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Guardian Technologies 004702-0 User's Manual

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1. Replace Fuel Filter HOUT Replace Spark Plugs 15 NOTES 16 Section 4 Notes Recreational Vehicle Generators PART Il INSTALLATION INSTRUCTIONS SAFETY RULES Safety Rules Recreational Vehicle Generators DANGER For fire safety installation of a generator into a recreational vehicle must comply strictly with article 551 NFPA 70 ANSI C1 1975 AND ANSI A119 2 1975 NFPA 501C Standard for Recreational Vehicles Part 3 Installation of Electrical Systems In addition installation must comply with the manufacturer s instructions and recommendations NOTICE TO INSTALLER These Installation Instructions have been published by the manufacturer to aid in the installation of the products described in this manual The manufac turer assumes that installation personnel are familiar with the procedures for installing such products or similar products manufactured The manufacturer also assumes that personnel have been trained in the recommended installation procedures for these products and that such training includes a use of common hand tools b use of special tools and c use of any tools and or equipment from other sup pliers The manufacturer cannot possibly know of and advise the recreational vehicle trade of all conceivable methods procedures or techniques by which to per form an installation Nor can the manufacturer antic ipate every
2. Air cooled Rated Hor Se DOWEL 6225299999 805290880 u Sent toss 27 at 3600 rpm 760cc garrie 8 6 to 1 Cylinder Block Aluminum w Cast Iron Sleeve Type of Governor Mechanical Fixed Speed Engine Governor Speed 5 2200 rpm COU TPAC 2571 rpm Air Cleaner Paper Element w Foam Precleaner Il NT acon 12 volt DC Electric Ignition System Solid state w Flywheel Magneto Recommended Spark Plug A 14 455 Fram 65 Spark Plug Gap 0 030 inch 0 8 mm Recommended Min Battery 400 Cold Cranking Amps OPERATION Section 2 Operation Recreational Vehicle Generators 1 6 5 GENERATOR SPECIFICATIONS SERIES Rotor RPM 3600 Rotor Poles 2 Engine RPM 2200 Rated Max Continuous AC Output Watts 5500 Voltage 120 Rated Max Continuous Current Amps 240V 45 8 22 9 Phase 1 Frequenc 60 Hertz Battery Charging Current Max 2 amps Weight 326 lbs Length 33 7 in QP75LP 3600 2 2571 7500 120 62 5 31 2 1 60 Hertz 2 amps 333 Ibs 33 7 in 22 2 in 19 6 in apese apese 5 3600 3600 2 1 3600 3600 2
3. Section 7 Post Installation Recreational Vehicle Generators OPTIONAL LP GAS FUEL SYSTEM Fuel system is properly installed and checked for leaks Pressure at regulator inlet is correct Rated flow of primary regulator is correct All parts are properly installed Fuel system is properly tested adjusted EXHAUST SYSTEM 1 Exhaust system complies with all applicable codes 1 Exhaust system is properly and safely installed ELECTRICAL CONNECTIONS 1 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 BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Cables are clean and tight Cables are connected properly Proper ventilation is provided DL Terminals are coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES 1 Check that remote start stop panels if used are installed properly 1 Check that hourmeter kit if used is installed properly Check that any other options and accessories if used are installed properly POST INSTALLATION TESTS Check that all tests are completed properly 35 TROUBLESHOOTING Section 8 Trou
4. CONDUIT B E SOLE VEHICLE AC 6 DISTRIBUTION DOUBLE PANEL amp THROW 6 SWITCHING 30 AMP MAIN BREAKER DEVICE HACR BREAKERS FOR AIR CONDITIONERS BREAKERS POWER SUPPLY CORD Figure 6 16 Installation With Isolation Receptacle DOCKSIDE POWER RECEPTACLE JUNCTION FLEXIBLE CONDUIT POWER SUPPLY CORD VEHICLE AC DISTRIBUTION PANEL 33 INSTALLATION Section 7 Post Installation Recreational Vehicle Generators 6 9 OPTIONAL ACCESSORIES A plug in receptacle Figure 6 18 is provided on the generator set above the muffler enclosure Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit starting and stopping the gen erator engine from any convenient location inside the vehicle Figure 6 18 Remote Panel Plug in Receptacle a ZN y j 5 lt 5 5 4 lt MALE 7 0 lt o 0 j 12 00 WIRE WIRE No COLOR LENGTH mm FUNCTION 0 WHITE 12 0 305 GROUND 14 RED 12 0 305 ENGINE RUN SIGNAL 15 ORANGE 12 0 305 12 VDC 17 YELLOW 12 0 305 START 18 BROWN 12 0 305 STOP 14A BLUE 12 0 305 PRIME P N 0D9099 B 6 9 1 REMOTE PANEL MODELS The remote panels mount a rocker type start stop switch a Generator Ru
5. Do not lay tools or metal parts on top of the battery e Disconnect any charging source prior to connecting or disconnecting battery terminals and Do not use any jumper cables or booster battery to crank and start the generator engine If any battery has discharged remove it for recharging wanNiNG Do not open or mutilate the battery Released electrolyte has been known to be harmful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried 3 9 MAJOR SERVICE MANUAL To obtain a service manual for the generator contact the nearest Authorized Service Dealer Make sure to identify the MODEL NUMBER and SERIES Manuals can be obtained from the internet websi
6. Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end If nec essary re form the wire terminal to obtain a tight fit 3 5 FUEL FILTER GASOLINE ONLY Remove and replace the fuel filter Figure 3 5 once each year or every 400 hours of operation whichever comes first MAINTENANCE 2 Section 3 Maintenance Recreational Vehicle Generators Figure 3 5 Fuel Filter FUEL FILTER TO FUEL PUMP q CUSTOMER FUEL CONNECTION 36 CLEAN SPARK ARRESTOR The engine exhaust muffler has a spark arrestor screen Inspect and clean the screen every 50 hours of operation or once each year whichever comes first NOTE If using the generator on any forest covered brush covered or grass covered unimproved land it must equipped with a spark arrestor The spark arrestor must be maintained in good condition by the owner operator Clean and inspect the spark arrestor as follows Remove the screen retaining bracket by removing the screw Slide the spark arrestor screen out from the tail pipe Inspect screen and replace if torn perforated or otherwise damaged DO NOT USE a defective screen If screen is not damaged clean it with com mercial solvent Replace the screen and the retaining bracket Figure 3 6 Spark Arrestor TAILPIPE P N 0E0907 RETAINER A P N 0D5133A d SPARK ARRRESTOR SCREEN P N 0D51
7. The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense If mounting the generator in an enclosed compart ment the base of the generator must rest flat on the floor without any gaps When using a suspended mounting system ensure the base of the generator is flush with the sur rounding bodywork If the unit is mounted higher in the structure heated air may recirculate into the generator causing it to overheat 6 1 2 GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding The metal framework on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams These beams should consist of a 1 1 2 inch square 11 gauge steel tub ing OR b 1 1 2 inch 11 gauge angle iron A typical supporting frame with horizontal support tubing is shown in Figure 6 1 Figure 6 1 Typical Horizontal Support Frame SUPPORT TUBING The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the genera tor below the horizontal support tubing by means of suitable structurally sound metal framework The following general rules apply Vehicle construction MUST be capable of support ing the weight of the generator
8. GUARDIAN by Generac Power Systems Inc RY Owner s Manual Air cooled Recreational Vehicle Generators QUIETPACT 55 65 and 75 Models 004702 0 004703 0 004704 0 004705 0 004706 0 amp 004707 0 This manual should remain with the unit INTRODUCTION READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood con tact the nearest Authorized Service Dealer for start ing operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular opera tion that may be hazardous if performed incorrectly or carelessly Observe them carefully Their defini tions are as follows A After this heading read instructions that if not strictly complied with will result in personal inju ry including death and property damage WARNING A After this heading read instructions that if not strictly complied with may result in personal inju ry or property damage cauroN amp After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli
9. Loads connected across 1 Red to T2 White and T3 Black to T2 White must not exceed rat ings for the specific generator see Section 1 6 3 NOTE Do NOT connect loads in excess of circuit breaker ratings 6 1 LOCATION AND SUPPORT 6 1 1 GENERATOR LOCATION The most desirable location for the generator set is between the vehicle s main frame members However this is seldom possible Most units must be installed on the side of the vehicle and are difficult to rein force Many recreational vehicles have been factory equipped with an area for the generator set Some vehicles may even have a generator compartment provided by the vehicle manufacturer Plan the generator location based on the following The generator set must be installed on a frame work that is part of the recreational vehicle as outlined in Section 6 1 2 The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from under neath the supporting framework The location must provide easy access to frequent ly serviced components such as filters oil drains spark plugs and other common maintenance parts ee The location must provide sufficient room to allow minimum clearances as outlined in Section 6 2 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
10. ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the Danger Warning and Caution blocks The type of information each indicates follows This symbol points out important safety infor mation that if not followed could endanger personal safety and or property of others This symbol points out potential explosion hazard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator driver is responsible for proper and safe use of the vehicle and its equipment and the safety of all vehicle occupants We strongly recom mend that the operator read this manual and thor oughly understand all instructions before using this equipment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of repair parts for generator model numbers 004702 0 004703 0 004704 0 004705 0 004706 0 and 004707 0 In addition the latter por tion of this manual contains information necessary for the proper installation of these generators OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks
11. 1 3600 Lo a 3 a ee x q 1 j 1 1 Width 22 2 in Height 1961 All units reconnectable to 120 and or 240 volts dual voltage output Units are not listed RVIA ANSI when reconnected for dual voltage output 2 2 1 1 1 6 5 EMISSIONS COMPLIANCE PERIOD For nonhandled engines the Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal emission requirements For engines less than 225 cc displacement Category C 125 hours B 250 hours and A 500 hours For engines of 225 cc or more Category C 250 hours B 500 hours and A 1000 hours 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 2 1 1 FUEL PRIMER Before starting a cold engine if it has not been started in more than two weeks press this switch for approximately ten seconds to bring fuel from the tank to the fuel pump This rocker type switch springs back into its original position when it is released 2 1 2 START STOP SWITCH To crank and start the engine hold this switch in the START position Release the switch when the engine starts To stop an operating engine press and hold the switch in the STOP position until the engine shuts off The switch center position is the RUN position 2 1 5 7 5 AMP FUSE The fuse protects the engine s DC contro
12. 120V 35A QP75 NEUTRAL CONNECTION BY CUSTOMER ELECTRONIC REMOTE PANEL VOLTAGE OPTIONAL Y REGULATOR T RED CB2 BLACK ON 9 T1 2 6 T3 DPE WINDING OF k 4 FIELD WHITE 120V 20A QP55 BLACK LEGEND BCR BATTERY CHARGE RECTIFIER CB1 CIRCUIT BREAKER 30A QP55 amp QP65 MODELS CIRCUIT BREAKER 35A QP75 MODEL CB2 CIRCUIT BREAKER 20A QP55 MODEL CIRCUIT BREAKER 30A QP65 MODEL CIRCUIT BREAKER 35A QP75 MODEL CB3 CIRCUIT BREAKER 2 5A QP55 MODEL CIRCUIT BREAKER 3 0A QP65 amp QP75 MODELS CH CHOKE HEATER GASOLINE MODELS ONLY CS CHOKE SOLENOID GASOLINE MODELS ONLY F1 FUSE 7 5A FP FUEL PUMP OR LPG SHUT OFF VALVE FS FUEL SOLENOID GT TERMINAL GROUND HM METER HOUR OPTIONAL HTO SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP IM1 IGNITION MAGNETO 1 CYL IM2 IGNITION MAGNETO 2 CYL L1 LIGHT RUN OPTIONAL LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE PCB ENGINE CONTROLLER R1 RESISTOR 1 OHM 25W SC STARTER CONTACTOR SCR STARTER CONTACTOR RELAY SM STARTER MOTOR SW1 SWITCH START STOP SW2 SWITCH FUEL PRIMER SP1 SPARK PLUG 1 CYL SP2 SPARK PLUG 2 CYL TC TERMINAL CONN 4 TAB E CONNECTOR RED YELLOW WHITE ORANGE BROWN Section 10 Electrical Data Recreational Vehicle Generators Electrical Schematic V Twin Drawing No 0E1057 E
