 PUSH ROD GUIDE PLATE 36 0E9304 1 CYLINDER HEAD CYL 1 37 003591 2 VALVE 38 003590 2 EXHAUST VALV
20. Part No Material Color Order As Steel G Gray Roof 0G3397 S Steel G Gray 0G33970ST08 B Black Upper Blower Hsg 063392 Steel B Black 0G33920ST03 41 Exploded Views amp Parts Lists Control Panel Drawing No 0H3635 C 42 4344 REAR VIEW 063530 42 Control Panel Drawing No 0H3635 C a mn a oo U ITEM PART NO TY DESCRIPTION 045757 1 SCREW HHC M6 1 0 X 25 G8 8 0F5458 2 SCREW PLASTITE HI LOW 10X3 8 0234848 1 BUSHING SNAP SB 1093 937 069081 1 WIRE HARNESS C PNL FRAME 049813 1 NUT HEX M6 X 1 0 G8 YEL CHR 022473 2 WASHER FLAT 1 4 M6 ZINC 041658 1 WASHER LOCK SPECIAL 1 4 063380 1 FUEL PUMP MOUNTING BRACKET 0F9176 28 75 HOSE 1 4 SAE30R7 063662A 1 CLAMP HOSE BAND 50 028414 1 BARBED STR 1 8NPT X 1 4 0D3700 5 NUT FLANGE M6 1 0 NYLOK 065225 1 FUEL PUMP 028916 1 ELBOW 90D STREET 1 8 BRASS 087769 1 FILTER FUEL 1 8P 1 4H 025965 1 SCREW HHC 1 4 20 X 2 1 4 G5 022097 2 WASHER LOCK M6 1 4 065318 1 AC HARNESS 530RV 5500 6500W 0H3634 1 AC HARNESS 530RV EVAP 4500W 064602 1 GROMMET DOUBLE SLIT 07968 3 NUT HEX JAM 3 8 16 BRASS 022237 2 WASHER LOCK 3 8 044456 1 WASHER LOCK SPECIAL 3 8 007423 1 STUD 3 8 16 X 2 1 4 BRASS 022259 2 NUT HEX 5 16 18 STEEL 022129 2 WASHER LOCK M8 5 16 022145 1 WASHER FLAT 5 16 M8 ZINC 0E0593 1 STUD 1 4 20 TO 5 16 18 0D8502 1 NEUTRAL CONNECTOR UL
21. Unit does not start through entire start cycle e 4 Flashes Overspeed Alternator spins at 4200 rpm 72 Hz or greater 5 Flashes Low Oil Pressure Drops below the 5 psi threshold of the switch NOTE There is a five second delay of the alarm when the engine is first started up 6 Flashes High Oil Temperature Unit shuts down when tem perature switch limit is reached NOTE As the unit cools down it will attempt to restart automatically when the temperature switch opens again e 7 Flashes Underspeed Alternator spins less than 3240 rpm 54 Hz for three 3 seconds NOTE After a fault is indicated press stop momentarily to clear the alarm once the problem is fixed 2 2 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel is available that allows start ing and stopping the generator engine conveniently from inside the vehicle The remote panel includes a Start Stop switch hourmeter generator run lamp and a wire harness 2 3 AUTOMATIC CHOKE This engine is equipped with an automatic choke that consists of two main components a choke solenoid and prechoke Gasoline only 2 3 1 CHOKE SOLENOID During engine cranking Start Stop switch at START a solid state choke module signals the choke solenoid to activate and cycle choke on choke off until the engine starts The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking When the engine
22. 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 4 ENGINE SPECIFICATIONS Type OF Engelm ertt rir RE E EE MEE Coolirig Metliod tte dtc eerte tee Rated Horsepower Displa cerment k uuu ertt nti iier ott Cornipressior allocate totg endet 8 5 to 1 Cylinder Aluminum w Cast Iron Sleeve Type of Governor sss Electronic Fixed Speed Engine Governor Speed Air Ignition System Recommended Spark Plug BPR6HS Spark Plug Gap cette ts 0 030 inch 0 76 mm Recommended Min Battery 400 Cold Cranking Amps Class Il Emission Certified 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 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 operat
23. corrosive vapors road splash etc Permitting dirt and moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor which is detrimental to the generator 14 A CAUTION Do NOT use a forceful spray of water to clean the generator Water will enter the gen erator interior and cause problems and may also contaminate the generator fuel system 3 8 BATTERY MAINTENANCE NOTE This generator is not equipped with an internal battery charger It is intended for use in systems where an external battery char ger is installed by the RV O E M or an aftermarket installer All lead acid batteries will discharge when not in use The generator battery should be inspected as follows 3 6 1 WEEKLY Inspect the battery posts and cables for tightness and corro sion Tighten and clean as necessary Check the battery fluid level of unsealed batteries and if nec essary fill with Distilled Water Only Do not use
24. of 1 2 inch 13 mm on the front top sides and from the 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 2 Clearance on Top 1 2 Clearance 2 2 2 COMPARTMENT CONSTRUCTION The generator compartment should be either constructed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum s low melting point If the compartment is lined with galvanized steel it may be constructed of any material The manufacturer recommends that the compartment be constructed of 1 2 inch thick plywood not strandboard with the floor made of a double thickness of 1 2 inch plywood with the grain of the wood at cross section for added strength Figure 2 5 If constructing a compartment line the exterior underside of 1 Lat GRADE 5 BOLTS VEHICLE CHASSIS METAL LINED BOTTOM the compartment floor with 26 gauge galvanized steel All seams splices and joints of the compartment walls unless vapor tight by design should be caulked to prevent poison ous flammable or explosive vapors from entering the vehicle interior 23 Installation Figure 2 5 Typical Compartment Construction CROSS SECTION VIEW METAL LINING
25. windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENC
26. 0 N FIELD GRND 2 84 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 4 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 125 to 120 volts Figure 2 4 Solid State Voltage Regulator fOr 8 a SENSING 4 4 4 TO ROTOR o DIRECT CURRENT 9 5 FROM STATOR EXCITATION WINDING ALTERNATING CURRENT S S 11 Maintenance 2 8 5 OPERATION IN HIGH GRASS OR BRUSH A WARNING A 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 dur ing operation and remains hot for a long time after it has shut down 3 1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements see the Engine Oil Requirements section Check the engine crankcase oil level at least every eight hours of operation or before it is used To check the engine oil level proceed as follows see Figu
27. 065233 2 SCREW PPHTF 8 18 X 1 2 AB 063825 1 CONTROL PANEL COVER 063689 1 C PNL FACE 092036 4 SCREW PPHM 6 32 X 1 4 SEMS 049611 1 FUSE 7 5AXBK AGC7 5NX 032300 1 HOLDER FUSE 064215 1 SWITCH RKRSPDT ON OFF ON ILLUM Exploded Views amp Parts Lists ITEM PART NO QTY DESCRIPTION 36 082025 4 NUT HEX LOCK M5 0 8 NYINS ZINC 37 079719 1 ASSY PCB VREG AIR COOLED 2006 38 003977 1 ASSY PCB RV CONTROLLER 39 003530 FRAME RV 40 075476 2 SCREW PPHM M4 0 7 X 16 41 090987 2 SCREW PPHM M3 0 5 X 12 42 0C2174 1 RELAY 12V 25A SPST 43 031879 2 WASHER FLAT 4 ZINC 44 009784 2 NUT HEX LOCK M3 0 5 NY INS 45 075235 4 SCREW HHC 5 0 8 X 30 68 8 46 074908 4 SCREW HHTT M5 0 8 X 10 BP 47 075210A 1 BLOCK 1 POSITION 4 TAB 48 0E6480 2 NUT HEX LOCK M4 0 7 NY INS 49 090144 5500W 1 20X1 MAG 10 32 CARL 090145 6500W 1 CIRCT BRK 30X1 MAG 10 32 CARL 50 090145 1 CIRCT BRK 30X1 MAG 10 32 CARL 4500W 5500W 6500W 51 0C2417A 1 EARTH STRAP 52 005986 1 NYLON SPACER 26 X 1 00 X 1 73 53 061669 1 PLUG PLASTIC 75 5410 1 5412 1 5414 1 ONLY 54 059502 1 BARBED EL 90 NPT X 5 16 5751 5752 5753 ONLY 55 069598 1 BULKHEAD ADAPTER 5751 5752 5753 ONLY 56 035579 1 BUSHING REDUCER HEX TO 1 8 NPT 5751 5752 5753 ONLY 57 035483 1 NIPPLE PIPE 1 8 NPT X 1 5751 5752 5753 ONLY 58 000247 1 SOLENOID 12 VDC 5751 5752 5753 ONLY 59 028740 1 BARBED EL 90 1 8 NPT X 4 5751 5752 5753 ONLY HARNESS NOT SHOWN 43
28. 1 ASSY GOVERNOR ROD 78 077091 1 COTTER PIN 30 004378 1 GASKET AIRBOX CARB 80 075763A 1 BOOT BATT CABLE 31 040173 1 CLAMP HOSE WORM GEAR 81 0742600173 1 WIRE ASSY BATT POS 32 063406 1 WRAPPER ENGINE OIL ADAPTOR 83 022473 2 WASHER FLAT 1 4 M6 33 003455 1 SNORKEL AIR BOX 84 061906 2 SCREW HHC M8 1 25 X 85 34 063413 1 AIRBOX BASE 85 049813 2 NUT M6 1 0 35 078601 1 AIR FILTER 86 056892 2 SCREW CRIMPTITE 10 24 X 3 8 36 005057 1 AIRBOX SEAL 87 0E9323 1 START MOTOR 37 0 9511 1 AIRBOX QUARTER KNOB 88 022129 2 WASHER LOCK M8 5 16 38 003414 1 AIRBOX COVER 89 0A4456 1 WASHER LOCK SPECIAL 3 8 40 003408 1 OIL DRAIN LINE 90 022746 4 SCREW HHC 3 8 16 X 1 3 4 G5 41 045756 4 SCREW HHTT M6 1 0 X 10 YELLOW 91 055934M 1 CLAMP VINYL 75 X 343 CHROME 92 006725 1 INSULATOR 42 080998 1 CLAMP VINYL 9 5 0 D 93 066729 1 GASKET MANIFOLD TO CARB MIXER 43 063432 2 3 4 NPT TO 3 8 0 D FLARE 94 07864306 2 BOLT CARB MOUNT M6 1 0 X 95 44 0E0393A 1 ASSY CAP AND DIPSTICK 95 096290A 2 STUD M6 1 0 X 100 45 0E0361B 1 OIL DRAIN DIPSTICK TUBE 96 046526 3 WASHER LOCK M10 46 043790 1 90 DEGREE ELBOW 3 8 NPT X 3 8 97 069148 1 PLUG RUBBER 4703 5 6 amp 7 BARBED 98 0G7757A 1 HOSE MOLDED EVAP PORT 05751 47 0G3662B 2 HOSE OETIKER CLAMP 05752 amp 05753 48 OF0452B 8 HOSE 3 8 1 0 99 0H4269 1 SCREW BHSC M6 1 X 8 49 064426 1 ASSY OIL DRAIN FITTING 100 069062 1 SCREW BHSC M6 1 X 8MM BLACK 47 Exploded Views amp Parts Lists 48 52 1 24 39 44 48
29. Figure 2 2 has normally closed N C contacts that are held open by engine oil pressure during cranking and operat ing Should oil pressure drop below a preset level switch contacts close and the engine automatically shuts down The unit should not be restarted until oil is added 28 2 HIGH TEMPERATURE SWITCH This switch Figure 2 2 which has normally open N O contacts is mounted near the oil filter The contacts close if the temperature should exceed approximately 2709 F 1329 C for gasoline mod els Figure 2 2 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE SWITCH ENGINE OIL OIL PRESSURE FILTER SWITCH nas Operation 2 8 3 FIELD BOOST The Controller Circuit Board houses a field boost diode and resistor that are not part of the automatic choke circuit These two compo nents are part of a field boost circuit Figure 2 3 During engine cranking only a positive DC battery voltage is delivered through a diode resistor brushes slip rings and the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Figure 2 3 Field Boost Circuit CONTROLLER CIRCUIT CLOSEST TO BOARD BEARING 4
