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Guardian Technologies 02010-2 Portable Generator User Manual

1. IFC OU reer UE IFC Operation and IFC How Obtain Service ieri rient Heroes IFC Authorized Service Dealer Locator Number IFC Safety 2 Section 1 General Information 4 1 1 Generator 4 1 2 Generator Applicability ds 5 1 3 eI NM 5 1 4 Generator AC Connection System 5 Do 1 0 612 10 0 suited 5 Section 2 Operation 7 2 1 Generator Control 7 2 2 Optional Remote Start Stop Panel 7 2 3 Automatic Choke Gasoline Only 7 2 4 Before Starting the Engine 8 20D wtar ng The us cA 8 2 0 Stopping The Genel alr ui eoo 9 2 7 Applying Loads to 9 2 8 Summer Winter Heat Riser System 9 29 Procion 10 2 10 Additional Information
2. 22 2 1 Location and Support torte tree 22 2 2 Generator CORHIDArUnelpnls 23 2 3 Cooling and Ventilating 26 2 4 Gasoline 1 lt eret rena ebria rin 27 29 AP Gas Fuel SVSICTI 28 20 Exhaust Sye 30 2 8 525 31 2 0 Battery 25 5 34 2 9 OpHIODaLACCOSSOLEIOSuusesienbe rise ni Foe odes aetate canescens 34 Section 5 Post installation Start up Adjustments 35 ol Post Installation T6808 rs 35 3 2 Before Initial uocis aso eoe 35 S Minal AE tere rc 35 o Testing Under pn RUP Sean do 35 3 5 Installation Checklisb oue oed bey Rex DUE 36 Section 4 Troubleshooting 37 Section 5 Electrical Data 38 Section 6 Exploded Views and Parts Lists 40 Section 7 Warranty cen 52 A SAFETY RULES Safety Rules Recreational Vehicle Generator SAVE THESE INSTRUCTIONS manufacturer sugges
3. e 6 B ws aA SEN Section 6 Exploded Views and Parts Lists Qi Recreational Vehicle Generator Engine Sheet Metal Model 02010 2 and 04164 3 Drawing 0D1760 E PART NO TY DESCRIPTION 1 044323 1 SCROLL FLYWHEEL 2 045756 8 SCREW M6 1 0 X 10MM 3 029289 4 SRV 091222D 1 FLYWHEEL 5 067198N 1 WASHER BELLVILLE M20 X 2 2 6 067890 1 NUT M20 X 1 5 FLYWHEEL 7 0A4456 1 3 8 SPECIAL LOCK WASHER 8 056893 21 SCREW CRIMPTITE 10 24 X 0 5 9 0A6358 1 COVER TOP FLYWHEEL 10 091646 1 DEFLECTOR EXHAUST PORT 11 092572 1 ASSEMBLY IGNITION COIL 12 092079 2 SCREW TAPTITE M6 1 0 X 25MM 13 022717A 1 GROMMET RUBBER 14 073132 1 BOOT SPARK PLUG 15 061669 1 PLUG BUTTON 94 16 089685 2 GROMMET RUBBER 17 022129 6 LOCK WASHER M8 18 049813 1 NUT HEX M6 1 0 19 057821 2 CAPSCR HEX HD M8 1 25 X 40MM 20 059637 2 SCREW TAPTITE 3 8 16 X 0 75 21 0D9004A 1 ASSY STATER MOTOR 22 059985 2 SOCKET HD CAPSCR M8 1 25 X 45MM 23 025034 1 PLUG BUTTON 1 1 16 24 0A8875 1 ASSEMBLY DIPSTICK amp CAP 25 0A7299 1 OIL DRAIN DIPSTICK TUBE 26 0A9539 1 OIL DRAIN HOSE ASSEMBLY 27 047838 1 PIPE NIPPLE 3 8 X 8 LG 28 038593 1 BRASS STREET ELBOW 3 8 29 022473 1 FLAT WASHER 1 4 6 30 0A6357 1 WRAPPER ENGINE SPARK PLUG 31 0A6360 1 WRAPPER STARTER SIDE 32 0A6489 1 WRAPPER REAR GEAR CASE 33 0A6359 1 WRAPPER C
4. eese 11 Section 5 Maintenance sss 11 3 1 Checking the Engine Oil 11 3 2 Changing the Engine Oil and or Oil Filter 12 3 9 Maintaining the Engine Air 12 Clem Air Vol 020 RE bilans 13 3 5 Checking the Engine Spark Plug 13 3 6 Fuel Filter Gasoline 14 3 7 Spark Arrestor 14 uo Cleaning the Generator ceni eerte 14 S9 Battery MaritenalleEuoiisdeseseraeeeu voa tenens 14 3 10 Major Service 15 Dre clk ee ee ene TM 15 9 12 Exercising the Generator pee oe bono 15 3 13 Out of Service PrOCCOULEe s iere rer rere erepti 15 Table of Contents E OF CONTENTS Recreational Vehicle Generator Part Il Installation Instructions Safety RUGS 18 Section 1 General Information 20 1 1 Purpose and Scope of the Manual 20 vp 20 1 3 SOixudards DOOR GISu uiuspo cy ERR ON 20 LA Equipment Description uvis uiae eroi 20 1 5 Generator Engine Operating Speed 20 1 6 Generator AC Connection System 20 Section 2 Installation
5. FUEL LINE CONNECTION 642 0 25 3 AIR CLEANER OIL FILTER OIL DRAIN HOSE OIL FILL BATTERY CONNECTION o LI eo SIDE EXHAUST OUTLET i AN AI NN ALL DIMENSIONS ARE IN MILLIMETERS INCHES 426 7 16 8 21 INSTALLATION Section 2 Installation Recreational Vehicle Generator 2 1 LOCATION AND SUPPORT 2 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 the Generator Support section The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from under neath the supporting framework The location must provide easy access to fre quently serviced components such as filters oil drains spark plugs and other common mainte nance parts The location must provide sufficient room to allow minimum clearances as outlined in the Generator