13. Apply electrical loads equal to about 75 to 100 per cent of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling airflow is available Do not allow the unit to overheat during prolonged operation NOTE The generator engine is equipped with a high tem perature switch The switch has normally open N O contacts When the engine temperature is too high switch contacts close and the engine shuts down automatically THE MANUFACTURER RECOMMENDS THAT THE GENERATOR BE TESTED FOR ADEQUATE COOL ING 75 INSTALLATION CHECKLIST LOCATION AND SUPPORT Generator is properly located Generator is properly supported Generator is properly restrained GENERATOR COMPARTMENT Compartment construction is proper 1 Holes Openings are vapor sealed 1 Compartment size is correct 1 Compartment is vapor sealed 1 Sound insulation is correct Q Floor cutouts are properly completed COOLING AND VENTILATING AIR U Airflow is adequate Air inlet opening is correct 1 Compensate for restrictions Check that installation has been tested GASOLINE FUEL SYSTEM Fuel tank complies with all applicable codes Fuel system is properly installed and checked for leaks DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER INSTALLATION
14. The gas is heavier than air and tends to settle in low areas Even the slightest spark can ignite it and cause and explosion Only competent qualified people should be allowed to install test adjust or ser vice an LP gas fuel system Install the optional fuel system in compliance with applicable codes standards and regulations After the installation do not do anything that might render the sys tem in noncompliance with applicable codes and standards The LP powered range of generators are fitted with a nonadjustable factory set system These systems are tamper proof to meet 1997 California Air Resources Board requirements for engine emission 6 5 1 LP FUEL CONSUMPTION LB HOUR Idle 50 Load 100 Load 27 INSTALLATION Section 6 Installation Recreational Vehicle Generators 6 5 2 PARTS NOT INCLUDED IN FUEL SYSTEM The propane fuel system does NOT include such items as a gas tank b gas piping c fittings d valves and e primary regulator used to store the gaseous fuel and deliver it to the gaseous fuel sole noid Figure 6 11 DIT A Use only approved components in the fuel sup ply system All components must be properly installed in accordance with applicable codes Improper installation or use of unauthorized components may result in fire or an explosion Follow approved methods to test the system for leaks No leakage is permitted Do not allow fuel vapors to e
15. The low pressure from the carburetor venturi acts on the regulator diaphragm to pull the diaphragm toward the source of low pressure A lever attached to the diaphragm opens a valve to permit gas glow through the carburetor Figure 6 12 LP Gas Carburetion Diagram AIR GAS AT FLOW POSITIVE 4 PRESSURE LOW PRESSURE AREA GAS AT ZERO PRESSURE The greater the airflow through the carburetor ven turi the lower the pressure at the venturi throat The lower the pressure at the venturi throat the greater the diaphragm movement and the greater the move ment of the regulator valve The more the regulator valve opens the greater the gas flow that is propor tional to airflow through the generator The following facts about the secondary regulator must be emphasized The regulator must be sensitive to venturi throat pressure changes throughout the operating range The regulator must be properly adjusted so it will stop the flow of gas when the engine is not running no air flow through the carburetor The slightest airflow and vacuum in the venturi throat should move the regulator valve off its seat and permit gas to flow 6 5 7 FUEL SUPPLY LINES LP gas lines must be accessible but protected against possible damage Do NOT connect electrical wiring to any LP gas fuel line or run wiring alongside the lines Route gas lines away from hot engine exhausts Retain gas lines with metal clamps that
16. You also have other rights from state to state GENERAC POWER SYSTEMS INC BOK 297 WHITEWATER WI 531 90 Revision 02 05 Part OE1015 Revision L 09 15 05 Printed in U S A
17. below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part If the part fails prior to the first scheduled replacement the part shall be repaired or replaced by Generac according to Subsection 4 below Any such emissions related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsible for diagnostic cost
18. 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 ter minals Figure 1 2 shows the generator lead wire connections for 120 240 VAC loads Also refer to section 2 1 4 Line Breakers for circuit breaker ratings This procedure should be done by an Authorized service Dealer or other qualified installer 5 Section 1 General Information INFORMATION Recreational Vehicle Generators GENERAL Figure 1 1 Connection for 120 Volts Only T1 ex aS 33 O RED A EE BLACK 120V 120V 2 jue WHITE 277 Us WHITE STATOR POWER WINDINGS GROUNDED NEUTRAL Figure 1 2 Connection for 120 240 Volts T1 RED A 120 VAC 2 Y 240 WHITE VAC 120 VAC E _ CB2 T3 44 _ BLACK STATOR WINDINGS GROUNDED NEUTRAL 999 v 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 10 Load 5096 Load 10096 Load QuietPact 55G QuietPact 65G QuietPact 75G NOTE Some installations using a shared fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine s pickup
19. 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 ven tilating air is critical to correct generator opera tion and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or permit even partial blockage of ventilation provi sions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement Before performing any maintenance on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel lea
20. lt sux udin TO 12V BATTERY ELECTRONIC VOLTAGE REGULATOR CLOSEST TO BEARING REMOTE 0 PANEL s CONNECTOR CBI T T2 RED 15 11 14 CB2 14A 14A LI WHITE M GREEN m _ CUSTOMER AC CONNECTION NEUTRAL CONNECTION BUER BY CUSTOMER WHITE 3g i us Section 11 Exploded Views and Parts Lists Recreational Vehicle Generators 0 Base amp Pulley Drawing No 0 1323 ITEM PART NO 1 0 0196 2 022129 3 022145 4 022259 5 067758 6 063168 7 062417 8 077603 9 0 0588 10 029451 11 008912 12 0 0571 13 008911 14 043107 15 009021 16 096289 17 008940 18 070006 19 070008 20 040976 21 056893 22 023897 23 081078 24 0C4138 25 043116 26 022097 022097 27 022473 28 061751 29 0 1753 073106B 30 075224 075224 Section 11 Exploded Views and Parts Lists Recreational Vehicle Generators Base amp Pulley Drawing No 0E1323 C IY DESCRIPTION 1 12 15 6 4 1 1 2 1 FRAME 760 ENGINE WASHER LOCK M8 5 16 WASHER FLAT 5 16 M8 ZINC NUT HEX 5 16 18 STEEL VIB MNT 1 5 X 1 38 X 5 16 18 WASHER LOCK SPECIAL 5 16 EARTH STRAP SCREW HHC 5 16 18 X 3 5 SPC SPACER SAFETY BOLT 375 I D 1 5 FT TAPE ELEC UL FOAM 1 8 X r gt 1 1 1 DUCT AIR OUT GASKET AIR OUT DUCT BRACKET MUFFLER SUPPORT SCREW HHC M8 1 25 X 25 08 8 MUFFLER GTV760 RV CLAMP EXHAUS
21. 1 INSTALLATION Generator installation must have been properly com pleted so it complies with all applicable codes stan dards and regulations and with the manufacturer s recommendations 2 1 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommended oil before starting Refer to Section 1 6 3 and Sections 3 1 and 3 2 for oil servicing pro cedures and recommendations CAUTION Any attempt to crank or start the engine before it has been properly serviced it with the recom mended oil may result in an engine failure 2 1 5 FUEL SUPPLY The engine must have an adequate supply of proper fuel to operate Before starting it check that suffi cient fuel is available NOTE Depending on the installation the generator may have either a separate fuel tank or it may share the vehicle engine s fuel tank 2 1 4 COOLING AND VENTILATING AIR Air inlet and outlet openings in the generator com partment must be open and unobstructed for con tinued proper operation Without sufficient cooling and ventilating airflow the engine generator quickly overheats which causes it to shut down and may damage the generator 2 1 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 gase
22. 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 6 3 All bolts must be long enough so that when tight at least three threads are visible past the retaining lock nuts Refer to Section 6 2 for the location of the generator mounting holes INSTALLATION Section 6 Installation Recreational Vehicle Generators Figure 6 3 Typical Generator Restraint METAL LINED INCH THICK BASE 1 PLYWOOD METAL LINED VEHICLE BOTTOM CHASSIS 6 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compartment that the installer constructs the compartment MUST meet certain spec ifications as outlined in the following sections 6 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a mini mum clearance of 1 2 inch 13 mm on the front and top 1 inch 25 mm on the sides and 1 2 inch 13 m from the back for air circulation AFTER the compartment has been lined with metal and sound insulation Figure 6 4 NOTE Refer to
23. CHOKE LP ONLY RHMS 4 40 X 5 16SEMS SPRING CHOKE RETURN WRAP VALLEY UPPER SPCC WRAPPER UPR 1 W M8 WELD NUT WRAP VALLEY RV SPCC LISTS WRAPPER UPR 2 W M8 WELD NUT ASSY GROUNDING WIRE ASSY GROUND WIRE CONNECTOR ASSY IGN COIL W DIODE NO ADV WASHER LOCK M6 1 4 SCREW HHTT M6 1 0 X 25 BP O RING 59 92 X 66 98 X 3 53MM O RING 21 89 X 27 13 X 2 62MM KEY WOODRFF 4 X 19D ADPTR OIL PAD FLARE TUBE ENGINE OIL RETURN TUBE ENGINE OIL OUT O RING 20 35 X 23 91 X 1 BOLT OIL ADAPTOR WRAP CYL 2 GTV760 RV 78MM SPCC INTAKE TUBE 1 25 X 20 GA HOSE CLMP BAND 1 5 8 BOOT INTAKE AIRBOX BOOT CARB ADAPTOR BOLT CARB MOUNT M6 X 1 0 85LG ADAPTER AIR INTAKE CARB GASKET CARB TO ADAPTOR CARBURETOR GASOLINE ONLY CARBURETOR LP ONLY GASKET CARB TO INTAKE MANIFOLD GASKET INTAKE PORT MANIFOLD INTAKE RV SCREW SHC 8 1 25 X 30 G12 9 WASHER FLAT M8 SS WASHER LOCK M8 SS BARBED STR 1 4NPT X 3 8 CLAMP HOSE OETIKER 16 5mm HOSE 3 e IDX6 L 300F COOLER OIL DUCT OIL CLR RV SPCC PLASTITE 1 4 15 X 34 SCREW 10 32 X 3 8 SCREW HHTT 4 40 X PLATE THROTTLE WASHER LOCK 10 NUT HEX 10 32 STEEL SCREW HHC M6 1 0 X 12 G8 8 WASHER FLAT M6 SCREW HHC 6 1 0 X 16 68 8 SCREW HHTT M5 0 8 X 8 BP CLAMP HOSE 8 53 1 00 LP ONLY 2 25FT HOSE 1 2 ID LP ONLY SCREW PPHM 4 0 7 X 16 GASOLINE ONLY CLIP J VINYL COAT 375 ID GASOLINE ONLY WASHER FLAT 8 GASOLINE ONLY
24. STATOR ASSEMBLY 6 5 KW ONLY STATOR ASSEMBLY 7 5 KW ONLY BEARING BALL ROTOR ASSEMBLY 5 5 KW ONLY ROTOR ASSEMBLY 6 5 KW ONLY ROTOR ASSEMBLY 7 5 KW ONLY BEARING STUD RV STATOR D C BEARING CARRIER LOW NYLON SLIDE SLIDE NYLON SUPPORT SLIDE SPRING GEN MOUNT WASHER SPRING CENTER CIRCUIT BREAKER 30 X 1 5 5 amp 6 5 KW ONLY CIRCUIT BREAKER 35 X 1 7 5 KW ONLY CIRCUIT BREAKER 20 X 1 5 5 KW ONLY CIRCUIT BREAKER 30 X 1 6 5 KW ONLY CIRCUIT BREAKER 35 X 1 7 5 KW ONLY SCREW RHM 6 32 X 1 4 SIMS FUSE 7 5 AMP HOLDER FUSE SWITCH SPDT ON MOM ON SWITCH 6A SPDT SCREW HHC 5 0 8 X 25 68 8 PANEL TOP CONTROL PARTS Ce LISTS Control Panel Drawing No 0E1013 A 0 ITEM PART NO QTY DESCRIPTION 34 054502 1 CIRCUIT BREAKER 3 X 1 35 031879 4 WASHER FLAT 4 ZINC 36 043182 4 WASHER LOCK M3 37 051714 4 NUT HEX M3 0 5 G8 YEL CHR 38 092234 1 ASSY POTTED RV CNTL 39 049226 5 WASHER LOCK 5 40 051716 3 NUT HEX M5 0 8 G8 YEL CHR 41 023484R 2 BUSHING SNAP 42 003700 1 NUT FLANGE M6 1 0 NYLOK 43 009378 1 PANEL BOTTOM CONTROL 44 052619 1 SCREW HHC M5 0 8 X 20 G8 8 45 075476 2 SCREW PPHM M4 0 7 X 16 46 065795 1 RECTIFIER BATTERY CHARGE 47 0 2174 1 RELAY 12V 25 SPST 48 092120 4 NUT LOCK TRIC M6 X 1 0 Y ZNC 49 049721 2 SCREW HHC M6 1 0 X 35 G8 8 BLK 50 0 1658 2 WASHER LOCK SPECIAL 1 4 51 074260 146 1 WIRE ASM GRD STD CONN 52 049813 4 NUT HEX M6 X 1 0 G8 YEL CHR 53 023484D 1 BUSHING SNAP 54 074260 151 1 GROUND W
25. The second part of the cooling system a suc tion fan draws air that is heated from a hot engine into a collector pan at the base of the unit This heated air although cooler than exhaust muffler is then deflected out the bottom toward the ground 25 INSTALLATION Section 6 Installation Recreational Vehicle Generators Figure 6 8 Compartment Floor Cutout HOT AIR EXHAUST TAILPIPE LOCATION 25 4 17 526 2 20 11 16 516 2 469 8 20 5 16 495 19 1 2 x 18 1 2 x 70 8 2 13 16 95 6 3 3 4 183 6 45 305 9 12 1 16 821 2 32 5 16 469 18 7 16 195 8 233 2 7 11 16 9 3 16 VIEW FROM ANM m Eh P ram 536 2 21 1 8 REF 564 1 22 3 16 AIR INTAKE 344 6 13 9 16 FUEL INLET 7 1 4 3 8 16 WELDNUTS 8 PLACES 219 8 8 5 8 568 i 4 22 3 8 545 FRONT 21 7 16 842 4 33 3 167 NOTE ALL AIR INTAKES AND EXHAUST OUTLETS MUST BE KEPT CLEAR OF ANY OBSTRUCTIONS ALL OPEN AREA IS REQUIRED FOR COOLING Figure 6 9 Airflow Through Engine Generator XN RIO NN 6 5 2 TESTING THE INSTALLATION The manufacturer recommends testing the installa tion to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of o