30. T3 BLACK 120V T2 wq WHITE 77 T2 v WHITE gt 11 CB20 STATOR POWER WINDINGS 00000007 gt gt GROUNDED NEUTRAL 91 4 121 1 101 8158 Ses 131100 LSNVHXI 9 S ud 530 18 5 THL 91 8 e 5 100 aIv LO 9NI100 S x e L2 1 8H 669 gt S T3ddIN0I 4D 9411113 1809 3AiiyaodwA3 2 L9VEI D 553229 31713 710 3 91 6 vl T 601 j NI NI NIV L8 S L2 1 811 Ed 3ONVN3LNIVW ANIONI 941009 TI 669 o 03 553099 000 IND33 Leven SsanavH dus 218100297 AALLW93N gt NDILO3NNDO A3118 L L LL I 5329144 P S dAL i 91 8 91 81 D gt os 13NI s OY GENE N GALISUD JA DU NDLLO3NNOO 31198 8628 NDILO3NNDO 1591 ILOWIIT gt L91 L 121 21 Installation Figure 1 3 Connection for 120 240 Volts 11 TO E 17 CB1 RED A A 120 VAC T2 240 amp T WHITE VAC 120 VAC CB2 T3 44 BLACK i STATOR POW
31. breaker ratings This procedure should be done by an Authorized Service Dealer or other qualified installer Figure 1 2 Connection for 120 240 Volts 11 eT 4 1 CBI RED A A 120 x T2 Y 240 WHITE VAC 120 VA CB2 Ad T3 4 tib BLACK STATOR POWER GROUNDED NEUTRAL WINDINGS 1 6 SPECIFICATIONS 1 6 1 FUEL REQUIREMENTS GASOLINE This generator is equipped with a gasoline fuel system as standard equipment Specific installations may provide either a separate fuel tank for the generator or the generator may share the vehicle engine s fuel tank 1 6 1 1 Fuel Consumption gph Mode 10 Load 50 Load 100 Load 0 35 5 49 RV656 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 A CAUTION The manufacturer does not recommend using any gasoline containing alcohol such as gasohol If using any gasoline contain ing alcohol it must not contain more than 1
32. cover on the interior or exterior wall of the area planned for installa tion of the generator NOT on the generator Route the generator s AC output leads into this junction box through approved flexible conduit This is the point of first termination for generator AC output leads 26 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 trans fer switch or b approved isolation receptacle Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being connected to two different power supplies at the same time such as generator and dockside power Conductors must be rated 221 F 105 C o
33. deadly carbon monox ide 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 8 This airflow cools the engine generator and electronic components The second part of the cooling system a suction fan draws air that is heated from a hot engine into a col lector pan at the base of the unit This heated air although cooler than exhaust muffler is then deflected out the bottom toward the ground Figure 2 8 Airflow Through Engine Generator COOLING AIR IN ENGINE AIR IN COOLING An OUT 25 1ND23 ONTIODI 3dD2d 303 03410934 SI 9349 N3dU 119 SNDILODnaBISSU ANY 30 49312 Ld35 38 LSAW 51 ISOVHX3 NV 533 1 NIV 1Y ALON 9 p S ga 6 088 LH fio 91 6 n LI 2 9146 6n L8 S D E0 n T96y Ti Lib I i 1 L 91 S 21 965 TY L8 5 Sor o i v amp io x 5300 3OIANSS CNY S L37NI TY L2 1 811 SO e 1 9 LL 1 12 1 S 669 LL i E Zeer L91 Z 22 10 6 1 Q
34. 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 FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installation do noth ing that might alter a safe
35. excessively high electrical loads may dam age the generator and may shorten its life Add up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one time This total should not be greater than the watt age capacity of the generator If an electri cal device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts Some elec tric motors require more watts of power or amps of current for starting than for con tinuous operation 1 3 INSTALLATION This Owner s Manual has been prepared under the assumption that a competent qualified technician installed the generator into a recreational vehicle We also assume the installer complied with all applicable codes standards and regulations pertaining to installation An INSTALLATION MANUAL was shipped with the generator That Manual contains manufacturer s instructions and recommenda tions for installing the unit into an industrial vehicle After installa tion installers should forward the Installation Manual to Owners Operators for their information Owners Operators have the responsibility to make sure that noth ing is done that might render the installation unsafe or in non compliance with applicable codes standards and instructions 1 4 SAFETY Before using the generator set carefully read GENERAL SAFETY RULES inside the cover Comply with these RULES to prevent accidents and d
36. sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or permit even partial blockage of ven tilation provisions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued 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 e
37. tap water in batteries 3 6 2 EVERY SIX MONTHS Have the state of charge and condition checked This should be done with an automotive type battery hydrometer NOTE Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precau tions Keep unauthorized personnel away from batteries Damage will result if the battery connections are made in reverse A DANGER Do not dispose of the battery in a fire The battery is capable of exploding Storage bat teries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an 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 battery presents risk of electrical shock and high short circuit current The following precautions are to be observed when work ing 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 charg
38. very important step to insure longest life for the engine To check valve clearance The engine should be cool before checking If valve clearance is 0 002 0 004 0 05 0 1mm adjustment is not needed Remove spark plug wires and position wires away from plugs e Remove spark plugs Make sure the piston is at Top Dead Center TDC of its com pression stroke both valves closed To get the piston at TDC remove the intake screen at the front of the engine to gain access to the flywheel nut Use a large socket and socket wrench to rotate the nut and hence the engine in a clockwise direction While watching the piston through the spark plug hole The piston should move up and down The piston is at TDC when it is at its highest point of travel To adjust valve clearance if necessary Make sure the engine is at 60 to 80 F Make sure that the spark plug wire is removed from the spark plug and out of the way Remove the four screws attaching the valve cover with a 2 or 3 Phillips screwdriver Loosen the rocker jam nut Use an 10mm allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Correct clearance is 0 002 0 004 inch 0 05 0 1 mm Figure 3 7 Figure 3 7 Valve Clearance Adjustment Rocker Pivot Ball Arm Jam Nut NOTE Hold the rocker arm jam nut in place as the pivot ball stud is turned When valve clearance is
39. 0 percent ethanol Do not use E85 and it must be removed from the generator during storage Do NOT use any gasoline contain ing methanol If using gasoline with alcohol inspect more frequently for fuel leaks and other abnormalities 1 6 2 ENGINE OIL REQUIREMENTS All oil should meet minimum American Petroleum Institute API Service Class SJ SL or better Use no special additives Select the oil s viscosity grade according to the expected operating tempera ture also see chart e SAE gt Above 32 e 10W 30 gt Between 40 F and 10 F e Synthetic 5W 30 gt 10 F and below Temperature Range of Expected Use Crankcase and oil filter capacity is approximately 1 4 L or 1 5 U S quarts DO NOT use special additives See sections Checking the Engine Oil Level and Changing the Engine Oil and or Oil Filter for oil level check and filling procedures General Information 1 6 3 GENERATOR SPECIFICATIONS Rotor RPM Rotor Poles Engine RPM Rated Max Continuous AC Output Watts Rated Max Continuous Current Amps 240V Phase 3600 3600 3600 2571 2571 2571 4500 5500 6500 Frequency 60 Hertz 60 Hertz 60 Hertz All units are re connectable to 120 and or 240 volts dual voltage output Units are not listed per RVIA ANSI when reconnected for dual voltage output Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature
40. 14 14 x 0 sc 16 16 13 15 REMOTE Fi PANEL CONNECTOR 13 BATTERY 12 AQ 1 0 0 0 Os BO18 18 712 OF 17 17 14 OE DO BLACK 119 118 ees caees 4 14 0 10 6 16 2 12 4500W ONLY VOLTAGE CUSTOMER Col REGULATOR AC CONNECTION NEUTRAL CONNECTION BY CUSTOMER 11 11 22 22 44 6 2 0 4 WA WHITE GREEN BLACK POWER WINDINGS DPE WINDING FIELD BA LEGEND BA BRUSH ASS CB 1 CB CH CHOKE HEA CS CHOKE SOL ES EVAPORATI F1 FUSE 7 9 FP FUEL PUMP FS FUEL SDLE GRDI CONTROL GRD2 UNIT GR HTO HIGH OIL IM1 IGNITION IM2 IGNITION IMS IGNITION LED ALARM IN LOP LOW DIL SC STARTER C SCR STARTER SM STARTER M SP1 SPARK PL SP2 SPARK PL SW1 PRIME ST TB TERMINAL EMBLY SEE CHART TER ENOID VE GAS SOLENOID A NOID PANEL GROUND OUND STUD TEMPERATURE SWITCH MODULE CYL 1 MODULE CYL 2 MODULE STUD DICATUR PRESSURE SWITCH ONTACTOR CONTACTOR RELAY UG CYL 1 UG CYL 2 ART RUN OFF SWITCH BLOCK 4 TAB R 4500W CB 1 30A 1 POLE CIRCUIT BREAKER 39 Exploded Views amp Parts Lists nclosure Drawing No 0G3881 F Enclosure Drawing No 0G3881 F Exploded Views amp Parts Lists ITEM PART NO TY DESCRIPTION 1 0G3396 1 ENCLOSURE DOOR 2 005644 2 SLIDE LATCH FLUSH 3 065236 1 FOAM ENCLOSURE DOOR 4 0D3700 23 NUT FLANGE M6 1 0 NYLOK 5 063401 1 DU