6. vv LL G i 1 4 vy I ONISV38 OL 1535019 LI 1 va GI 0 92 9 J 0 v SeeSt i i 1 YIwWOLSNI A8311V8 G3l lddfis S 3WDIS2 A8 G 3rl ladans 3g Section 6 Exploded Views and Parts Lists Regulator Model 02010 2 Drawing No 0F1125 C Recreational Vehicle Generator NI N LO 11 G5 7 V 28 co PART NO 0D5694 0F4795 0 5022 0 6070 0C4680 0C4647 0C4643 0D3973 0 6183 072683A 0D3308 070728 0C5764A 0C4643A 0C6066 0C5968 0C5759 0C5761 0C6069 0C6731 0C6067 0C4706 0C6068 0C5762 045764 0C6606 0E4170 0C5760 TY c c c c Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Regulator Model 02010 2 Drawing No 0F1125 C DESCRIPTION CASTING TWIN REGULATOR HOUSING SCREW PPHM SEMS M4 0 7 X 10 SOLENOID COIL 12VDC SPRING SOLENOID PLUNGER PLUNGER LP REG ASSY GASKET SOLENOID INLET TWIN REGULATOR NO HOLE PLUG EXPANSION 16MM TWINREG ELBOW 90D STREET 1 2 BRASS PLUG 1 8 NPTF PIPE WASHER FLAT 3 2MM ID X 10MM OD SCREW PFILHM M3 0 5 X 5 SPRING REGULATOR 45N M 29MM INLET TWIN REG 11 11 DIA SEAL INLET REGULATOR SUPPORT INLET SEAL PIN PIVOT ARM LEVER REGULATOR GASKET DIAPHRAGM RIVET 118 X 125 ALUMINUM SUPPORT DIAPHRAGM DI
7. Figure 2 11 Suspended Mount Inlet Door Using ductwork Figure 2 12 The installer must be sure air is available to the top of the generator since air inlets are located at the top By providing an opening in the vehicle skirt and space behind the generator for cooling airflow Figure 2 13 Recommended clearance behind the back of the generator is at least 1 2 inch 13 mm Figure 2 12 Air Inlet Using Ductwork ANTI SPLASH BAFFLE AIR OUT Figure 2 13 Air Inlet in Vehicle Skirt VEHICLE FLOOR VEHICLE SKIRT AIR INLET MINIMUM CLEARANCE 1 1 2 2 5 5 COMPENSATING FOR RESTRICTIONS ouch materials as screening louvers or expanded metal can restrict the free flow of air Compensate for this restriction by making the actual air opening proportionately larger some materials may offer only a 60 percent free air inlet area Other more efficient materials may pro vide up to a 90 percent free air inlet area The per centage of free air inlet opening is usually available from the material supplier or manufacturer To determine the actual air inlet opening size required divide 100 square inches by the per centage of free air inlet area for the material being used For example If planning to use screening with an 80 percent free air inlet area divide 100 by O 8 which results in 125 square inches Minimum actual size of air inlet opening in this case is 125 square inches INSTALLATION
8. GUARDIAN by Generac Power Systems Inc RY Owner s Manual and Installation Instructions Air cooled Recreational Vehicle Generators Model 02010 2 PRIMEPACT 50 e Model 04164 3 PRIMEPACT 50LP INTRODUCTION Thank you for purchasing this model manufac tured by Generac Power Systems Inc This model is designed and manufactured to supply electrical power for recreational vehicles READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood 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 A After this heading read instructions that if not strictly complied with will result in personal injury or property damage warninc amp After this heading read instructions that if not strictly complied with may result in personal inju ry including death or property damage caution 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
9. for cranking and starting instructions The engine may require more cranking for initial starting since the fuel lines have to be primed use of the primer switch will shorten this time Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load See the Testing Under Load section 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 5 4 TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 per cent of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling airflow