26. be of a larger conductor size 6 7 5 GENERATOR AC CONNECTIONS Generator AC output leads T1 red T2 white and T3 black come out of the generator as shown in Figure 6 14 Leads T1 red and T3 black are hot while T2 white is the grounded neutral lead There is also a green lead that connects to ground in the junction box of the recreational vehicle Line T1 red to T2 white is protected against overload by a circuit 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 cir cuit breaker CB2 Use this line to neutral connec tion 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 INSTALLATION Section 6 Installation Recreational Vehicle Generators Figure 6 14 Generator AC Output Leads p e o caution amp AN Do NOT connect electrical loads in excess of any circuit breaker rating or problems will develop with circuit breaker tripping which causes a loss of AC output Also do NOT exceed the gener ator s rated wattage capacity Add the watts or amperes of all lighting appliance tool and motor loads the generator will operate at one tim
27. cap then remove it again The oil level should be at the dipstick Full mark 4 If necessary remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dip stick Full mark DO NOT FILL ABOVE THE FULL MARK caution amp 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 operating the engine 11 MAINTENANCE 2 O Section 5 Maintenance Recreational Vehicle Generators 5 2 CHANGING THE ENGINE OIL AND OR OIL FILTER Change the engine oil after the first 25 hours of operation after the 25 hour break in period see Section 2 8 5 Thereafter change the oil every 100 operating hours Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures Change the engine oil filter after the first 25 hours of operation and every 100 operating hours there after To change the oil and or oil filter proceed as fol lows 1 Run the engine until it is thoroughly warmed up at least five minutes then shut OFF the engine 2 With the engine still warm from running remove the oil drain plug Figure 3 1 Drain the oil into a suitable container Figure 3 1 Oil Dipstick Fill Tube and Location of Oil Drain Plug Cil Dipstick Q 9 Oil Drain Hose 3 After
28. do not have sharp edges Install an approved length of flexible hose between the gaseous fuel solenoid valve and rigid fuel supply lines The flexible line must be nonmetal lic nonorganic and nonconductive It must be approved for use with LP gas A Gaseous fuel lines between the tank and the secondary regulator are under a positive pres sure about 11 inches water column Gas pres sure at the outlet side of the secondary regula tor however is a negative pressure and can draw flame inside a line or fitting and cause an explosion INSTALLATION LED Section 6 Installation Recreational Vehicle Generators 6 5 8 EXCESS FLOW VALVE LP gas tanks should have an excess flow valve according to NFPA 501C This valve and the gas lines must be carefully sized so the valve will close when a fuel line is severed or broken Consult the Natural LP Gas Association for information and limitations of excess flow valves Manual shutoff valves on the supply tank and else where in the system must be fully open when oper ating the generator The excess flow valve functions properly only if all valves are fully open 6 5 9 LEAKAGE TESTS Do not place the generator into service until the gas system has been properly tested for leaks To test the system a separate source of 12 volts DC to open the gaseous fuel solenoid valve is needed The leak test must comply fully with NFPA Paragraph 318 connections
29. fuel from a tank to the generator must comply with applicable codes stan dards and regulations The following general rules apply to rigid fuel lines INSTALLATION Section 6 Installation Recreational Vehicle Generators Rigid lines should be of annealed seamless drawn aluminum or steel Lines and fittings must comply with SAE 4512 Standard Automotive Fittings or with ANSI B126 26 latest edition Route the fuel line so that at least 2 inches 51 mm of clearance is maintained between the line and any exhaust system parts Do not attach electrical wiring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so if they leak fuel does not drip onto any electrical or exhaust system parts Use nonferrous metal straps without sharp edges to secure fuel lines 6 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 follow ing rules apply The flexible hose must comply with SAE J30B Standard for Fuel and Oil Hose It must be approved for use with gasoline 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 6 5 LP GAS FUEL SYSTEM DIG A LP gas is highly EXPLOSIVE
30. fuel system components include a fuel filter b 12 volt DC electric pump c engine carburetor and d interconnecting lines and fittings Connect a fuel supply line to the fuel filter inlet Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines 6 4 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 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 operat ing periods caution amp Do NOT tee the generator fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not run ning generator operation may drain the vehicle engine supply line making it difficult to start the vehicle engine 6 4 2 GENERATOR FUEL SUPPLY LINE 6 4 2 1 Rigid Fuel Lines Those lines used to supply
31. hoses valve regulators fittings and other fuel system parts must be tested under gas or air pressure of not less than 90 psi 620 kPa while using soap and water or an equivalent solution to check for leaks Other approved methods of testing for leaks may be used if appropriate DO NOT USE ANY FLAME TO TEST FOR LEAKS 6 6 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used A properly installed exhaust system must be vapor tight quiet and completely safe A A The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coher ently b vomiting c twitching muscles d throbbing temples e dizziness f headaches g weakness and h sleepiness IF FEELING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Do not operate the generator until its exhaust system has been inspected and properly repaired es INSTALLATION Section 6 Installation Recreational Vehicle Generators cautio
32. in potential hazard areas of the recreational vehicle Safety should be stressed to all operators and potential operators of this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this manual and with the unit The gen erator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique that chosen does not render the generator unsafe A Despite the safe design of this generator operating this equipment imprudently neglect ing its maintenance or being careless can cause possible injury or death Permit onl
33. interrupters GFCIs on all external and some internal electrical recepta cles be installed Contact the manufacturer or dealer for recommendations 6 8 BATTERY INSTALLATION 6 8 1 RECOMMENDED BATTERY Install a battery that meets the following require ments The battery must be a 12 volt automotive type storage battery For prevailing ambient temperatures above 32 F O C use a battery rated 70 amp hours and capable of delivering 400 cold cranking amperes For prevailing ambient temperatures below 32 O C use a battery rated 95 amp hours capable of delivering 400 cold cranking amperes NOTE If the battery is to be used to power other vehicle accessories as well as start the generator a bat tery with a larger capacity may be needed 6 8 2 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes starting problems For the best cold weather starting the voltage drop between battery terminals and the generator connection point should not exceed 0 12 volts per 100 amperes of cranking current PRIMEPACT generators are rated at about 100 DC amperes of cranking current Select battery cables based on a cable length and b prevailing ambient temperatures Generally the longer the cable and the colder the weather the larger the cable size must be as shown in the chart CABLE LENGTH CABLE SIZE 16 to 20 4 5 to 6
34. is provided to you by Generac pursuant to California and federal law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty ser vice evidence must be presented showing the date of the sale to the original purchaser owner The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and or transportation of the product to from the inspection or repair facilities The purchaser owner also shall be responsible for any and or all damages or losses incurred while the engine is being transported shipped for inspection or warranty repairs If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 52 Section 12 Warranty Re
35. possible hazard that might result from each installation method procedure or technique The manufacturer has not undertaken any such wide evaluation Therefore people who use a method pro cedure 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 products safety is not endangered by the method procedure or technique selected Information illustrations specifications etc con tained in these Installation Instructions are based on the latest information available at the time of publica tion Every effort has been expended to be sure that such data is both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time without prior notice DIG A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators 18 N GENERAL HAZARDS For safety reasons the manufacturer recommends that t
36. starting and stopping the gen erator engine conveniently from inside the vehicle The remote panel includes a Start Stop switch hour meter generator run lamp a fuel prime switch and a wire harness Figure 2 2 Optional Remote Panel Part Numbers 0F0429 and 0F0430 FUEL 2 5 AUTOMATIC CHOKE This engine is equipped with an automatic choke that consists of two main components a choke solenoid and prechoke PRIME 2 5 1 CHOKE SOLENOID During engine cranking Start Stop switch at START a solid state choke module signals the choke sole noid to activate and cycle choke on choke off until the engine starts The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking When the engine starts the choke stops cycling 2 3 2 PRECHOKE The choke system also has a temperature sensitive metal strip that adjusts choke valve angle according to ambient temperatures i e in cold ambient tem peratures choke valve closes more Once the engine starts an element heats the temperature sensitive strip to a normal operating condition opening the choke valve This may take about three minutes in cooler weather 2 4 BEFORE STARTING THE ENGINE NOTE Instructions and information in this manual assume the generator has been properly installed connected serviced tested and adjusted by a qualified installation technician or installation contractor 2 1
37. the means pro vided such as a main circuit breaker or transfer switch 2 6 STOPPING THE GENERATOR 1 Turn OFF all electrical loads using the means provided such as a main circuit breaker or transfer switch 2 Letgenerator 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 appli ances may be extremely sensitive to voltage Incorrect voltages can damage such appliances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when suf ficient power is not available may shorten engine life Never turn ON electrical loads until after the genera tor engine has started and stabilized at no load OPERATION Section 2 Operation J gt Recreational Vehicle Generators 2 72 NOT OVERLOAD THE GENERATOR Read the rated wattage amperage capacity of the gen erator on the generator data decal see Section 1 1 Applying electrical loads in excess of the units rated capacity will cause the
38. the oil has drained replace the oil drain plug If only changing the oil go to step 7 4 With the oil drained remove the old oil filter by turning it counterclockwise Figure 3 2 5 Apply a light coating of clean engine oil to the gasket of the new filter 6 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn 7 Remove the dipstick and fill crankcase with the proper type and amount of recommended oil see Section 1 6 2 The engine crankcase can hold about 1 8 liters or 1 9 quarts with oil fil ter change DO NOT FILL ABOVE THE FULL MARK 8 Install and tighten the dipstick before operating the engine 12 9 Start the engine and check for leaks Figure 3 2 Engine Oil Filter ENGINE OIL FILTER TWIST COUNTER CLOCKWISE TO LOOSEN NOTE Check the oil level and fill to the FULL mark after checking for leaks The filter will retain some oil 5 5 MAINTAINING THE ENGINE AIR CLEANER 5 5 1 CLEANING THE FOAM PRECLEANER Clean and re oil the foam precleaner every three months or every 25 hours of operation whichever occurs first Service the foam precleaner more fre quently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 3 1 Turn the knob counterclockwise to loosen 2 Remove the cover foam precleaner and paper filter 3 Remove the foam
39. 33 _ RETAINING amp SCREW P N 045764 13 MAINTENANCE 2 O Section 5 Maintenance Recreational Vehicle Generators 5 7 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor which is detrimental to the gen erator caution amp Do NOT use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also con taminate the generator fuel system 3 8 BATTERY MAINTENANCE All lead acid batteries will discharge when not in use The generator battery should be inspected as follows 5 8 1 WEEKLY Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary Check the battery fluid level