41. A CAUTION Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end If necessary re form the wire terminal to obtain a tight fit 3 5 FUEL FILTER GASOLINE Remove and replace the fuel filter Figure 3 5 every 400 hours of operation Figure 3 5 Fuel Filter TO FUEL PUMP CUSTOMER FUEL CONNECTION Maintenance 3 6 CLEAN SPARK ARRESTOR The engine exhaust muffler has a spark arrestor screen Inspect and clean the screen every 200 hours of operation or once each year whichever comes first NOTE If using the generator on any forest covered brush covered or grass covered unimproved land it must equipped with a spark arrestor The spark arrestor must be maintained in good condi tion by the owner operator Clean and inspect the spark arrestor as follows e Remove the screen by removing the screw e Slide the spark arrestor screen out from the tail pipe nspect screen and replace if torn perforated or otherwise damaged DO NOT USE a defective screen If screen is not damaged clean it with commercial solvent e Replace the screen and the screw Figure 3 6 Spark Arrestor TAILPIPE P N 0G5857 _ SPARK ARRRESTOR SCREEN P N 089680 RETAINING SCREW P N 056892 3 7 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt
42. CME LOCK FOLD LOCKED STANDING OFF SET DOUBLE LOCK DOUBLE SEAM GORDON SEAM LOCK SEAM STANDARD LAP JOINT A DANGER A Do not install any flammable material directly above or around the compartment Heat transferred through the compartment struc ture may be sufficient to ignite char or dis color seat cushions fiberboard and other flammable materials Use approved nonflam mable insulating materials in high tempera ture 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 A DANGER Do not install sound insulation or any absor bent material on the compartment floor inte rior 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 effectiv
43. CT AIR IN DOOR 6 064077 1 GROMMET OIL FILTER 7 064433 1 U CHANNEL 1 8 8 063377 1 TRAY 530 RV 9 003431 1 GASKET AIR BOTTOM DUCT 10 0F9199 1 PLUG PLASTIC 1 093 1 125 11 0G3430 1 GASKET AIR IN TOP DUCT 12 0G3402 1 DUCT AIR IN ROOF 13 090388 13 SCREW HHTT M6 1 0X12 ZINC 14 063422 1 TOP DIVIDER PANEL 15 065237 1 FOAM SIDE ENCLOSURE 16 063399 1 ENCLOSURE SIDE BACK 17 0D3472 1 GROMMET OVAL 31 75X50 8 18 064933 18 SCREW SWT 1 4 20X5 8 W W 23 065238 1 FOAM BACK ENCLOSURE ALT SIDE 24 063397 1 ENCLOSURE ROOF 25 064391 1 ENCLOSURE BACK PANEL 530 RV 26 065239 1 FOAM BACK PANEL ENCLOSURE 28 063392 1 UPPER BLOWER HOUSING 29 063754 1 UPPER BLOWER HOUSING GASKET 30 063398 1 EXHAUST DIVIDER PANEL 31 063912 1 MUFFLER HOLD DOWN 32 0G3400 1 ENCLOSURE EXHAUST SIDE PANEL 33 0G5240 1 FBR GLASS ENCLOSURE MFLR BACK 34 0G5242 1 FOAM EXHAUST END ENCL FRONT 35 005241 2 FBR GLASS ENCLOSURE MFLR SIDE 36 045756 9 SCREW HHTT M6 1 0X10 ZYC 37 0G5755 1 BUMPER 38 0G5761 1 STAND OFF 39 022473 1 WASHER FLAT 1 4 40 022097 1 WASHER LOCK 1 4 41 022287 1 SCREW HHC 1 4 20 X 3 4 G5 42 063429 1 GASKET SCROLL DUCT SHEET METAL PAINT MATERIAL CODE LEGEND The following exploded views contain part numbers of various sheet metal components Only the base part number is listed When ordering sheet metal the correct color and material information must be included as a suffix at the end of the part number as shown below Material Color Example Desc
44. DER 19 066849 2 SCREW HHTT M5 0 8 X 16 20 063542 1 FAN UPPER ALTERNATOR 21 022131 1 WASHER FLAT 3 8 M10 ZINC 22 042633 1 SCREW HHC 3 8 24 X 1 G5 23 022237 1 WASHER LOCK 3 8 51 CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and the United States Environmental Protection Agency EPA together with Generac Power Systems Inc Generac are pleased to explain the Emission Control System warranty on your new 2008 and later generator New equip ment that use small spark ignited engines must be designed built and equipped to meet stringent anti smog standards for the state of California and the federal government Generac will warrant the emission control system on your generator for the period of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your equipment Your emission control system may include parts such as the carburetor ignition system fuel system catalytic converter and other associ ated emission related components if equipped MANUFACTURER S WARRANTY COVERAGE This emission control system is warranted for two years If during such warranty period any emission related part on your equipment is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Dealer OWNER S WARRANTY RESPONSIBILITIES
45. DUCT 0G5676A 1 GASKET AIR OUT DUCT OPPOSITE SIDE 30 0G4692 1 SCREEN BOTTOM AIR OUT 31 022473 3 WASHER FLAT 1 4 M6 ZINC 32 0A2110 3 SCREW SWAGE 1 4 20 X 1 2 ZYC 33 063410 5 ISOLATION SPRING 34 063393 1 MUFFLER 530 RV 067887 1 MUFFLER 530 MODELS 5410 1 5412 1 5414 1 ONLY 35 025145 1 BOLT U 5 16 18 X 1 25 W SADDLE 36 008565 4 SCREW SHC M8 1 25 X 18 G8 8 37 056892 1 SCREW CRIMPTITE 10 24 X 3 8 38 089680 1 SCREEN SPARK ARRESTOR 39 094670 2 CLAMP EXHAUST 40 063394 1 EXHAUST FLEX 41 063395 1 EXHAUST MANIFOLD 42 056893 6 SCREW CRIMPTITE 10 24 X 1 2 43 023897 6 WASHER FLAT 10 ZINC 44 0G4260 2 GASKET EXH BASE 530 RV 45 0E9369 2 GASKET EXHAUST GT530 45 Exploded Views amp Parts Lists Engine Accessories Drawing No 0G7718 K DETAILA SCALE 2 000 49 8 FEST 2 gt e m SA A NEAR C V E 8 WEY VE 3 SEE DETAILA 46 Engine Accessories Drawing No 0G7718 K Exploded Views amp Parts Lists ITEM PART NO QTY DESCRIPTION ITEM PART NO QTY DESCRIPTION 1 007670 1 FRAME 50 063386 1 OIL FILTER SUPPORT 3 003404 1 ENGINE WRAPPER STARTER SIDE 51 0 2311 2 SCREW SWAGE 1 4 20 X 1 4 0 9507 8 SCREW HHFC M8 1 25 X 14 52 070185B 1 OIL FILTER 5 0234845 1 SNAP BUSHING 53 009235 1 OIL PRESSURE SWITCH 5 PSI 6 056893 14 SCREW CRIMPTITE 10 24 X 1 2 54 064793 1 SWITCH THERMAL 270F 9 1 SHIELD WRAPPER CYLINDER 1 55 043182 2 WASHER
46. E 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 P O BOX 297 WHITEWATER WI 53190 Rev A 06 09 Part No 0H3467 Revision B 04 15 10 Printed in U S A
47. E 39 0E9351 2 GASKET CYLINDER HEAD 40 065728 1 SCREEN 41 0 9455 4 PUSHROD 42 083235 4 TAPPET 43 0G7679 1 CAM SHAFT amp GEAR 44 0E9350 1 GASKET CRANKCASE 45 0E9334G 1 COVER ROCKER 46 0E9305 1 CYLINDER HEAD CYL 2 47 0E9429C 1 CRANKCASE 48 0E9366 1 GASKET BREATHER ASSEMBLY 49 0G5670 1 BREATHER ASSY 50 008566 1 SCREW HHFC 6 1 0 20 51 005943 1 SEAL OIL PASSAGE 92 060273 1 GASKET 53 065896 1 BREATHER KIT 54 060275 1 KIT HEAD ASSY CYLINDER 1 55 0G0276 1 KIT HEAD ASSY CYLINDER 2 49 E 19 o 197 gt tc Exploded Views amp Parts Lists 50 Rotor amp Stator Drawing No 0G3953 B Exploded Views amp Parts Lists ITEM PARTNO DESCRIPTION 1 052858 6 NUT TOP LOCK FL M8 1 25 2 075237 4 WASHER SPRNG CENTER 3 075242 4 SPRING GEN MOUNT 4 001878 2 SUPPORT SLIDE 5 073146 4 SLIDE NYLON 6 052203 2 SCREW HHC M8 1 25 X 70 G8 8 7 022145 6 WASHER FLAT 5 16 M8 ZINC 9 063913 4 STUD 530 RV STATOR 10 029459 2 TENSION SPRING 11 075215 2 WASHER SPRING CENTR 12 063382 1 LOWER BEARING CARRIER 13 0G3877H 1 RTR 200 4 5AD1 RV 0G3878H 1 RTR 200 5 5AD1 RV 0G3879H 1 RTR 200 6 5AD1 RV 14 0G3893H 1 STR 200 4 5AD1 RV 0G3894H 1 STR 200 5 5AD1 RV 0G3895H 1 STR 200 6 5AD1 RV 15 003381 1 UPPER BEARING CARRIER 16 022129 4 WASHER LOCK M8 5 16 17 045771 4 NUT HEX M8 1 25 G8 CLEAR ZINC 18 066386 1 ASSEMBLY BRUSH HOL
48. ER GROUNDED NEUTRAL WINDINGS e The AC connection system on air cooled generators uses a GROUNDED neutral A separate green ground wire is connected to the recreational vehicle s junction box Total load connected across T1 Red to T2 White and T3 Black to T2 White must not exceed rating for the specific generator see Generator Specifications NOTE Do NOT connect loads in excess of circuit breaker ratings 2 1 LOCATION AND SUPPORT 2 1 1 GENERATOR LOCATION NOTE Be sure the installation complies with all standards and codes listed in the Standards Booklets section of this manual The most desirable location for the generator set is between the vehicle s main frame members However this is seldom possible Most units must be installed on the side of the vehicle and are difficult to reinforce Many recreational vehicles have been factory equipped with an area for the generator set Some vehicles may even have a genera tor compartment provided by the vehicle manufacturer Plan the generator location based on the following The generator set must be installed on a framework that is part of the recreational vehicle as outlined in the Generator 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 compon
49. GENERAC Ee ee GENERAC Air cooled Recreational Vehicle Generators RV 45 55 and 65 www generac com or 1 888 GENERAC Table of Contents Part Operating Instructions Introduction 1 Read This Manual 9 1 Contents i isti dr ute Abana danas 1 Operation and 1 How to Obtain Service 1 Authorized Service Dealer Locator Number 1 Safety Rules ee 2 Section 1 General Information 4 1 1 Generator Identification sees 4 1 2 Generator Applicability 5 1 9 InstallatiOni ine tent 5 1 4 Safes fenera 5 1 5 Generator AC Connection 5 1 6 SpPOCifiCaliONnS idee ddd ete nets 6 1 7 Exhaust Emissions Information Gasoline 7 1 8 Evaporative Emissions Information 8 Section 2 Operation 8 2 1 Generator Control 8 2 2 Optional Remote Start Stop Panel 9 2 3 Automatic Choke 2 2 20 1 1 02 9 2 4 Before Starting the 9
50. Installer and Safety Rules Comply with all safety rules to prevent death personal injury or damage to equipment and or property Stress safety to all installers operators and service technicians who work on this equipment 1 3 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The following standards booklets latest revi sion 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 RVIA EGS 1 available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 available from the State of California Documents Section PO Box 1015 North Highlands CA 95660 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 20 1 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to air cooled generators These generat
51. KE HEATER CS CHOKE SOLENOID WHITE GREEN BLACK ES EVAPORATIVE PORT SOLENOID F1 FUSE 7 54 FP FUEL PUMP FS FUEL SDLENUID CUSTOMER GRD1 CONTROL PANEL GROUND CONNECT BOX GRD2 UNIT GROUND STUD HTD HIGH DIL TEMPERATURE SWITCH 4500W IM1 IGNITION MODULE CYL 1 CB 1 30A 1 POLE CIRCUIT BREAKER IM IGNITION MODULE CYL 2 IMS IGNITION MODULE STUD LED ALARM INDICATOR 1 LOP LOW OIL PRESSURE SWITCH SC STARTER CONTACTOR 4 SCR STARTER CONTACTOR RELAY BA SM STARTER MOTOR SP1 SPARK PLUG CYL 1 CLOSEST TO BEARING SP2 SPARK PLUG CYL 2 SW1 PRIME START RUN DFF SWITCH TB TERMINAL BLOCK 4 TAB 38 Wiring Diagram Drawing No 0H3633 A Electrical Data Je 56 GOVERNOR ACTUATOR v e CONTROL PRINTED CIRCUIT BOARD 0 16 HTO LOP SP1 7g J1 1 2 3 4 5 6 7 819 lt 17 14 85 56 0 spe 18 15 86 712 90 18 0 85 0 86 18 0 241 BLK RED 5 LED 0 0 86 712 712 21 0 85 18 18 17 18 56 56 17 4 1 56 5 90 90 14 712 0 14 14 0 16 0 0 0 e 0 es
52. LOCK M3 8 008563 12 SCREW HHFC M6 1 0 X 12 68 8 56 061085 2 SCREW PPHM M3 0 5 X 8 9 063405 1 ENGINE WRAPPER BACK 58 004576 1 OIL TUBE 10 0G4985A 1 BACKPLATE 59 042110 1 SCREW SWAGE 1 4 20 1 2 11 0E9525A 1 ASSY FLYWHEEL amp RING GEAR 29D 60 003407 1 WRAPPER ENGINE VALLEY 12 0E4997 1 ASSY GROUND WIRE CONNECTOR 61 003915 1 WRAPPER UPPER VALLEY 13 067198N 1 WASHER BELV 20 X 2 2 62 063840 1 WRAPPER INNER CYLINDER 2 14 067890 1 NUT HEX M20 1 5 G8 63 063839 1 WRAPPER INNER CYLINDER 1 15 063911 1 BLOWER HOUSING 64 0E9368 2 SPARKPLUG 16 004130 1 SHIELD WRAPPER CYLINDER 2 65 007671 1 OIL LINE OUT 17 082774 1 KEY WOODRUFF 4 X 19D 66 003389 1 OIL LINE IN 18 003454 1 BREATHER HOSE 67 047094 2 SCREW PPHM 224 40 X 1 4 19 022131 3 WASHER FLAT 3 8 M10 ZINC 68 008590 1 ASSEMBLY BI METAL HEATER 20 005221 1 IGNITION COIL CYLINDER 1 69 008591 1 CHOKE SOLENOID 21 0G5221B 1 IGNITION COIL CYLINDER 2 70 003984 1 CONTROLLER ASSEMBLY 22 006432 4 SCREW HHFC M6 1 0 X 25 SEMS 71 043146 2 SCREW M6 1 0 X 10 68 8 23 9 2 GASKET 72 022097 6 WASHER LOCK 6 1 4 24 0E9333 1 INTAKE MANIFOLD 73 0D6342 1 BALL STUD 10 MM 25 040976 4 SCREW SHC M8 1 25 X 20 G12 9 74 009784 1 LOCK M3 0 5 26 0E9471 1 GASKET MANIFOLD TO CARB MIXER 75 064016 1 BRACKET CONTROLLER SUPPORT 27 0 93830 1 CARBURETOR 76 043116 2 SCREW HHC M6 1 0 X 12 G8 8 28 069640 1 ROD CHOKE CONTROL 77 07177 1 ASSY GROUNDING WIRE W 0 DIODES 29 063890
53. Perform more often when operating in dusty conditions 1 Atthe Air Cleaner Cover turn the yellow plastic knob 4 turn counter clockwise 2 Pullthe top of the Cover out as it hinges on the bottom of the Air Cleaner Base 3 Separate the Cover by lifting up and out from the Base Pull the old filter out and discard safely 5 Install the new filter in place on the Air Cleaner Base Figure 3 3 6 Interlock the Air Cleaner Cover to hinge with the Air Cleaner Base 7 Align the Cover and gently push the top closed 8 Engage the yellow plastic knob and turn W turn clockwise to secure gt Figure 3 3 Engine Air Cleaner Air Cleaner Base Air Cleaner 3 4 CHECKING THE ENGINE SPARK PLUG Reset the spark plug gap or replace the spark plugs as necessary See the Service Schedule section for maintenance requirements 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine 2 Remove the spark plugs and check the condition Replace the spark plugs if worn or if reuse is questionable See the Service Schedule section for recommended interval Clean by scrap ing or washing using a wire brush and commercial solvent Do not blast the spark plugs to clean 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76mm 0 030 inch by carefully bending the ground electrode if necessary Figure 3 4 Figure 3 4 Setting the Spark Plug Gap wy
54. UATE COOLING 33 Post Installation 3 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT Generator is properly located Generator is properly supported Generator is properly restrained GENERATOR COMPARTMENT Compartment construction is proper Holes Openings are vapor sealed Compartment size is correct Compartment is vapor sealed Sound insulation is correct Floor cutouts are properly completed COOLING AND VENTILATING AIR D Airflow is adequate J Air inlet opening is correct Compensate for restrictions Check that installation has been tested GASOLINE FUEL SYSTEM Fuel tank complies with all applicable codes Q Fuel system is properly installed and checked for leaks EXHAUST SYSTEM Exhaust system is properly and safely installed DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER 34 Exhaust system complies with all applicable codes ELECTRICAL CONNECTIONS 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 Generator is always isolated from other power sources BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Cables are clean and tig
55. UND STUD HTO HIGH OIL TEMPERATURE SWITCH 4500W IM1 IGNITION MODULE CYL 1 CB 1 20A 1 POLE CIRCUIT BREAKER IM2 IGNITION MODULE CYL 2 CB 2 20A 1 POLE CIRCUIT BREAKER IMS IGNITION MODULE STUD LED ALARM INDICATOR 55004 L n LUP LOW DIL PRESSURE SWITCH c SE STARTER CONTACTOR ne SCR STARTER CONTACTOR RELAY BA SM STARTER MOTOR SP1 SPARK PLUG CYL 1 6500W CLOSEST TO BEARING SP2 SPARK PLUG CYL 2 CB 1 30A 1 POLE CIRCUIT BREAKER SW1 PRIME START RUN HFF SWITCH CB 2 30A 1 POLE CIRCUIT BREAKER TB TERMINAL BLOCK 4 TAB 36 Wiring Diagram Drawing No 0G4221 C Electrical Data Je 96 16 NOS 5 CONTROL PRINTED CIRCUIT BOARD E HTO LOP spia 31 1T 13141816 T7T8 ET lt Ime 17 14 85 56 0 4 spe lz 18 15 86 712 90 18A 0 85 0 86 18 0 241 BLK RED 56 o o l P 86 712 712 85 18 18 17 1 18 56 56 17 4 56 Cs 90 90 M 14 712 0 0 CH 14 14 0 13 16 0 O 0 0 0 ES 0 ES 14 4 14 4 Iw 0 0 GA o sc 16 16 13 15 V REMOTE Fi PANEL CONNECTOR 13 BATTERY 12 0 0 0 0 4 Os BO 1 18 18 712 CO7 17 14 QE DO BLACK 14 718
56. amage to equipment and or property The manu facturer suggests copying and posting the GENERAL SAFETY RULES to potential operators of this equipment 1 5 GENERATOR AC CONNECTION SYSTEM These air cooled generator sets are equipped with dual stator AC power windings These two stator windings supply electrical power to customer electrical loads by means of a dual 2 wire connection system Generators may be installed to provide the following outputs 1 120 VAC loads only two loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120V across the generator output terminals Figure 1 1 shows the generator lead wire connections for 120VAC ONLY Figure 1 1 Connection for 120 Volts Only ON n 33 CB1 O RED x 11 6 2 T 2 BLACK zo 59 120V az oz z 120V 4 T2 EN WHITE T2 v 77 WHITE GROUNDED NEUTRAL General Information 2 120 240 VAC loads one load with a maximum total watt age requirement equal to the generator s rated power output and 240V across the generator output terminals or two sepa rate loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120V across the generator output terminals Figure 1 2 shows the generator lead wire connections for 120 240 VAC loads Also refer to the Line Breakers section for circuit
57. art repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS warranty shall be warranted for the remainder of the period prior to the first scheduled replacement point for that part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 Notwithstanding the provisions of subsection 4 above warranty services or repairs must be provided at Generac Authorized Service Facilities 6 When the engine is inspected by a Generac Authorized Warranty Service Facility the purchaser owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such parts 8 Any Generac authorized and approved emission related replacement parts may be used in the performance of any ECS warranty maintenanc
58. ater from one engine can damage the other engine 2 5 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 Or an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable for any damage injury or warranty expense that might be caused by such unapproved installation or modification Failure to provide and maintain a spark arrestor may be in violation of the law If this generator is used on any forest covered brush covered or grass covered unimproved land a spark arrestor must be provided The vehicle owner or operator must maintain this device in good condition In the state of California the preceding is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands When installing replacing the tailpipe or spark arrestor compo nents verify that the tailpipe has a hole to securely fasten the spark arrestor components see Figures 2 11 and 2 12 Use only manufacturer supplied hardware Substitution of parts may cause damage to the screen or a loose fit to the tailpipe 28 Figure 2 11 Spark Arrestor TAILPIPE P N 0E0683 SPARK ARRRESTOR SCREEN P N 089680 RETAINING SCREW P N 056892 Figure 2 12 Spark Arresto
59. ch if so equipped is set to wrong position 3 Failure in vehicle electrical system 4 Generator component failure Automatic choke not operating properly Correction 1 2 FI m OF eS O go c gx GO Replace blown fuse Tighten clean or replace as necessary Recharge or replace battery Replace switch Replace starter contactor Replace starter motor Contact an authorized service dealer Refill fuel tank Repair or replace pump Repair replace or adjust Wait 5 10 minutes try again Replace filter if clogged Clean regap or replace as needed Replace if defective Adjust repair or replace Clean or replace as needed Clean or replace as needed Free choke linkage as needed Clean regap or replace Replace it if defective Add oil as needed Replace if bad Replace if bad Drain fuel tank and refill Disconnect remote harness Contact authorised service facility Close main breaker s Reset transfer switch See vehicle manual Contact an authorized service facility Electrical Data Wiring Diagram Drawing No 0G4221 C