40. 4 Checking the Engine Spark Plug 13 3 5 Fuel Filter Gasoline Only 13 3 6 Clean Spark Arrestor 13 a7 Cleaning the Generator u u w ua uwina 14 3 8 Battery Maintenance 14 3 9 Major Service Manual 15 DEI usa 15 3 11 Exercising the Generator 15 3 12 Out of Service Procedure 15 3 13 RV Generator Service Interval 15 Section 4 Notes 16 Table of Contents OF CONTENTS Recreational Vehicle Generators Part II Installation Instructions 17 Safety CT mee 18 Section 5 General Information 20 5 1 Purpose and Scope of the Installation Mm 20 V MEE AOT 20 5 3 Standards Booklets 20 5 4 Equipment Description 20 5 5 Generator Engine Operating Speed 20 5 6 Generator AC Connection System 20 Major Features and Dimensions 21 Section 6 Installation 22 6 1 Locatio
41. 5 hours complete the tasks recommended under Section 2 8 6 MAINTENANCE 2 Section 3 Maintenance Recreational Vehicle Generators 2 8 6 25 HOUR CHECK UP After the 25 hour break in period contact an Authorized Service Dealer for the following mainte nance The vehicle owner is responsible for any charges relating to normal unit maintenance Change the engine crankcase oil and oil filter Check all fluid levels Inspect the cooling and ventilation openings Check the engine ignition system Inspect the entire electrical system Inspect the engine exhaust system 2 8 7 OPERATION IN HIGH GRASS OR BRUSH wanNiNG Never operate the generator while the vehicle is parked over high grass weeds brush leaves or any other combustible substance Such mate rials can ignite and burn from the heat of the exhaust system The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down 3 1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements see Engine Oil Requirements Section 1 6 2 Check the engine crankcase oil level at least every eight hours of opera tion or before it is used To check the engine oil level proceed as follows see Figure 3 1 1 Be sure the generator is as level as possible 2 Remove the dipstick and wipe it dry with a clean lint free cloth 3 Install and tighten the dipstick
42. 8 1 ASSEMBLY HEAD 2 1 COVER GEROTOR 58 0C2229 2 VALVE INTAKE 1 GEROTOR INNER 59 086516 2 VALVE EXHAUST 1 GEROTOR OUTER 60 0098530 4 PUSHROD 147 2 COVER OIL RELIEF 61 083897 4 TAPPET SOLID 2 SPRING OIL RELIEF 62 0 9323 1 STARTER 2 BALL 1 2D OIL RELIEF 63 022129 2 WASHER LOCK M8 1 1 4 NPT PIPE PLUG 64 061906 2 SCREW HHC M8 1 25 X 85mm 49 Section 11 Exploded Views and Parts Lists Recreational Vehicle Generators LP Regulator Drawing No 0E1530 C 5Q Section 11 Exploded Views and Parts Lists Qi Recreational Vehicle Generators LP Regulator Drawing No 0E1530 C O ITEM PART N TY DESCRIPTION 1 0D5694 1 CASTING TWIN REGULATOR HOUSING 2 0F4795 4 SCREW PPHM SEMS M4 0 7 X 10 5 0F5022 1 SOLENOID COIL 12VDC 6 0 6070 1 SPRING SOLENOID PLUNGER 7 0C4680 1 PLUNGER LP REG ASSY 8 0 4647 1 GASKET SOLENOID 9 0C4643 1 INLET TWIN REGULATOR NO HOLE 10 0D3973 1 PLUG EXPANSION 16MM TWINREG 11 0C6606 1 BARBED STR 1 2 X 1 2NPT W VS 12 026073 2 PLUG STD PIPE 1 8 STEEL SQ HD 13 0D3308 2 WASHER FLAT 3 2MM ID X 10MM OD 14 070728 2 SCREW PFILHM M3 0 5 X 5 15 0C5764 1 SPRING REGULATOR 45N M 32MM 16 0C4643A 1 INLET TWIN REG 11 11 DIA 17 0C6066 1 SEAL INLET REGULATOR 18 0C5968 1 SUPPORT INLET SEAL 19 0C5759 1 PIN PIVOT ARM 20 0C5761 1 LEVER REGULATOR 21 0C6069 1 GASKET DIAPHRAGM 22 0C6731 1 RIVET 118 X 125 ALUMINUM 23 0C6067 1 SUPPORT DIAPHRAGM 24 004706 1 DIAPHRAGM TWIN REGULATOR 25 0 6068 1 CAP DI
43. 82025 51 0E1247 52 055173 53 022129 54 022145 55 009403 56 081246 Section 11 Exploded Views and Parts Lists Recreational Vehicle Generators Sheet Metal Drawing No 0F1996 C IY DESCRIPTION IX l lk j gt c NO N PO ND NOP SCREW HHTT M6 1 0 X 10 YC GUARD FAN 12KW HSB HOUSING BLOWER V TWIN RV NUT GROMMET 1 4 PLUG HOSE BREATHER NUT HEX M24 2 0 G8 YEL CHR WASHER BELLEVILLE 25MM BOLT SCREW HHC 8 1 25 X 12 G8 8 WASHER SHAKEPROOF INT 8 SS PLATE FAN FAN NYLON FLYWHEEL ASSY PLATE BACKING WITH OIL COOL BUSHING SNAP WRAP CRANKCASE RV SPCC VERTICAL SHAFT RV ENGINE WRAP CYL 1 RV SPCC SCREW CRIMPTITE 10 24 X SPARK PLUG CLAMP VINYL 9 5 O D TUBE TUBE OIL DRAIN amp CHECK BARBED EL 90 3 8NPT X 3 8 ASSEMBLY OIL DRAIN HOSE OIL DRAIN DIPSTICK TUBE VTW ASSEMBLY CAP amp DIP STICK SCREW TAP R 10 32 X 9 16 GASOLINE ONLY SCREW TAP R 10 32 X 9 16 LP ONLY SPRING CLIP HOLDER 37 62 SCREW HHTT 3 8 16 X 1 1 4 CZ WASHER LOCK SPECIAL 3 8 SCREW SWAGE 1 4 20 X 1 Z YC OIL FILTER SWITCH OIL PRESSURE HOBBS SUPPORT OIL FLTR FLARE WASHER LOCK M3 SCREW PPHM M3 0 5 X 8 SWITCH OIL HIGH TEMP GASOLINE ONLY SWITCH OIL HIGH TEMP LP ONLY ASSEMBLY GOVERNOR LEVER SPRING GOV 5 5 KW amp 5 0 KW 50HZ ONLY SPRING GOV 6 5 7 5 KW amp 7 0 KW 50HZ
44. A SNOILO3NNOO 91 61 8 65 Loret or 7 2 19 561 v8 SS3NHVH 0 INdLNO OV 9 91 6 LL 6c ONI1009 Q3uIf103H SI V3dV SNOILONYLSEO ANY dO HV3T19 Lda 3 amp 8 LSAW S131100 LSNVHXS ANY S3 IV LNI Hl TIY ALON YOLOANNOO TANVd 940 33 3ONVN3ALNIVIA 303 SS399V 3009 LNOYS 8 6 8 22 191 01 8598 dau 196611 v 26 91 vovg 8 zz 896 91 41 INOWS s3ovd 8 SLANG1SM 91 8 6 pg Z 9 96 15 6 161 191 6 06 19 1 8 02 x 91 6 18 98 8612 1 21 98 1915 9 rvt 9111 6906 98 zz 96 18 1121 2965 8 12 rS 1 9 TL 5 906 19 21 8 961 dOL 19 781 69v 1919 zg 2128 1181 Lors 02 8 69 2916 121611 191 010 967 2925 Le vSc NOILVOOT1 3dld1lV1 1 LOH 21 INSTALLATION Section 6 Installation Recreational Vehicle Generators Figure 5 3 Connection for 120 240 Volts RED A 120 VAC T2 Y 240 WHITE VAC STATOR WINDINGS GROUNDED NEUTRAL The AC connection system on all air cooled PRIMEPACT series generators uses a GROUNDED neutral A separate green ground wire is connected to the recreational vehicle s junction box
45. APHRAGM SUPPORT 26 0C5762 1 COVER TWIN REGULATOR 27 045764 8 SCREW HHTT M4 0 7 X 8 BP 51 Section 12 Warranty WARRANTY Recreational Vehicle Generators CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and the United States Environmental Protection Agency EPA together with Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine New utility and lawn and garden equipment engines must be designed built and equipped to meet stringent anti smog standards for the state of California and the federal government Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition and exhaust systems Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed
46. ENANCE 2 Section 3 Maintenance Recreational Vehicle Generators 3 12 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Check the tag on the engine for oil viscosity and classification Verify that the correct recommend ed oil is used in the engine see Section 1 5 4 If necessary drain and refill with the proper oil 2 Check the state of the battery Fill all cells of unsealed batteries to the proper level with dis tilled water DO NOT USE TAP WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defective replace the battery 3 Clean and wipe the entire generator 4 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 5 Turn OFF all electrical loads Add fuel if neces sary and then start the engine 6 Allow the unit to warm up thoroughly 7 Apply electrical loads to at least 50 percent of the units rated wattage capacity 8 When the engine is thoroughly warmed up shut it down 9 The generator is now ready for service 5 13 RV GENERATOR SERVICE INTERVAL DO TOUS Clean Spark Arrestor 1st 50 Hours then every 500 Hours Adjust Valve Lash TOO Change Engine Oil Filter TOO HOUDI Clean Air Pre filter 100 Hours Inspect Spark Plugs 250 Hours Replace Paper Air Filter Element 400 Hours
47. Figure 5 2 Major Features and Dimensions Figure 6 4 Clearances Plywood Compartment 1 2 Clearance on Top 1 Clearance Insulation 6 2 2 COMPARTMENT CONSTRUCTION The generator compartment should be either con structed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum s low melting point 23 INSTALLATION Section 6 Installation Recreational Vehicle Generators If the compartment is lined with galvanized steel it may be constructed of any material The manu facturer recommends that the compartment be constructed of 1 2 inch thick plywood not strand board with the floor made of a double thickness of 1 2 inch plywood with the grain of the wood at cross section for added strength Figure 6 5 Figure 6 5 Typical Compartment Construction CROSS SECTION VIEW METAL LINING FIREPROOF SOUND INSULATION METAL LINING VAPOR SEALED AT ALL TIMES SS METAL LINING PLYWOOD If constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel All seams splices and joints of the compartment walls unless vapor tight by design should be caulked to prevent poisonous flammable or explo sive vapors from entering the vehicle interior NOTE Caulking must be done so that the caulking mate rial will stay in pl
48. For warm weather use No 2 cable up to 20 feet 3e 6 8 3 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or to the lug on the starter contactor Figure 6 17 NOTE Check to be sure the battery cable boot for the starter cable has been installed 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connection Figure 6 17 3 Connect cables so the connectors are clean and tight Figure 6 17 Connecting Battery Cables Positive Cable E Battery Negative Cable 7 gt 9 Chassis Ground 6 8 4 BATTERY COMPARTMENT Install the generator battery in its own vented com partment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage Section 6 Installation INSTALLATION y Recreational Vehicle Generators R Figure 6 15 Transfer Switch Isolation Method 2ND AIR FROM 20 AMP CONDITIONER HACR BREAKER JUNCTION BOX _ VEHICLE FLEXIBLE E
49. HING SNAP GASOLINE ONLY PLUG PLASTIC 0 687 LP ONLY STUD M6 1 0 OFFSET ELEMENT AIR FILTER PRECLEANER AIR GTH990 GASOLINE FILTER GASKET RV GASOLINE ONLY FILTER GASKET RV LP ONLY WASHER FLAT 281 ID X 1 25 OD NUT WING M6 1 0 NUT FLANGE M6 1 0 NYLOK GASOLINE ONLY NUT FLANGE M6 1 0 NYLOK LP ONLY FILTER FUEL GASOLINE ONLY ASSEMBLY NON SHTOFF FUEL PUMP GASOLINE ONLY ASSEMBLY RV V TWIN FUEL LINE GASOLINE ONLY GROMMET 38 1 DIA CROSS SLIT GASOLINE ONLY PLUG PLASTIC 1 50 LP ONLY WASHER LOCK SPECIAL 1 4 SCREEN SPARK ARRESTOR RETAINER SPARK ARREST SCREEN SCREW HHTT M4 0 7 X 8 GASKET EXHAUST BASE 41 PARTS qp is 00 e iu o GROUND 29 Ps 31 30 32 GROUND TO CONT PANEL Section 11 Exploded Views and Parts Lists Recreational Vehicle Generators Enclosure Drawing No 0E1011 C 28 27 26 STARTER VIEW 20 v 2 19 Section 11 Exploded Views and Parts Lists Qi Recreational Vehicle Generators Enclosure Drawing No 0E1011 C O ITEM PART N TY DESCRIPTION 1 0D8827 1 PANEL ENCLOSURE ROOF 2 0A7215 22 SCREW SW 1 4 20X5 8 N WA JS500 3 029451 DESEE TAPE ELEC UL FOAM 1 8 X 1 2 4 0D8825 1 PANEL SIDE AND BACK ENCLOSURE 5 003700 14 NUT FLANGE M6 1 0 NYLOK GASOLINE ONLY 0D3700 17 NUT FLANGE M6 1 0 NYLOK LP ONLY 6 090388 8 SCREW HHTT M6 1 0 X 12 YC 7 0D8979 1 PANEL AIR IN DUCT BASE 8 008960 1 PANEL CUSTOMER CON
50. IGH TEMPERATURE SWITCH This switch Figure 2 3 which has normally open N O contacts is mounted near the oil filter The contacts close if the temperature should exceed approximately 270 F 132 C for gasoline models and 284 F 140 C for LP models initiating an engine shutdown Figure 2 3 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE ENGINE OIL OIL PRESSURE FILTER SWITCH 2 8 3 FIELD BOOST The Controller Circuit Board houses a field boost diode and resistor that are not part of the automatic choke circuit These two components are part of a field boost circuit Figure 2 4 During engine cranking only a positive DC battery voltage is deliv ered through a diode resistor brushes slip rings and the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Figure 2 4 Field Boost Circuit Ed CONTROLLER CIRCUIT CLOSEST TO BOARD BEARING N FIELD GRND 2 8 4 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 5 controls the generators AC output voltage This regulator supplies an excitation current to the rotor By regulat ing the rotor s excitation current the strength of its magnetic field is regulated and i
51. IRE C PNL TO STUD V T RV 55 084867 1 RUBBER U CHANNEL 56 043181 2 SCREW PHM M3 0 5 X 10MM 57 075210 1 BLOCK 1 POSITION 58 022264 2 WASHER LOCK 8 M4 59 051715 2 NUT HEX M4 0 7 G8 YEL CHR 60 0 7605 2 SCREW HHC 5 0 8 X 60 G8 8 61 083049 1 ASY POTTED REG W FIN 62 089047 2 SPACER 25 X 48 X 55 ST ZNC 63 075234 1 RESISTOR WW LUG 1R 5 25W 64 0 2053 1 SCREW HHC M6 1 0 X 65 G8 8 65 058000 2 NUT TRIC M5 X 8 66 008941 1 COMPARTMENT AIR BOX 67 029451 2 3 1 2 X 1 16 CLOSED CELL 68 0 0583 1 WIRE HARNESS RV GASOLINE ONLY NOT SHOWN 0E1812 1 WIRE HARNESS QP RV LP ONLY NOT SHOWN 69 081375 1 WIRE ASS Y STARTER TO C PNL NOT SHOWN 47 Section 11 Exploded Views and Parts Lists Recreational Vehicle Generators 760 V Twin Engine Drawing No 0F1997 LISTS OG PARTS der Lr EUN 0 oP 3 aa ITEM PART NO 1 0C5730A 2 0 9843 3 090388 4 065372 5 0C3005 6 0E3372A 7 008067 8 0029816 9 071983 10 0 2985 11 021533 12 0 1466 13 004041 14 002983 15A 0 2985 158 0 2985 16 004042 17 0 7811 18 062977 19 0 5943 20 0 4356 21 0 3222 22 062978 23 093873 24 021374 25 062994 26 062997 27 062995 28 062996 29 063011 30 003009 31 0C3010 32 050873A Section 11 Exploded Views and Parts Lists Recreational Vehicle Generators PARTS Ce LISTS 760 V Twin Engine Drawing No 0F1997 0 DESCRIPTION ITEM PAR