60. correct hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut Tighten the jam nut to 174 in Ibs torque After tightening the jam nut recheck valve clearance to make sure it did not change Install new valve cover gasket Re attach the valve cover NOTE Start all four screws before tightening or it will not be possible to get all the screws in place Make sure the valve cover gasket is in place Install spark plugs e Re attach the spark plug wire to the spark plug e On the GT 530 repeat the process for the other cylinder Maintenance 3 10 MAJOR SERVICE MANUAL To obtain a service manual for the generator contact the near est Authorized Service Dealer Make sure to identify the MODEL NUMBER and SERIES 3 11 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement Drive belt tension was properly adjusted before the unit was shipped from the factory If suspect that drive belt tension is incorrect contact an Authorized Service Dealer 3 12 EXERCISING THE GENERATOR The manufacturer recommends starting and operating the genera tor at least once every seven days Let the unit run for at least 30 minutes to exercise the engine 3 13 OUT OF SERVICE PROCEDURE 3 13 1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days and it is to be out of service longer than 30 days prepare the generator for storage as follows
61. dd the watts or amperes of all lighting appliance tool and motor loads the generator will operate at one time This total should be less than the unit s rated wattage amperage capacity 2 6 4 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The following general rules apply Cut wiring to the required length and allow extra wire for junc tion box connections Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation Route conduit so it does not interfere with generator move ment If using metallic conduit vapor seal the end of the conduit where it enters the junction box Do this because flexible metal lic conduit is not vapor proof along its entire length 2 6 5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 2 14 An alternate method for isolating different power sources is by using an isolat ing receptacle Figure 2 15 Whichever method is used be certain that both power sources are NOT connected at the same time 2 6 6 POWER SUPPLY CORD The power supply cord must comply with all applicable codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected 2 6 7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code NFPA 70 article 551 requires that ground fault circu
62. e door perimeter Figure 2 7 Typical Noise Abatement EXTERIOR SOUND INSOLATION MATERIAL PLYWOOD 5 8 OR 3 4 THICK PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 inch 25 mm thick fiberglass with a 2 pound density 2 2 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items Figure 2 9 e Engine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts See Generator Restraint A DANGER Fuel lines and exhaust piping must not pen etrate into the vehicle living area 2 3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling ventilating and engine combustion be supplied to the generator set Without sufficient airflow the engine generator quickly overheats Such overheating can cause serious operating difficulties and also may cause fire and personal injury The installer must make sure that sufficient 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 A DANGER Never use discharged cooling air for heating or permit such air to enter the vehicle inte rior This air contains
63. e on gasoline The emission control system on the generator consists of the following 2 2 8 4 2 1 1 37 5 18 7 45 8 22 9 54 1 27 Fuel Metering System Carburetor assembly Fuel pump and lines Air Induction System Intake pipe manifold Air cleaner e Ignition System Spark plug Ignition module e 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 gt 66cc lt 22500 250Hours 1000 Hours B 500 Hours 250 Hours gt 225 cc 1 8 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
64. e or repairs and will be provided without charge to the purchaser owner Such use shall not reduce Generac ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of Generac equipment caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING IF EQUIPPED 1 FUEL METERING SYSTEM 4 AIR INJECTION SYSTEM A CARBURETOR AND INTERNAL PARTS A PULSE AIR VALVE B PRESSURE REGULATOR 5 EXHAUST SYSTEM 2 AIR INDUCTION SYSTEM A CATALYST A INTAKE MANIFOLD B THERMAL REACTOR B AIR FILTER C EXHAUST MANIFOLD 3 IGNITION SYSTEM A SPARK PLUGS B IGNITION COILS MODULE Part 2 Part No 0H1912 Rev A 05 09 53 Warranty GENERAC POWER SYSTEMS THREE YEAR LIMITED WARRANTY FOR GENERAC 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 fou
65. e the unit until advised by competent authority A DANGER 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 standards and instructions Use the generator set to supply electrical power for operating one of the following electrical loads RV 45 G 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 4500 watts 4 5 kW of total power but cannot exceed 37 5 AC amperes of current at 120 volts breaker is limited to 30 Amps RV 55 G 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 5500 watts 5 5 kW of total power but cannot exceed 45 8 AC amperes of current at 120 volts or exceed 22 9 AC amperes at 240 volts RV 65 G 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 6500 watts 6 5 kW of total power but cannot exceed 54 1 AC amperes of current at 120 volts or exceed 27 AC amperes at 240 volts A CAUTION Do not overload the generator Some instal lations may require that electrical loads be alternated to avoid overloading Applying
66. eaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load see Testing Under Load Run the unit at least 30 min utes with loads applied 6 Turn off all electrical loads by setting the generator s main Circuit breakers to their OFF or open position 7 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine NOTE The generator set was thoroughly tested and adjusted at the fac tory before shipping No additional adjustment should be neces sary Only qualified service technicians who have been trained should perform adjustments outlined in this manual 3 4 TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 percent of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling airflow is available Do not allow the unit to overheat during prolonged operation NOTE The generator engine is equipped with a high temperature switch The switch has normally open N 0 contacts When the engine temperature is too high switch contacts close and the engine shuts down automatically THE MANUFACTURER RECOMMENDS THAT THE GENERATOR BE TESTED FOR ADEQ
67. ectrical loads Add fuel if necessary and then start the engine 6 Allow the unit to warm up thoroughly 7 Apply electrical loads to at least 50 percent of the unit s rated wattage capacity 8 When the engine is thoroughly warmed up shut it down 9 The generator is now ready for service 3 14 RV GENERATOR SERVICE INTERVAL 1st 8 Hours then every 200 Change Engine Oil Filter 1st 50 Hours then every 500 Adjust Valve Lash 200 ess Clean Spark Arrestor 200 ROUSE es Replace Paper Air Filter Element 400 ctt teet dern Replace Fuel Filter 500 HOS as Replace Spark Plugs Part II Installation Instructions Part Il Installation Instructions ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION Safety Rules DANGER For fire safety installation of a generator into a recreational vehicle must comply strictly with article 551 NFPA 70 ANSI C1 1975 AND ANSI A119 2 1975 NFPA 501C Standard for Recreational Vehicles Part 3 Installation of Electrical Systems In addition installation must comply with the man ufacturer 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 fami
68. ely than a single material For example a sheet of lead or visco elastic material along with a layer of other acoustical material is more effective than when a single material is used Installation 2 2 4 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement compartment NOTE Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compart ment In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise levels Such a compartment might be constructed as follows Figure 2 7 Use 5 8 inch thick or 3 4 inch thick plywood in the compart ment Construct the compartment floor of a double thickness of 5 8 inch or 3 4 inch plywood Line the compartment interior walls and floor as well as the underside of the floor with 26 gauge galvanized steel Vapor seal all compartment seams and joints Over the galvanized steel lining install a combination of acousti cal materials as mentioned in Sound Insulating Materials A DANGER To prevent fire or explosion do not install any insulation or other absorbent materials on the interior or underside of the compart ment floor Seal all compartment door edges to prevent noise leakage around th
69. ents such as filters oil drains spark plugs and other common maintenance parts 22 The location must provide sufficient room to allow minimum clearances as outlined in Generator Compartments If sound insulation is to be used on the compartment walls and ceiling the minimum recommended applies to the space between the generator and such insulation The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense If mounting the generator in an enclosed compartment the base of the generator must rest flat on the floor without any gaps When using a suspended mounting system ensure the base of the generator is flush with the surrounding bodywork If the unit is mounted higher in the structure heated air may recirculate into the generator causing it to overheat 2 1 2 GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding The metal framework on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams These beams should consist of a 1 1 2 inch square 11 gauge steel tubing OR b 1 1 2 inch 11 gauge angle iron A typical supporting frame with horizontal support tubing is shown in Figure 2 1 Figure 2 1 Typical Horizontal Support Frame SUPPORT TUBING The generator can be installed so that it s
70. er ate Before starting it check that sufficient fuel is available NOTE Depending on the installation the generator may have either a separate fuel tank or it may share the vehicle engine s fuel tank 244 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 4 5 ENGINE EXHAUST GAS Before starting the generator engine be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals Close windows doors and other openings in the vehicle that if open might permit exhaust gases to enter the vehicle A DANGER The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentrations can cause uncon sciousness 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 Shut down the generator and do not operate it until it has been inspected and repaired SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coherently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weak
71. folds Generac RV generators manufactured prior to December 31 1997 DO NOT have a transferable warranty Generac RV generators manu factured 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 Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechani cal devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake
72. hat this warranty shall not apply to any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replace ment of the defective part s This warranty is in place of all other warranties expressed or implied Specifically Generac makes no other warranties as to the merchantability or fitness for a particular purpose Some states do not allow limitations on how long an implied warranty lasts So the above limitation may not apply to you The ECS Warranty applies only to the emission control system of your new equipment If there is any conflict in terms between the ECS Warranty and the Generac Warranty the Generac Warranty shall apply Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty service evidence must be presented showing the date of the sale to the original purchaser owner If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the following address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC BOX 297 WHITEWATER WI 53190 Part 1 Part No 0H1912 Rev A 05 09 52 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS warranty for equipment using small spark ignited engines a Applicab
73. his 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 Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators 18 GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and maintenance of this equipment is carried out by an Authorized Service Dealer The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area Shut down the generator and do not operate it until it has been inspected and repaired DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coherently b nausea c vomiting d twitching muscles e throbbing temples f dizzi ness g headaches h weakness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Never
74. ht Cables are connected properly Proper ventilation is provided Terminals are coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES Check that remote start stop panels if used are 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 A Check that all tests are completed properly Troubleshooting 4 1 TROUBLESHOOTING GUIDE Problem Engine won t crank Engine cranks won t start Engine starts hard runs rough Engine starts then shuts down No AC output voltage Cause 7 5 amp fuse blown Loose or corroded or defective battery cable s Battery is discharged or defective Defective Start Stop switch Defective starter contactor Defective starter motor Defective Engine Control Board DX E Om 69 Out of fuel Fuel pump not operating Engine is flooded Fuel filter is clogged Engine spark plugs defective Bad ignition magneto on engine Bad carburetor Dirty air cleaner O Go TX MO Dirty engine air cleaner Automatic choke is sticking Defective spark plugs Defective ignition magneto qoo Don Engine oil level is low Bad low oil pressure switch Defective high temp switch Water in fuel Defective remote harness Cn Eoo arcs 1 Main breaker s open Transfer swit
75. ient temperatures Generally the longer the cable and the colder the weather the larger the cable size must be as shown in the chart CABLE LENGTH in Feet meters CABLE SIZE 2 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 NOTE Where a minimum of 1025 CCA cold cranking amps battery current is available up to 30 feet of AWG 2 battery cable is permitted 2 7 3 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or 4 to the lug on the starter contactor Figure 2 16 NOTE Check to be sure the battery cable boot for the starter cable has been installed 2 Connectthe battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connection Figure 2 16 3 Connect cables so the connectors are clean and tight Installation Figure 2 14 Typical Transfer Switch Isolation Method 2ND AIR FROM 20 AMP CONDITIONER HACR BREAKER JUNCTION BOX VEHICLE WIRING FLEXIBLE CONDUIT BU HE VEHICLE AC DOUBLE DISTRIBUTION PANEL THROW m ud ij SWITCHING 30 AMP DEVICE MAIN BREAKER HACR BREAKERS FOR AIR CONDITIONERS GFCI POWER SUPPLY CORD BREAKERS Figure 2 15 Typical Installation With Isolation Receptacle DOCKSIDE POWER RECEPTACLE JUNCTION gt BOX FLEXIBLE CONDUIT POWER pami SUPPLY OT CORD
76. ility This warranty shall apply to equipment that uses small off road engines The ECS Warranty period shall begin on the date the new equip ment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each sub sequent purchaser owner that the ECS when installed was 1 Designed built and equipped so as to conform with all applicable regulations and 2 Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS Warranty Period c The warranty on emissions related parts will be interpreted as follows 1 Any warranted part that is not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it 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 part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in the Owner s Manual to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such p
77. ing source prior to connect ing or disconnecting battery terminals and Do not use any jumper cables or booster battery to crank and start the generator engine If any battery has discharged remove it for recharging A WARNING Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electri cally conductive and corrosive The follow ing 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 bicarbonate of soda solution is to be added until the evidence of reaction foam ing has ceased The resulting liquid is to be flushed with water and the area dried 3 9 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation check the valve clearance in the engine adjust if necessary Important If feeling uncomfortable about doing this procedure the proper tools are not available please contact the Authorized Dealer for service assistance This is a
78. 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 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 a
79. ires terminals connections etc while the unit is running Ensure all appropriate covers guards and bar riers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle have the generator prop erly grounded bonded either by solid mounting to the vehicle frame or chassis or by means of an approved bonding conduc tor DO NOT disconnect the bonding conductor if so equipped DO NOT reconnect the bonding conductor to any generator part that might be removed or disassembled during routine mainte nance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum In case of accident caused by electric shock immediately shut down the source of electrical power If this is not pos sible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting implement such as a rope or board to free the victim from the live conductor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in
80. it interrupters GFCIs on all external and some internal electrical receptacles be installed Contact the manufac turer or dealer for recommendations 2 7 BATTERY INSTALLATION NOTE This generator is not equipped with an internal battery charger It is intended for use in systems where an external battery char ger is installed by the RV O E M or an aftermarket installer 30 2 7 1 RECOMMENDED BATTERY Install a battery that meets the following requirements e 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 7 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 These generators are rated at about 100 DC amperes of cranking current Select battery cables based on a cable length and b prevail ing amb
81. its on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the generator below the horizontal support tubing by means of suitable structurally sound metal framework The fol lowing general rules apply Vehicle construction MUST be capable of supporting the weight of the generator Whether the generator is mounted above the horizontal support tubing or suspended below the tubing the supporting frame used must be structurally sound If the generator cannot be bolted directly to the supporting frame or support tubing consider using additional tubing angle brackets or other supports to give the supporting frame sufficient strength Installation 2 1 3 SUSPENDED MOUNTING If planning to suspend the generator below the horizontal sup port tubing the suspension method to use with the vehicle frame members must a be able to support the weight of the generator AND b provide sufficient restraint for the generator One typical suspended mounting system is shown in Figure 2 2 The location of a suspended mounting system must be carefully planned keep ing the following general rules in mind Protect the generator against road splash and 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