52. LASTIC 1 50 GASOLINE ONLY 44 0A5606 1 ELBOW 90DEG 3 8X3 4 LP ONLY 45 0E1528 1 BRACKET LP REGULATOR MOUNTING LP ONLY 46 0A1495 2 SCREW HHTT M4 0 7 X 10 BP LP ONLY 47 039253 2 SCREW HHC M8 1 25 X 20 G8 8 LP ONLY 48 022145 1 WASHER FLAT 5 16 M8 ZINC GASOLINE ONLY 022145 3 WASHER FLAT 5 16 M8 ZINC LP ONLY 49 0D8979A 1 PANEL AIR IN DUCT 43 TO LP REGULATOR x 115 116 EY We I AT gt EX RE Section 11 Exploded Views and Parts Lists 2 Recreational Vehicle Generators Sheet Metal Drawing No 0F1996 C 3 p TAN S ko d Pac y N f Sa T q 7 A aN VzzsipaW D e a Cs E 112 414 110 Ds 109 55 54 53 48 43 26 N 0 0 e a tA SS NS D 22 16 ee ITEM PART NO 1 045756 2 001131 OF1169G 4 069763 5 009782 6 003034 7 003033 8 051754 9 045992 10 0C3032 11 0C3031 12 0063725 13 0F1170A 14 0234845 15 009679 16 0 8775 17 0F1167A 18 056893 19 0 7585 20 080998 21 0D8384 22 043790 23 003083 24 OE08361A 25 0E0393 26 0C2824 0C2824 2 065852 28 075246 29 0 4456 30 0 2311 31 070185B 32 0 8584 33 045360 34 043182 35 0C1085 36 081497 075281 37 009399 38 009513 0E1498 39 001366 40 009395 41 077075 42 0 7094 43 008590 44 008591 45 045770 46 049226 47 051713 48 009402 49 077091 50 0
53. NECTION 9 023484D 1 BUSHING SNAP SB 875 11 10 0 0594 1 COVER RV AIR CLEANER BOX 11 064113 1 STUD WINGNUT M6 1 0 X 20MM NY 12 0 0575 1 FOAM SEALING STRIP 1 X 12FT 13 0D8980 1 PANEL AIR IN DUCT BACK 14 0E1376 1 BAFFLE V TWIN RV SHORT 15 0E1377 1 BAFFLE V TWIN RV LONG 16 008628 3 5 FOAM AIR OUT COMPARTMENT 17 008910 1 PANEL MUFFLER SHIELD 18 0D8826 1 PANEL ENCLOSURE SIDE 19 0D9162 1 PANEL FRONT amp SIDE ENCLOSURE 20 0C5644 2 SLIDE LATCH FLUSH 21 0D8828 1 PANEL ENCLOSURE DOOR 22 0 0585 1 PANEL DOOR 1 2 RV 23 0 1486 1 HARNESS OUTPUT 5 5 6 5 amp 7 5 KW ONLY 0E1774 1 HARNESS AC OUTPUT 5 0 amp 7 0 KW 50 Hz ONLY 24 0D9099 1 CUST CONN 4KW RV REMOTE 25 074908 4 SCREW HHTT M5 0 8 X 10 BP 26 022473 1 WASHER FLAT 1 4 M6 ZINC 27 022097 1 WASHER LOCK M6 1 4 28 022507 1 SCREW 1 4 20 X 1 2 G5 29 0742600149 1 WIRE ASM BATT NEG QP RV 30 0C7968 4 NUT HEX JAM 3 8 16 BRASS 31 022237 2 WASHER LOCK 3 8 32 0C7423 1 STUD 3 8 16 X 2 1 4 BRASS 33 0742600151 1 GND WIRE C PNL TO STUD V T RV 34 0A4456 1 WASHER LOCK SPECIAL 3 8 35 0D8502 1 NEUTRAL CONNETCTOR UL 36 0 0593 1 STUD 1 4 20 5 16 18 37 0742600148 1 WIRE ASM BATT POS QP RV 38 022129 2 WASHER LOCK M8 5 16 GASOLINE ONLY 022129 4 WASHER LOCK M8 5 16 LP ONLY 39 022259 2 NUT HEX 5 16 18 STEEL 40 045756 8 SCREW HHTT M6 1 0 X 10 YC 41 0A2115 1 WASHER NYLON 250 42 029451A 6 5 FT 1 2 X 1 16 CLOSED CELL 43 0E1534A 1 PLUG P
54. ONLY BUSHING GOVERNOR ROD ROD GOVERNOR BOOT CHOKE SOLENOID GASOLINE ONLY RHMS 4 40 X 1 4 SEMS GASOLINE ONLY ASSY BI METAL HEATER GASOLINE ONLY SOLENOID CHOKE GASOLINE ONLY SCREW HHC M5 0 8 X 10 G8 8 WASHER LOCK M5 WASHER FLAT M5 LINKAGE CHOKE GASOLINE ONLY COTTER PIN GASOLINE ONLY NUT LOCK HEX M5 0 8 SS NYL INS ASSEMBLY GOV ADJUSTMENT SCREW HHC M8 1 25 X 20 G10 9 WASHER LOCK M8 5 16 WASHER FLAT 5 16 M8 ZINC LINKAGE CHOKE BELLCRANK CARB ASSEM CHOKE BRACKET GASOLINE ONLY ITEM PART NO 0D9400 57 0 7095 58 009404 59 009801 60 0C3018A 61 0D9680A 62 0D1143A 63 OF1177 64 0 4997 65 0 1409 66 022097 67 092079 68 0C1546 69 061547 70 082774 71 0A5358 72 009312 73 009314 74 0C1557 75 0 9028 76 009682 77 009270 78 048031 79 009269 80 0 0142 81 078643B 82 009219 83 0 0573 84 008807 0E1217 85 0 0572 86 003043 87 008836 88 049821 89 070008 90 070006 91 035461 92 OF6301 93 0C9806 94 063026 95 009683 96 0069764 97 036933 98 0 0246 99 009394 100 022152 101 022158 102 043116 103 049811 104 047411 105 066849 106 048031 107 077065 108 075476 109 082121A 110 038150 111 022264 112 051715 113 006029 114 055934 115 022473 116 090388 117 0E3200 IY DESCRIPTION 1 2 1 1 1 1 1 1 1 2 8 4 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 2 1 4 4 4 2 4 2 1 1 4 1 1 1 1 1 2 4 2 2 2 5 1 1 age BRACKET
55. 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 I Section 2 5 Starting the Generator for cranking and starting instruc tions The engine may require more cranking for initial starting since the fuel lines have to be primed use of the primer switch will shorten this time 3 Letthe engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load See Section 7 4 Run the unit at least 30 minutes with loads applied 6 Turn off all electrical loads by setting the gener ators main circuit breakers to their OFF or open position 7 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine NOTE The generator set was thoroughly tested and adjusted at the factory before shipping No addi tional adjustment should be necessary Only quali fied service technicians who have been trained should perform adjustments outlined in this manual 14 TESTING UNDER LOAD
56. T 1 25 MANIFOLD EXHAUST WASHER LOCK M8 SS WASHER FLAT M8 SS SCREW SHC 8 1 25 X 20 G12 9 SCREW CRIMPTITE 10 24 X WASHER FLAT 10 ZINC GASKET EXH BASE GTV760 RV GASKET EXHAUST PORT SCREW HHC M6 1 0 X 12 G8 8 5 5 KW ONLY WASHER LOCK M6 1 4 5 5 KW ONLY WASHER LOCK M6 1 4 6 5 amp 7 5 KW ONLY WASHER FLAT 1 4 M6 ZINC 5 5 KW ONLY FAN NYLON 7 DIA 5 5 KW ONLY PULLEY ALTERNATOR 2200 RPM 5 5 KW ONLY PULLEY ALTERNATOR 2500 RPM 6 5 amp 7 5 KW ONLY PULLEY ENGINE 2100 RPM 5 5 KW ONLY PULLEY ENGINE 2500 RPM 6 5 amp 7 5 KW ONLY ITEM PART NO 31 0E0586 32 007176 33 0 1334 34 008824 35 081105 36 073118 37 046526 38 022131 39 002824 40 0E1077 41 042633 42 022237 43 049451 44 001441 45 001112 46 023484E 0E1534 47 007530 48 009723 49 004511 50 008981 0D8981 51 008451 52 087680 53 003700 0D3700 54 087769 55 0E0570 56 009919 57 0 1330 0E1534A 58 0 1658 59 005133 60 005133 61 045764 62 0 1078 PARTS qea 00 DESCRIPTION GASKET BOTTOM AIR OUT QPRV WASHER SELF LOCKING 1 DIA 12GA SCREEN BOTTOM AIR OUT TRAY V TWIN RV NUT FLG 5 16 18 LOCK SCREW HHC 3 8 24 X 2 1 4 G8 WASHER LOCK M10 WASHER FLAT 3 8 M10 ZINC SCREW TAP R 10 32 X 9 1 BLOWER HOUSING GTV760 RV SCREW HHC 3 8 24 X 1 G5 WASHER LOCK 3 8 WASHER FLAT 406ID X 1 6200 SET BLOWER HOUSING GASKET BELT V RIB 4LX42 5 BUS
57. T NO QTY DESCRIPTION 1 ASSEMBLY CRANKCASE RV 33 062991 2 E RING GOVERNOR ARM 1 SEAL 38 I D CRANKCASE 34 001667 1 ARM GOVERNOR 6 SCREW HHTT M6 1 0 X 12mm 35 0 2088 1 THRUST WASHER GOVERNOR 1 ASSEMBLY BREATHER 36 002992 1 BUSHING GOVERNOR LOWER 1 GASKET BREATHER COVER 37 065732 1 ASSEMBLY SUMP WITH SLEEVE 1 SEPARATOR OIL BREATHER 38 002993 1 SEAL GOVERNOR SHAFT 1 ASSEMBLY HEAD 1 39 0 9842 1 SEAL 42 I D CRANKSHAFT 1 COVER ROCKER 40 009756 1 CONNECTOR 3 8NPT TO INVTD FLR 4 RETAINER PISTON PIN 20 3 80D 2 PISTON HC 41 063006 10 SCREW HHFC M10 1 5 X 55mm 2 SET PISTON RING 90mm 42 080318 8 SCREW HHFC M6 1 0 X 25mm 2 PIN PISTON 43 0 2982 1 COVER ROCKER WITH OIL FILL 1 ASSEMBLY CAMSHAFT amp GEAR 44 093064 1 ASSEMBLY OIL FILL CAP 1 SHAFT GOVERNOR 45 0C2979 2 GASKET VALVE COVER 2 ROLLER BEARING GOVERNOR PLATE 46 086515 8 KEEPER VALVE SPRING 1 ROLLER BEARING GOVERNOR 47 002274 4 RETAINER VALVE SPRING 1 ASSEMBLY GOVERNOR GEAR 48 003867 4 SPRING VALVE 1 SPOOL GOVERNOR MACHINED 49 078672 2 SEAL VALVE STEM D7 1 GASKET CRANK CASE 50 065371 4 WASHER VALVE SPRING 1 SEAL OIL PASSAGE 51 003998 4 NUT HEX M8 1 0 G8 1 ASSEMBLY CRANKSHAFT 52 0 3273 1 SCREEN CRANKCASE BREATHER 2 ASSEMBLY CONNECTING ROD 53 005313 4 ROCKER ARM 2 GASKET HEAD 54 072694 4 STUD ROCKER ARM PIVOT 3 WASHER LOCK RIB 6 55 006024 2 PLATE PUSH ROD GUIDE 3 SCREW SHC M6 1 0 X 30mm 56 0C2976 12 SCREW HHFC M8 1 25 X 65mm 1 SCREEN OIL PICKUP 57 008067
58. WASHER LOCK 8 GASOLINE ONLY NUT HEX M4 0 7 G8 YC GASOLINE ONLY SCREW HHTT M6 1 0 X 16 YC CLAMP VINYL 1 06 X 406 LP ONLY WASHER FLAT 1 4 M6 LP ONLY SCREW M6 1 0 X 12 LP ONLY CLAMP VINYL 437 X 281 45 Q us Section 11 Exploded Views and Parts Lists Recreational Vehicle Generators 0 Control Panel Drawing No 0 1013 46 ITEM PART NO 1 002375 2 022145 3 029459 4 075215 5 052858 6 047411 7 022097 8 022473 9 080925 10 009921 11 066849 12 066386 13 0 9674 14 0E0363H 0E0364H 0E0362H 15 073159 16 077005H 077004H 073163H 17 031971 18 077006 19 009675 20 0 5351 21 073146 22 061878 23 075242 24 075237 25 090145 0 1529 26 090144 090145 0 1529 2 025105 28 0 9611 29 032300 30 092113 31 087798 32 055440 33 009377 Section 11 Exploded Views and Parts Lists Recreational Vehicle Generators DESCRIPTION P PM P B Po hA HS HS HS SS SS S PO B po A SCREW HHC 8 1 25 X 90 68 8 WASHER FLAT 5 16 M8 ZINC TENSION SPRING WASHER SPRING CENTER NUT LOCK FL M8 1 25 SCREW HHC M6 1 0 X 16 G8 8 WASHER LOCK M6 1 4 WASHER FLAT 1 4 M6 ZINC WASHER NYLON 404 STANDOFF 1 2 HEX SCREW HHTT M5 0 8 X 16 ASSY BRUSH HOLDER BEARING CARRIER UP STATOR ASSEMBLY 5 5 KW ONLY
59. Whether the generator is mounted above the hori zontal support tubing or suspended below the tub ing the supporting frame used must be structur ally sound If the generator cannot be bolted directly to the supporting frame or support tubing consider using additional tubing angle brackets or other supports to give the supporting frame sufficient strength 6 1 5 SUSPENDED MOUNTING If planning to suspend the generator below the hori zontal support 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 sus pended mounting system is shown in Figure 6 2 The location of a suspended mounting system must be carefully planned keeping the following general rules in mind Protect the generator against road splash and debris Baffles or splash guards may be required to protect certain areas of the generator To make sure the generator is adequately protected road test the installation through mud water and slush Figure 6 2 Typical Suspended Mounting System GUAR The installer must make certain that the selected location will permit adequate cooling and ventilat ing airflow to be supplied 6 1
60. ace permanently Pressing such materials as putty tape onto joints and seams is not acceptable A high quality silicone rubber base sealant is recommended Holes and openings made in the compartment walls to allow for the passage of electrical conduit conductors hoses cables etc into the vehicle liv ing area must be sealed vapor tight with silicone rubber base sealant If flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartments electrical junction box NOTE Flexible metal conduit due to its unique construc tion is NOT vapor tight along its entire length ea 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 6 6 Installer constructed compartments typically utilize a standard lap joint Figure 6 6 Types of Lock Seams FOLD LOCKED STANDING DOUBLE LOCK DOUBLE SEAM os r _ GORDON SEAM LOCK SEAM STANDARD LAP JOINT After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material See Section 6 2 3 DX A Do not install any flammable material directly above or around the compartment Heat transferred through the compartment struct
61. berglass with a 2 pound density 6 2 5 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items Figure 6 8 Engine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts See Section 6 1 4 191 A Fuel lines and exhaust piping must not pen etrate into the vehicle living area 6 5 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling ventilating and engine combustion be supplied to the generator set Without sufficient airflow the engine generator quickly overheats Such overheating can cause serious operating difficulties and also may cause fire and personal injury The installer must make sure that sufficient air is avail able to the generator for cooling ventilating and combustion The installer also must provide for a path for exhausting the cooling air to the exterior of a compartment if so equipped A A AA Never use discharged cooling air for heating or permit such air to enter the vehicle interior This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases 6 5 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 6 9 This airflow cools the engine generator and electronic compo nents
62. bleshooting Recreational Vehicle Generators 8 1 TROUBLESHOOTING GUIDE Problem Engine won t crank Engine cranks won start Engine starts hard runs rough Engine starts then shuts down No AC output voltage 36 Cause 1 7 5amp fuse blown 2 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 e e 59 Out of fuel Fuel shutoff valve is closed Fuel pump not operating Engine is flooded Fuel filter is clogged Engine spark plugs defective Bad ignition magneto on engine Bad carburetor 0 Dirty air cleaner 15009 DM EE deo De t Dirty engine air cleaner Automatic choke is sticking Defective spark plugs Defective ignition magneto Engine oil level is low Bad low oil pressure switch Defective high temp switch Water in fuel Defective remote harness cw pe et 1 Main breaker s open 2 Transfer switch 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 L4 pu Ie c9 10 pu xo m e o qw ct Replace blown fuse Tighten clean or replace as necessary Recharge or replace battery Replace switch Replace starter
63. by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage or responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 555 1522 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which
64. contactor Replace starter motor Contact an authorized service dealer Refill fuel tank Open fuel shutoff valve s Repair or replace pump Repair replace or adjust Wait 5 10 minutes try again Replace filter if clogged Clean regap or replace as needed Replace if defective Adjust repair or replace Clean or replace as needed Clean or replace as needed Free choke linkage as needed Clean regap or replace Replace it if defective Add oil as needed Replace if bad Replace if bad Drain fuel tank and refill Disconnect remote harness Contact authorised service facility Close main breaker s Reset transfer switch See vehicle manual Contact an authorized service facility Section 9 Notes Recreational Vehicle Generators NOTES 37 Section 10 Electrical Data Recreational Vehicle Generators ELECTRICAL lt diae Electrical Schematic V Twin Drawing No 0E1057 E _ BATTERY SC 13 p 16 0 13 16 e SCR w pe 17 O y START Swi o 0B 17 O A stop 4 HTO 85 I 0 1222 LOP Ji 85 85 J1 12 gt 0 REMOTE PANEL CONNECTOR AN Ui AN o ui POWER WINDING 44 GREEN 3 120V 30A QP65 2 T 120V 35A QP75 120V 30A QP55 amp QP65
65. creational Vehicle Generators WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1997 and later model year engines a Applicability This warranty shall apply to 1997 and later model year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use purchaser owner of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a warranted emissions related part to fail to be identical in all material respects to the part as described in the engine manufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4
66. e This total should be less than the unit s rated wattage amperage capacity 6 7 4 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The following general rules apply e Cut wiring to the required length and allow extra wire for junction box connections e Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation e Route conduit so it does not interfere with genera tor movement If using metallic conduit vapor seal the end of the conduit where it enters the junction box Do this because flexible metallic conduit is not vaporproof along its entire length 6 7 5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 6 15 An alternate method for isolating different power sources is by using an isolating receptacle Figure 6 16 Whichever method is used be certain that both power sources are NOT connected at the same time 31 INSTALLATION Section 6 Installation Recreational Vehicle Generators 6 76 POWER SUPPLY CORD The power supply cord must comply with all appli cable codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected 6 77 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code NFPA 70 article 551 requires that ground fault circuit
67. e applicable equipment with the product s installation requirements Give serious consideration to all information and instructions in the manual both for safety and for continued reliable operation of the equipment Because of the different recreational vehicle mod els and the variations between the models it would be extremely difficult if not impractical to provide detailed instructions for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all appli cable codes standards and regulations pertaining to the installation and use of this product If any portion of this manual appears to be in conflict with such codes standards or regulations the applicable codes standards or regulations must take prece dence over the manual 5 2 SAFETY Before handling installing operating or servicing this equipment carefully read the Notice to Installer and Safety Rules Comply with all safety rules to prevent death personal injury or damage to equip ment and or property Stress safety to all installers operators and service technicians who work on this equipment 5 5 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The follo
68. ed or is not permanently sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all applicable codes standards and regula tions 6 7 ELECTRICAL CONNECTIONS Be sure to read Section 5 6 The following general rules apply to electrical connec tions in a recreational vehicle Qualified electricians who are familiar with appli cable codes standards and regulations should install electrical wiring The wiring should comply with codes standards and regulations The National Electrical Code NFPA 70 and state and local codes apply Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent damage from road shock Wiring must be of adequate size have approved insulative qualities and be properly supported Conduit and wire openings into the generator com partment if used must be vapor sealed to prevent entry of flammable explosive or poisonous gases into the vehicle 6 7 1 ELECTRICAL JUNCTION BOX Install an approved square electrical junction box with a blank cover on the interior or exterior wa
69. ed to the solenoid valve must be properly regulated by means of a primary gas regu lator Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank The following rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inch es water column Do NOT exceed 14 inches water column The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommended MINIMUM gas flow rate for all air cooled PRIMEPACT series generators is 67 cubic feet per hour If an existing primary gas regulator does not have a sufficient flow capacity for the generator and other gas appliances in the circuit a install a primary regulator with adequate flow rate or b install a separate regulator only and rated at least 67 cubic feet per hour The inlet side of any pri mary regulator that supplies the generator must connect directly to a gas pressure tank Do NOT tee the generator line into a gas circuit feeding other areas 6 5 6 GASEOUS CARBURETION LP gas vapors should be supplied to the secondary regulator inlet at about 11 inches water column posi tive pressure The engine pistons draw air in dur ing the intake stroke Figure 6 12 This air passes through a carburetor venturi which creates a low pressure that is proportional to the quantity of air being pumped
70. educe noise must not adversely affect the flow of cooling and ventilating air into or out of the compartment In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise levels Such a compartment might be constructed as follows Figure 6 7 Use 5 8 inch thick or 3 4 inch thick plywood in the compartment Construct the compartment floor of a double thick ness of 5 8 inch or 3 4 inch plywood Line the compartment interior walls and floor as well as the underside of the floor with 26 gauge galvanized steel Vapor seal all compartment seams and joints Over the galvanized steel lining install a combi nation of acoustical materials as mentioned in Section 6 2 3 Figure 6 7 Typical Noise Abatement PLYWOOD EXTERIOR 5 8 0 3 4 THICK SOUND INSOLATION METAL LINER MATERIAL PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION INSTALLATION Hh Section 6 Installation Recreational Vehicle Generators A A To prevent fire or explosion do not install any insulation or other absorbent materials on the interior or underside of the compartment floor Seal all compartment door edges to prevent noise leakage around the door perimeter Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 25 mm thick fi
71. engine generator to automati cally shut down To avoid overloading add up the wattage of all con nected electrical lighting appliance tool and motor loads This total should not be greater than the 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 genera tor First figure the watts needed to start electric motors in the system To that figure add the run ning wattages of other items that will be operated by the generator Do not apply heavy electrical loads for the first two or three hours of operation 2 8 PROTECTION SYSTEMS 2 8 1 LOW OIL PRESSURE SWITCH This switch Figure 2 3 has normally closed N C contacts that are held open by engine oil pressure during cranking and operating Should oil pressure drop below a preset level switch contacts close and the engine automatically shuts down The unit should not be restarted until oil is added 10 2 8 2 H
72. he installation initial start up and main tenance of this equipment is carried out by an Authorized Service Dealer The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentra tions can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coherently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weak ness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired Never sleep in the vehicle while the genset is run ning unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ven tilating air is critical to correct generator opera tion and i
73. horoughly IFC oci IFC Operation and Maintenance IFC How to Obtain Sel VCC essere eo tonto audet IFC Authorized Service Dealer Locator Number IFC Safety Rules uuu 2 Section 1 General Information 4 11 Generator Identification 4 1 2 Generator Applicability 5 Lo 5 LE TN 5 1 5 Generator AC Connection System 5 LO ERIS 6 Section 2 Operation 7 2 1 Generator Control Panel 7 2 2 Optional Remote Start Stop 8 2 9 uuu R 8 2 4 Before Starting Engine 8 2 0 Starting the Generator 9 2 6 Stopping the Generator 9 2 7 Applying Loads to Generator 9 2 0 Protection u uu u 10 Section 3 Maintenance 11 3 1 Checking the Engine Oil Level 11 3 2 Changing the Engine Oil and or Oil Filter 12 3 9 Maintaining the Engine Air Cleaner 12 3
74. igure 6 13 Spark Arrestor Installation O D 38 1 1 50 24 0 95 3 5 9 64 DRILL BOTTOM SIDE ONLY 6 6 2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any combus tible material such as wood felt cotton organic fibers or other like material If the 3 inch 76 mm clearance cannot be maintained locate insulate 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 tempera ture 30 Extend the exhaust system at least 1 inch 25 mm past the outer edge of the vehicle Do not terminate the exhaust system under the vehicle Terminate the exhaust tailpipe such that exhaust gases will not be drawn back into the generator compartment and recirculated If there is any possibility of the tailpipe or muffler being damaged protect these damage prone areas by means of a protective device such as a skid bar Install the generator exhaust system according to safe automotive practices Use enough exhaust system hangers to prevent any part of the system from being dislocated Use exhaust system parts recommended by the manufacturer Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person s installing such unauthorized parts Do not terminate the exhaust system under any opening window or vent that can be open
75. kage oil leakage etc ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle have the generator properly grounded bonded either by solid mounting to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT disconnect the bonding conductor if so equipped DO NOT reconnect the bonding conduc tor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is u
76. l 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 4 LINE BREAKERS Protects generator s AC output circiut against over load i e prevents unit from exceeding wattage amperage capacity The circuit breaker ratings are as follows Circuit Breaker 1 Circuit Breaker 2 240 Volt QuietPact 55 QuietPact 65 QuietPact 75 NOTE If this generator has been reconnected for dual voltage AC output 120 240 volts install line breakers having an amperage rating that is differ ent than that stated above The replacement 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 reconnected for dual voltage it is no longer RVIA or CSA listed Figure 2 1 Typical Control Panel CONTROL CENTER START 0 0580 REV B IF GENERATOR D REMOVE AND INSPECT R S MANUAL TROUBLE SHOOTIN 5 ING GUIDE PRIM E PRESS PRIME SWITCH FOR 10 SECONDS BEFORE STARTING WHEN STARTING DO NOT PRESS START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT OPERATION Section 2 Operation J gt Recreational Vehicle Generators 22 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel Figure 2 2 is available that allows
77. ll of the area planned for installation of the generator NOT on the generator Route the generator s AC output leads into this junction box through approved flexible conduit This is the point of first termination for generator AC output leads 6 72 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 com partment wall If flexible metal conduit is used between the gen erator and the compartment junction box the con duit end that terminates the compartment junction box must be vapor sealed Flexible metal conduit is NOT vapor tight along its entire length From the junction box route power supply wires through approved conduit to either a double pole double throw transfer switch or b approved iso lation receptacle Connecting to a transfer switch or isolation receptacle must prevent vehicle electri cal circuits from being connected to two different power supplies at the same time such as genera tor and dockside power Conductors must be rated 221 F 105 C or must
78. materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline 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 Section 1 General Information Recreational Vehicle Generators 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 11 15 Behind Access Panel REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake Screen 11 Fuel Pump Behind access panel 2 Data Plate 12 Oil Filter 3 Engine Start Stop Switch 13 Oil Drain Plug 4 7 5 amp Fuse 14 Oil Dipstick and Filler Tube 5 Circuit Breaker 15 Air Filter Behind access panel 6 Optional Remote Panel Receptacle 16 Spark Plugs 7 Generator AC Output Leads 17 Exhaust Outlet 8 Starter Contactor 18 Fuel Fil