82. ks or any source of heat in the vicinity while handling gasoline Comply with all laws governing the storage and handling of gasoline This generator may use liquid propane LP gas as a fuel LP gas is highly EXPLOSIVE The gas is heavier than air and tends to settle in low areas where even the slightest spark can ignite the gas and cause an explosion General Information 1 1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage 5 Phase 6 Hertz 1017 3 45 1 12 11 14 16 1 DI lo J REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake 10 Fuel Pump 2 Data Plate 11 Oil Filter 3 Engine Start Stop Switch 12 Oil Drain Plug 4 7 5 amp Fuse 13 Oil Dipstick and Filler Tube 5 Circuit Breaker 14 Air Filter Behind access panel 6 Optional Remote Panel Receptacle 15 Spark Plugs 7 Generator AC Output Leads 16 Exhaust Outlet 8 Starter Contactor 17 Fuel Filter 9 Fuel Inlet 18 Evaporative Port General Information 1 2 GENERATOR APPLICABILITY These generators have been designed and manufactured for sup plying electrical power for recreational vehicles DO NOT modify the generator or use it for any application other than for what it was designed If there are any questions pertaining to its applica tion write or call the factory Do not us
83. l after the generator engine has started and stabilized at no load 2 7 2 DO NOT OVERLOAD THE GENERATOR Read the rated wattage amperage capacity of the generator on the generator data label See the Generator Identification section Applying electrical loads in excess of the unit s rated capacity will cause the engine generator to automatically shut down To avoid overloading add up the wattage of all connected electrical lighting appliance tool and motor loads This total should not be greater than the generator s rated wattage capacity Most lighting appliance tool and motor loads indicate their required watts on their nameplate or data plate For light bulbs simply note the wattage rating of the bulb 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 times more watts of power for starting than for running for a few seconds during motor starting Be sure to allow for this when connecting electrical loads to the generator First figure the watts needed to start electric motors in the system To that figure add the running wattages of other items that will be oper ated by the generator Do not apply heavy electrical loads for the first two or three hours of operation 2 8 PROTECTION SYSTEMS 28 1 LOW OIL PRESSURE SWITCH This switch
84. lation Do not terminate the exhaust system under any opening win dow or vent that can be opened or is not permanently sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all appli cable codes standards and regulations 2 6 ELECTRICAL CONNECTIONS 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 2 6 1 ELECTRICAL JUNCTION BOX Install an approved square electrical junction box with a blank
85. liar with the procedures for installing such products or similar products manufactured The manufacturer also assumes that personnel have been trained in the recommended installation procedures for these products and that such training includes a use of common hand tools b use of special tools and c use of any tools and or equipment from other suppliers The manufacturer cannot possibly know of and advise the rec reational vehicle trade of all conceivable methods procedures or techniques by which to perform an installation Nor can the manu facturer anticipate every possible hazard that might result from each installation method procedure or technique The manufactur er has not undertaken any such wide evaluation Therefore people who use a method 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 DANGER Despite the safe design of t
86. m drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ventilating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or permit even partial blockage of ven tilation provisions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing 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 Safety Rules ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical Shock Avoid contact with bare w
87. moving components causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installation do noth ing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regulations Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator elec trical system Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS 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 spar
88. nd 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 General Information 1 1 PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS 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 codes 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
89. nd to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac generators sold and rated for Recreational Vehicle RV applications as Generac has defined Recreational Vehicle generator applications The factory recommends exercising the unit one half hour every month WARRANTY SCHEDULE COMMERCIAL APPLICATIONS YEAR ONE 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 reinstallation listed Engine All components Alternator All components YEAR THREE 100 one hundred percent only on selected part s and labor listed Any labor and part s not listed and removal and reinstallation are the owner s responsibility Rotor Stator Computer Control Board part numbers 0A6060 and 0A3369 and inverter if applicable with regard to the generator Cylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Mani
90. ne 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 running generator operation may drain the vehicle engine supply line making it dif ficult to start the vehicle engine 24 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 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 2 4 2 2 Flexible Fuel Line Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines This prevents breaking of the line caused by vibration shifting settling or movement The following rules apply The flexible hose must comply with SAE J30R7
91. ness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP A DANGER Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust sys tem must be installed in accordance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area 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 certain DC lighting and other DC loads To crank and start the generator engine proceed as follows 1 Turn OFF electrical loads using the means provided in the vehicle such as a main line circuit breaker or transfer switch 10 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 should be turned ON after the generato
92. nter position is the RUN position To stop a running engine press momentarily the bottom half of the switch to kill the ignition 2 1 2 7 5 AMP FUSE The fuse protects the engine s DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine cannot be cranked If the fuse must be replaced use only an identical 7 5 amp replacement fuse 2 1 3 LINE BREAKERS Protects generator s AC output circuit against overload i e pre vents unit from exceeding wattage amperage capacity The circuit breaker ratings are as follows Ci Breaker 1 Cir Greater 2_ _240 vot 30A N A N A RV55 20A 30A RV65 30A 30A NOTE If this generator has been reconnected for dual voltage AC out put 120 240 volts install line breakers having an amperage rating equal to that stated in the preceding chart The replace ment line breakers consist of two separate breakers with a connecting piece between the breaker handles so that both breakers will operate at the same time If the unit is recon nected for dual voltage it is no longer RVIA listed 2 1 4 DIAGNOSTICS If the generator shuts down due to a fault the indicator will flash a code to identify the problem 2 Flashes Low Battery Voltage falls below 11 0 VDC for one minute NOTE Alarm will clear automatically if voltage rises over 11 0 VDC Battery voltage is not monitored during crank cycle 3 Hashes Overcrank
93. operating or servicing this equipment Become familiar with this manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique that chosen does not render the generator unsafe A DANGER Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only respon sible and capable persons to operate or maintain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators CALIFORNIA PROPOSITION 65 WARNING Engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm
94. ors are designed specifically for install ing in recreational vehicles They operate 120 volt single phase 60 Hertz AC electrical loads 1 5 GENERATOR ENGINE OPERATING SPEED The generator s revolving field rotor is driven by a two cylinder four cycle engine through a pulley and drive belt arrangement The generator supplies 120 volts AC at 60 Hertz when the rotor is oper ating at 3 600 rpm The drive belt arrangement allows the engine to operate at a lower speed than the rotor 1 6 GENERATOR AC CONNECTION SYSTEM These air cooled generator sets are equipped with dual stator AC power windings These two stator windings supply electrical power to customer electrical loads by means of a dual 2 wire connection system Generators may be installed to provide the following outputs 1 120 VAC loads only two loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120V across the generator out put terminals see Fig 1 1 2 120 240 VAC loads one load with a maximum total wattage requirement equal to the generator s rated power output and 240V across the generator output terminals or two separate loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120V across the generator output terminals see Fig 1 3 Figure 1 1 Connection for 120 Volts Only TI RED w e CB1 O