79. n advisory lamp and an hourmeter The hourmeter should be used in con junction with the maintenance operations found in Part I of this manual Part number 0 0429 includes the remote panel and a 10 foot long 6 wire harness Part number OF0430 includes the remote panel and a 30 foot long 6 wire harness 71 POST INSTALLATION TESTS The air cooled generator set was factory tested and adjusted It should not be necessary to adjust the unit any further except under special circumstances amp Do not make any unnecessary adjustments Factory settings are correct for most applica tions When making adjustments however be careful to avoid overspeeding the engine 12 BEFORE INITIAL START UP Before starting complete the following 1 Check the engine crankcase oil level and if nec essary fill to the dipstick FULL mark cross hatched area with the recommended oil Do not fill above the FULL mark 2 Check the fuel supply Gas fuel lines must have been properly purged and leak tested in accor dance with applicable fuel codes fuel shutoff valves in the fuel supply lines must be open A Dita A AN If a liquid propane LP gas fuel system has been installed it must be properly tested for leaks before operating the system in compliance with ANSI A119 2 NFPA 501C No leakage is permit ted Be sure that gasoline fuel vapors do not enter the vehicle interior 15 INITIAL
80. n amp Jh Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can dam age the other engine 6 6 1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U S Forest Service Use only mufflers and parts approved by the manufacturer Any person s installing an unapproved muffler or an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable for any damage injury or warranty expense that might be caused by such unapproved installation or modi fication 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 arres tor components verify that the tailpipe has a hole to securely fasten the spark arrestor components see Figure 6 13 Use only manufacturer supplied hard ware Substitution of parts may cause damage to the screen or a loose fit to the tailpipe F
81. n and Support 22 6 2 Generator Compartments 23 6 3 Cooling and Ventilating 25 6 4 Gasoline Fuel System 26 605 LP Gas Fuel Syste uuu 27 66 Exhaust SyS ema 29 6 7 Electrical Connections 30 6 8 Battery Installation 32 69 Optional ACCESSOLES ceccssencesscereczessscesvavcisecenscats 34 Section 7 Post Installation 34 7 1 Post Installation Tests 34 7 2 Before Initial Start Up cuo coo o etos 34 2 Minal Sia m 34 4l Testing Under 35 7 5 Installation Checklist 35 Section 8 Troubleshooting 36 8 1 Troubleshooting Guide 36 Section 9 Notes 37 Section 10 Electrical Data 38 Section 11 Exploded Views and Parts Lists 40 Section 12 Warranty 52 SAFETY RULES Safety Rules Recreational Vehicle Generators SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted
82. n operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mount ing to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum If the vehicle electrical circuits can be powered by any other source of electricity such as a dockside power receptacle there must be no possibility of connecting the different power sources to the vehi cle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operat ing Failure to isolate the vehicle circuits from the dockside power supply when the generator is running may result in damage to the generator or serious injury or death to dockside utility power workers due to backfeed of electrical energy In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conduc
83. n turn the voltage delivered to connected electrical loads is controlled When the AC frequency is 60 Hertz voltage is regu lated at 115 volts Figure 2 5 Solid State Voltage Regulator 1 SENSING C 4 TO ROTOR 3 00 DIRECT CURRENT LL 6 FROM STATOR EXCITATION WINDING ALTERNATING CURRENT The voltage regulator also incorporates a voltage surge protection circuit This circuit prevents trou blesome surges in the generator AC output voltage Voltage surge is a common cause of damage to elec tronic equipment 2 8 5 25 HOUR BREAK IN PERIOD The first 25 hours of operation is the break in period for the generator Properly breaking in the genera tor is essential to minimize fuel consumption and provide maximum engine performance During this 25 hour break in period follow this procedure Run the unit at varying electrical loads to help seat the engine piston rings properly Check the engine oil level frequently Add oil if needed It is normal for the generator engine to consume more oil than is normal until the piston rings have properly seated For the 75 hour operation following the break in period avoid light electrical loads Load the gen erator at 50 percent or more of its rated watt age capacity Repeated light loads during these 75 hours can cause improper seating of engine piston rings resulting in blowby and high oil consump tion After operating the unit for 2
84. ncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury TY RULE Safety Rules a Recreational Vehicle Generators FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regula tions Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical sys tem Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible
85. nter the vehicle interior Figure 6 11 Typical Propane Gas Fuel System CARBURETOR REGULATOR LOCKOFF SOLENOID PRIMARY REGULATOR VAPOR WIDTHDRAWAL TANK 6 5 5 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system consider seriously the following items All fittings lines hoses and clamps must be tight and free of leaks Apply a pipe sealant to threads when assembling threaded connections This reduces the possibility of leakage Test the entire fuel system for leaks using approved test methods Optimum gas pressure at the inlet to the gaseous fuel solenoid valve and secondary regulator is 11 inches water column The installer s fuel supply connection point is at the gaseous fuel solenoid valve This is a 3 4 inch female connection Provide a suitable 3 4 inch NPT male connector to attach to the fuel supply line 28 Use a length of approved flexible fuel hose between the gaseous fuel solenoid valve and rigid gas pip ing The flexible line should be at least 6 inches longer than necessary 6 5 4 VAPOR WITHDRAWAL LP gas is stored in pressure tanks as a liquid The gas systems used with these generators were designed only for vapor withdrawal type systems Vapor with drawal systems use the gas vapors that form above the liquid fuel in the tank Do NOT attempt to use the generator with any liquid withdrawal type system 6 5 5 PRIMARY REGULATOR Gas pressure deliver
86. nty Service Facility All transportation costs under the warranty includ ing return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac generators sold and rated for Recreational Vehicle RV applications as Generac has defined Recreational Vehicle generator applications The factory recommends exercising the unit one half hour every month WARRANTY SCHEDULE COMMERCIAL APPLICATIONS YEAR ONE 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components e Alternator components WARRANTY SCHEDULE CONSUMER PERSONAL APPLICATIONS YEARS ONE AND TWO 100 one hundred percent coverage on part s labor removal and reinstallation listed e Engine All components e 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 reinstal lation are the owner s responsibility Rotor Stator Computer Control Board part numbers 0A6060 and 0A3369 and inverter if applicable with regard to the generator Cylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Manifolds Generac RV generators manufactured prior to December 31 1997 DO NOT have a transferable warranty Generac RV generators manufactured after January 1 1998 have a transferable warranty to the second owner ONLY for
87. of current at 120 volts or exceed 27 AC amperes at 240 volts QUIETPACT 75G amp LP 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 7500 watts 7 5 kW of total power but cannot exceed 62 5 AC amperes of cur rent at 120 volts or exceed 31 2 AC amperes at 240 volts caution amp Do not overload the generator Some installa tions may require that electrical loads be alter nated to avoid overloading Applying exces sively high electrical loads may damage the generator and may shorten its life Add up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one time This total should not be greater than the wattage capacity of the generator If an electrical device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of cur rent for starting than for continuous operation Section 1 General Information z GENERAL Recreational Vehicle Generators INFORMATION 1 5 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 instal lation An INSTALLATION MANUAL was shipped with the generator That Manual c
88. of unsealed batteries and if necessary fill with Distilled Water Only Do not use tap water in batteries 3 8 2 EVERY SIX MONTHS Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer NOTE Servicing of the battery is to be performed or supervised by personnel knowledgeable of batter ies and the required precautions Keep unauthor ized personnel away from batteries Damage will result if the battery connections are made in reverse 14 DI A Do not dispose of the battery in a fire The battery is capable of exploding Storage batter ies give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explo sion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equip ment near the battery Discharge static electric ity from body before touching the battery by first touching a grounded metal surface A battery presents a risk of electrical shock and high short circuit current The following pre cautions are to be observed when working on batteries e Remove watches rings or other metal objects e Use tools with insulated handles e Wear rubber gloves and boots
89. ontains manufacturer s instructions and recommendations for installing the unit into an industrial vehicle After installation installers should forward the Installation Manual to Owners Operators for their information Owners Operators have the responsibility to make sure that nothing is done that might render the instal lation unsafe or in non compliance with applicable codes standards and instructions 1 4 SAFETY Before using the generator set carefully read GENERAL SAFETY RULES inside the cover Comply with these RULES to prevent accidents and damage to equipment and or property The manufacturer 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 elec trical loads by means of a dual 2 wire connection system Generators may be installed to provide the following outputs 1 120 VAC loads only one load with a maximum total wattage requirement equal to the generator s rated power output in watts and 120V across the generator output terminals Figure 1 1 shows the generator lead wire connections for 120VAC ONLY 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 genera tor output terminals or two seperate loads
90. or is operating at 3 600 rpm The drive belt arrangement allows the engine to operate at a lower speed than the rotor 5 6 GENERATOR AC CONNECTION SYSTEM These air cooled generator sets are equipped with dual stator AC power windings These two stator windings supply electrical power to customer electrical loads by means of a dual 2 wire connection system Generators may be installed to provide the following outputs 1 120 VAC loads only one load with a maximum total wattage requirement equal to the generator s rated power output in watts and 120V across the generator output terminals See Fig 5 1 2 120 240 VAC loads one load with a maximum total wattage requirement equal to the generator s rated power output and 240 V across the generator output terminals or two seperate loads each with a maximum total wattage requirement equal to half of the generator s rated power output in watts and 120 V across the generator output terminals See Fig 5 3 Figure 5 1 Connection for 120 Volts Only 33 M RED BLACK zo 50 120V 2 co oz z 120V ion 22 haan T2 44 E WHITE WHITE GROUNDED NEUTRAL ion General Informat Recreational Vehicle Generators Section 5 lt lt LLI o imensions Drawing No OE1058 E Figure 5 2 Major Features and D 02 1818 18 811 0 7 1940111 1304 768
91. precleaner from the cover 4 Wash the foam precleaner in liquid detergent and water 5 Wrap the foam precleaner in a clean cloth and gently squeeze it dry 6 Saturate the foam precleaner in clean engine oil Gently squeeze it in a clean cloth to remove excess oil and to distribute oil DO NOT TWIST 7 Install the foam precleaner into the cover fol lowed by the paper filter Tabs at edges of paper filter must lock into slots on cover 8 Install the cover foam precleaner and paper fil 9 Replace knob to retain the filter in place Figure 3 3 Engine Air Cleaner Flat Wing Washer Nut Precleaner Air Filter Offset Stud Lock Washer Gasket Airbox Compartment 3 4 CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug to clean 2 Remove the spark plug and check the condition Replace the spark plug if worn or if reuse is ques tionable 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 030 inch 0 76 mm by carefully bending the ground electrode Figure 3 4 Figure 3 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 030 inch 0 76 mm m Cue QY lt D 27 N caution amp
92. quipped b Ignition module 1 2 LPG carburetion assembly and its 4 Catalytic Muffler Assembly if so equipped including internal components if so equipped a Muffler gasket a Fuel controller if so equipped b Exhaust manifold b Mixer and its gaskets if so equipped 5 Crankcase Breather Assembly including c Carburetor and its gaskets if so equipped a Breather connection tube d Primary gas regulator if so equipped e LP liquid vaporizer if so equipped Generac engine types covered by this warranty statement include the following 1 Utility 2 Lawn and Garden Equipment 3 Recreational Vehicle RV Generator 4 Industrial Mobile IM Generator Part 2 53 Section 12 Warranty WARRANTY Recreational Vehicle Generators GENERAC POWER SYSTEMS THREE YEAR LIMITED WARRANTY FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS NOTE ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES For a period of 3 three years of operation from the date of original sale Generac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Facility is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warra
93. s if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the purchaser owner Such use shall not reduce Generac s ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 2 Air Induction System including 1 1 Gasoline carburetor assembly and its a Intake pipe manifold internal components if so equipped b Air cleaner a Fuel filter if so equipped 3 Ignition System including b Carburetor gaskets a Spark plug c Fuel pump if so e
94. s required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or permit even partial blockage of ventilation provi sions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Before performing any maintenance on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc Never insert any tool or other object through open ings in the generator interior even if the unit is not running serious injury or damage to the equip ment could be done AN ELECTRICAL HAZARDS A The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around a
95. s to enter the vehicle A JN The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coher ently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weakness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired A Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installa tion manual Make sure there is ample fresh air when operating the genset in a confined area 2 5 STARTING THE GENERATOR NOTE Read the vehicle manufacturer s instructions The owner operator should become familiar with the vehicle in which this generator is installed Differences exist between vehicles For example some vehicles may use a transfer switch to isolate dockside power from the generator while other
96. te or a service dealer 5 10 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement Drive belt tension was properly adjusted before the unit was shipped from the factory If suspect that drive belt tension is incorrect contact an Authorized Service Dealer 5 11 EXERCISING THE GENERATOR The manufacturer recommends starting and operat ing the generator at least once every seven days Let the unit run for at least 30 minutes to exercise the engine 3 12 OUT OF SERVICE PROCEDURE 3 12 1 REMOVAL FROM SERVICE If the generator cannot be exercised every seven days and it is to be out of service longer than 30 days pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down 3 While the engine is still warm from running drain the oil completely Refill the crankcase with SAE oW 30 oil having API classification For Service SE 4 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase o 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 MAINT
97. ter 9 FuelInlet 19 LP Fuel Inlet 10 Fuel Primer Switch 1 2 GENERATOR APPLICABILITY These generators have been designed and manufac tured for supplying electrical power for recreational vehicles DO NOT modify the generator or use it for any application other than for what it was designed If there are any questions pertaining to its applica tion write or call the factory Do not use the unit until advised by competent authority A A For fire safety the generator must have been properly installed in compliance with ANSI 119 2 1975 NFPA 501C 1974 Standard for Recreational Vehicles Part Installation of Electrical Systems The generator also must have been installed in strict compliance with the manufacturer s detailed installation instructions After installation do nothing that might render the unit in noncompliance with such codes stan dards and instructions Use the generator set to supply electrical power for operating one of the following electrical loads QUIETPACT 55G amp LP 120 and or 240 volts single phase 60 Hz electrical loads These loads can require up to 5500 watts 5 5 kW of total power but cannot exceed 45 8 AC amperes of cur rent at 120 volts or exceed 22 9 AC amperes at 240 volts QUIETPACT 65G amp LP 120 and or 240 volts sin gle 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
98. the remainder of the three year limited warranty Proof of pur chase 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 e Generac Guardian generators that utilize non Generac replacement parts Costs of normal maintenance adjustments installation and start up Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in
99. to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and accessories 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 locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER or locate us on the web at www generac com Part Operating Instructions Introduction Inside Front Cover Read This Manual T
100. tor 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 equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury TY RULE Safety Rules a Recreational Vehicle Generators FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regula tions Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical sys tem Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers cons
101. tube Such an arrangement causes the generator engine to run out of gas while adequate fuel for the vehicle remains in the tank To reduce lead and carbon deposits use high qual ity UNLEADED gasoline with the generator Leaded REGULAR grade gasoline is an acceptable substitute NOTE Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits caution A The manufacturer does not recommend using any gasoline containing alcohol such as gaso hol If using any gasoline containing alcohol it must not contain more than 10 percent ethanol and it must be removed from the generator dur ing storage Do NOT use any gasoline containing methanol If using gasoline with alcohol inspect more frequently for fuel leaks and other abnor malities 1 6 2 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum Institued API Classification SF SG SH or SJ The recommended oil viscosity weights include the following During summer months 40 deg F and higher SAE 30 or SAE 10W 30 During winter months 40 deg F to 20 deg F SAE 5W 30 or SAE5W20 DO NOT USE SAE 10W 40 Crankcase and oil filter capacity is approximately 1 8 L or 1 9 U S quarts DO NOT use special additives See Sections 3 1 and 3 2 for oil level check and filling procedures 1 6 5 ENGINE SPECIFICATIONS AIS OE GT 760 OT hi IO U PP
102. ult the local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline Fuel lines must be properly installed and fastened and free of leaks There must be no possibility of gasoline vapors entering the vehicle interior It is required that an approved flexible noncon ductive fuel line between the generator fuel connec tion point and rigid fuel lines be installed If the generator is equipped with a liquid propane LP gas fuel system install the unit so it complies with all codes standards and regulations pertain ing 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 explo sion Do not allow gas vapors to enter the vehicle 19 Recreational Vehicle Generators 5 1 PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of th
103. ure may be sufficient to ignite char or discolor seat cushions fiberboard and other flammable materials Use approved nonflammable insulat ing materials in high temperature areas 6 2 5 SOUND INSULATING MATERIALS Once installers have determined that a compartment is properly constructed and metal lined they can add acoustical material This may include additional seal ant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a nonflam mable type One excellent insulating material is a 1 inch 25 mm thick fiberglass having a 2 pound den sity When fiberglass is used its coated side should face toward the compartment interior A A Do not install sound insulation or any absorbent material on the compartment floor interior Such materials will become soaked with combustible or explosive vapors and liquids and will become a fire hazard Using a combination of sound insulating materials can often reduce noise more effectively than a single material For example a sheet of lead or visco elastic material along with a layer of other acoustical mate rial is more effective than when a single material is used 6 2 4 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement com partment NOTE Any method used to r
104. 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 pro vided in the vehicle such as a main line circuit breaker or transfer switch NOTE If starting from the generator control panel turn OFF loads by setting the generator s main circuit breaker to the OFF or open position If starting from a remote panel turn OFF loads using the means provided in the vehicle such as a main circuit breaker Electrical load circuits will be turned ON after the generator has started stabi lized and warmed up Section 2 Operation OPERATION Recreational Vehicle Generators J gt 2 If the engine has not been started in more than two weeks press the Fuel Pump Primer switch and hold it for about 10 seconds However if the engine is warm skip Step 2 3 crank and start the engine hold the start stop switch at START Release the switch when the engine starts cauroN amp If the engine does not start after it has been cranking for 15 seconds release the Start Stop switch and wait 1 minute before trying again Holding the switch for longer than 15 seconds can damage the starter motor 4 Letthe engine run at no load for a few minutes to stabilize and warm up 5 Turn ON electrical loads using
105. verheating enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate ee NOTE The installation must be tested especially if bring ing in air from below the generator set 6 4 GASOLINE FUEL SYSTEM DIT A Gasoline is highly flammable and its vapors are explosive Comply with all codes standards and regulations pertaining to gasoline fuel systems used in recreational vehicle generators Properly install and maintain the fuel system and keep it entirely free of leaks Gasoline vapors must not enter the vehicle interior The installation of a gasoline fuel system Figure 6 10 for a recreational vehicle generator set must comply with applicable codes standards and regula tions The entire fuel system must be completely free of leaks There must be no possibility of gasoline vapors entering the vehicle interior Figure 6 10 Generator Fuel System Fuel Pump im Behind Access HT ta nn Cover A 200 M mu a J Fuel Filter 1 Side of Unit BE j En i 000 Fuel Line Factory installed generator
106. wing standards booklets latest revision are available from the sources indicated 1 NFPA Standard 501 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 119 2 501C available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 available from the State of California Documents Section PO Box 1015 North Highlands CA 95660 eo Section 5 General Information 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 5 4 EQUIPMENT DESCRIPTION Instructions and information in this section per tain to air cooled generators These generators are designed specifically for installing in recreational vehicles They operate 120 volt single phase 60 Hertz AC electrical loads 5 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 rot
107. 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 e Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limita tion may not apply to you This warranty gives you specific legal rights
108. y 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 N GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start up and main tenance of this equipment is carried out by an Authorized Service Dealer The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentra tions can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coherently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weak ness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired Never sleep in the vehicle while the genset is run ning unless the vehicle has a working carbon monoxide detector The exhaust system must be

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