95. r Installation 3175 91 25 LD 16 L06 x 12 7 L50 1 e SLOTS i 25 4 1 00 1 1778 17 01 R50 8 1 58 rR2 00 1 N 25 5 17 32 1 DRILL SIDE ONLY 609 6 24 0 2 5 2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any combustible material such as wood felt cotton organic fibers or other like material If the 3 inch 76 mm clearance cannot be maintained locate insu late or shield the exhaust part s so that the temperature of any combustible material is not raised more than 117 F 65 C above the ambient air temperature Extend 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 Instal
96. r has started stabilized and warmed up 2 To crank and start the engine push up on the Start Stop switch momentarily and release There is a delay as the fuel pump primes and the generator automatically begins the start sequence Note the flashing light on the switch 3 Letthe engine run at no load for a few minutes to stabilize and warm up 4 Turn ON electrical loads using the means provided such as a main circuit breaker or transfer switch 2 6 STOPPING THE GENERATOR Turn OFF all electrical loads using the means provided such as a main circuit breaker or transfer switch 2 Let generator run at no load for a few minutes to stabilize internal engine generator temperatures 3 Place the Start Stop switch in its STOP position The engine will come to a complete stop 2 7 APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Before applying electrical loads let the generator stabilize and warm up for a minute or two DO NOT overload the generator 2 7 1 LETTING THE ENGINE STABILIZE The generator supplies correct rated voltage only at the proper governed speed Some electrical appliances may be extremely sensitive to voltage Incorrect voltages can damage such appli ances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when sufficient power is not available may shorten engine life Never turn ON electrical loads unti
97. r must be of a larger conductor size 2 6 3 GENERATOR AC CONNECTIONS Generator AC output leads T1 red T2 white and T3 black come out of the generator as shown in Figure 2 13 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 13 Generator AC Output Leads 3 a T2 AC Output Leads TTT Ground 4500 Watts Line T1 black to T2 white is protected by circuit breaker a CB1 Use this line to neutral connection to operate 120 volt single phase 60 Hz AC loads 5500 and 6500 Watts Line T1 red to T2 white is protected against overload by a cir cuit breaker CB1 Use this line to neutral connection separately to operate 120 volt single phase 60 Hertz AC loads Line T3 black to T2 white also is protected against overload by a circuit breaker CB2 Use this line 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 29 Installation A CAUTION Do NOT connect electrical loads in excess of any circuit breaker rating or problems will develop with circuit breaker tripping which causes a loss of AC output Also do NOT exceed the generator s rated wattage capac ity A
98. re 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 4 f necessary remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dipstick Full mark DO NOT FILL ABOVE THE FULL MARK A CAUTION Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 5 Install and tighten the oil fill cap and the dipstick before oper ating the engine Figure 3 1 Oil Dipstick Fill Tube and Location of Oil Drain Plug 8 I kal N Ce gt 0 m Cil Fill Oil Drain Hose Cil Dipstick 12 3 2 CHANGING THE ENGINE OIL AND OR OIL FILTER A CAUTION Hot oil may cause burns Allow engine to cool before draining oil Avoid prolonged or repeated skin exposure with used oil Thoroughly wash exposed areas with soap Oil Change Intervals see Section RV Generator Service Interval To change the oil and oil filter proceed as follows Run the engine until it is thoroughly warmed up at least five minutes then shut off the engine 2 With the engine still warm from running remove the round access grommet from underneath the front of the generator Place a suitable container underneath to catch all the drain
99. rvice Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workman ship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and acces sories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact an Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting an Authorized Service Dealer 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 ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER Safety Rules SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted in potential hazard areas of the recreational vehicle Safety should be stressed to all operators and potential operators of this equipment Study these SAFETY RULES carefully before installing
100. starts the choke stops cycling Gasoline only 2 3 2 PRECHOKE The choke system also has a temperature sensitive metal strip that adjusts choke valve angle according to ambient temperatures i e in cold ambient temperatures choke valve closes more Once the engine starts an element heats the temperature sensitive strip to a normal operating condition opening the choke valve This may take about three minutes in cooler weather Gasoline only 2 4 BEFORE STARTING 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 24 1 INSTALLATION Generator installation must have been properly completed so it complies with all applicable codes standards and regulations and with the manufacturer s recommendations See Part Il Installation Instructions 24 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommend ed oil before starting Refer to sections Engine Specifications Checking the Engine Oil Level and Changing the Engine Oil and or Oil Filter for oil servicing procedures and recommendations A CAUTION Any attempt to crank or start the engine before it has been properly serviced it with the recommended oil may result in an engine failure 24 3 FUEL SUPPLY The engine must have an adequate supply of proper fuel to op
101. tc Never insert any tool or other object through openings in the generator interior even if the unit is not running Serious injury or damage to the equipment could be done Safety Rules ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires terminals connections etc while the unit is running Ensure all appropriate covers guards and bar riers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while stand ing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle 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
102. ush up on the top half of the momentary switch Hold for one 1 second and release Note flashing indicator light on the switch Fuel pump engages automatically for a three 3 to five 5 second delay before starter motor cranks the engine for 16 seconds or until the engine starts If the engine does not start the starter will cool for seven 7 seconds and crank the engine again for 16 seconds If the engine does not start the starter will cool for seven 7 seconds before cranking for seven 7 seconds to a maximum cycle total of 90 seconds Once started the light on the switch stays on continuously If the generator does not start at the end of the start sequence a fault code will flash on the switch see Diagnostics The switch center position is the RUN position To stop a running engine press momentarily the bottom half of the switch to kill the ignition Figure 2 1 Typical Control Panel GENERAC To Start Generator Push up on control switch Hold for 1 second and release Note flashing indicator Generator will start automatically 2 FLASHES LOW BATTERY 3 FLASHES OVERCRANK 4 FLASHES OVERSPEED 5 FLASHES LOW OIL PRESSURE To Stop Generator Push down then release control switch Generator will shut down 6 FLASHES HIGH OIL TEMP Diagnostics 7 FLASHES UNDERSPEED If generator shuts down due to a fault the indicator will flash a code to identify the problem See chart to the right The switch ce
103. vice are essential to prevent ing accidents Four commonly used safety symbols accompany the Danger Warning and Caution blocks The type of information each indi cates follows This symbol points out important safety information that if not followed could endanger personal safety and or property of others 2 This symbol points out potential explosion sA hazard A This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator driver is responsible for proper and safe use of the vehicle and its equipment and the safety of all vehicle occupants We strongly recommend that the operator read this manual and thoroughly understand all instructions before using this equipment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts In addition the latter portion of this manual contains infor mation necessary for the proper installation of these generators OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Se
104. with all applicable evaporative emission regulations If this generator is configured such that it shares the primary fuel system of a vehicle in which it is installed reduced certification requirements may apply See the CARB guidance document MAC 05 05 located at http www arb ca gov msprog macs mac0505 mac0505 pdf for further details If this generator is installed such that it uses a dedicated fuel system detailed evaporative emission requirements apply contact a repu table fuel system manufacturer to purchase a complete fuel sys tem certified for use with this generator or consult the California Code of Regulations if you wish to obtain certification on your own See the installation instructions in this manual for connecting fuel system vapor lines to the engine This generator is not legal for sale in the state of California unless all CARB evaporative emission requirements are adhered to and is not legal for sale in any other state unless certified low per meation fuel line is used to supply the 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 882750 2773 EPA regulations can be found in 40 CFR Part 90 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 2 1 1 START STOP SWITCH This generator is started with a One Touch starting sequence P

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