10. 0 47 17 05 0 72 3 06 1 25 45 35 Gasoline is in gal h LP is in gal h and cf h 1 5 4 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum Institute Service Classification SE SG or SH The recommended oil weights include the following During summer months SAE 30 An acceptable substitute is SAE 10W 30 During winter months SAE 5W 30 DO NOT USE SAE 10 W40 Crankcase and oil filter capacity is approximately 1 400 mL or 1 5 U S quarts Do NOT use special additives See Checking the Engine Oil Level and Changing the Engine Oil and or Oil Filter sections for oil level check and fill procedures 1 5 5 ENGINE Type o EONO GN 410 Single cylinder Coole Air cooled Rated Horsepower 15 4 200 rpm IO FS ACS DO 407cc Cylinder Block Aluminum w Cast Iron Sleeve Type of Governor Mechanical Fixed Speed FUE CICANED nn Paper Element w Foam Precleaner EE NN 12 volt DC Electric Ignition System Solid state w Flywheel Magneto Recommended Spark Plug RE TRE RC14YC rc eaeee E T 455 Frani FOUTS epring AEE agin 65 OPa k PUn seraa 0 030 inch 76 mm Recommended Minimum Battery 400 Cold cranki
11. 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 Dia A 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 vehicles may use an isolating receptacle Some v
12. 3 Open Disconnected 0 wire 3 Reconnect or close wire between Start Stop switch and engine control board 4 Defective engine control board 4 Replace control board There is no AC output from 1 Main line circuit breaker open 1 Reset circuit breaker the generator to ON or CLOSED 2 Fault with vehicle circuit 2 Reset and replace if necessary breaker and or fuses 3 Transfer switch set to NORMAL 23 Set switch to GENERATOR 4 Start switch not held long 4 Stop then restart the engine enough to flash the field Hold Start switch for at least two 2 seconds 5 Generator internal failure 5 Contact an Authorized Service Dealer 37 Section 5 Electrical Data Recreational Vehicle Generator ELECTRICAL DATA Electrical Schematic and Wiring Diagram Drawing No 0D1754 A BATTERY 13 FER _ sm 16 O Jl 1 2 56 gt 99 cs o 3 J1 4 2 18 T J1 5 gt J1 6 gt 17 v START Ji 2 iuda Ra J1 9 3 4 854 0 1 102 66 Lop 12 85 85 H o0 TT J1 183 J1 132 66 REMOTE J1 142 18 4 PANEL J1 15 gt gt 18 17 CONNECTOR OI 1 1 L 17 2 e 14 14 3 3 LEGEND 18 4 4 BCR gt 22 BATTERY CHARGE RECTIFIER 50 CIRCUIT BREAKER 30A 66 CIRCUIT BREAKER 20 15 cuu CB3 CIRCUIT BREAKER 2 5A REMOTE PANEL gt CH CHOKE HEATER GASOLINE MO
13. 60 Hertz AC electrical loads that require 40 0 amps gasoline or 37 5 amps LP fuel at 120 volts 1 5 GENERATOR ENGINE OPERATING SPEED The generators revolving field rotor is driven by a single cylinder four cycle engine through a pulley and drive belt arrangement The generator supplies 120 volts AC at 60 Hertz when the rotor is operating at 3 600 rpm The drive belt arrangement allows the engine to operate at a lower speed than the rotor 1 6 GENERATOR AC CONNECTION SYSTEM The generator is equipped with dual stator power windings as shown in Figure 1 1 Figure 1 1 120 volt Single Voltage Connection STATOR POWER WINDINGS GROUNDED NEUTRAL The AC connection system on all air cooled genera tors uses a GROUNDED neutral A separate green ground wire is connected to the recreational vehicle s junction box For these units loads connected across red to T2 white MUST NOT exceed 30 amperes or 3 600 watts and loads connected across black and T2 white MUST NOT exceed 20 amperes or 2 400 watts each at 120 volts The combined loading of the two breakers should not exceed 5 500 watts NOTE Do NOT connect loads in excess of circuit breaker ratings Section 1 General Information i GENERAL Recreational Vehicle Generator INFORMATION Figure 1 2 Major Features and Dimensions Drawing 0F1127 o x lt LLI E BE FUSE OIL DIPSTICK
14. Install the generator battery in its own vented com partment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage 2 9 OPTIONAL ACCESSORIES A plug in receptacle Figure 2 21 is provided on the generator set above the muffler enclosure Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit starting and stoping the gen erator engine from any convenient location inside the vehicle Figure 2 21 Remote Panel Plug in Receptacle evt CQ e N EE Cw LEVON WIRE 18 lt lt WIRE 0 STOP b GROUND WIRE 14 WIRE 1 ENGINE RUN CRANK SIGNAL Section 3 Post installation Start up Adjustments POST 2 91 REMOTE PANEL MODELS The remote panels mount a rocker type start stop switch a Generator Run advisory lamp and an hourmeter The hourmeter should be used in con junction with the maintenance operations found in Part I of this manual Model 004057 includes the remote panel and a 10 foot long 4 wire harness Model 004184 includes the remote panel and a 30 foot long 4 wire harness 5 1 POST INSTALLATION TESTS The air cooled gen
15. Section 2 Installation Recreational Vehicle Generator 2 5 4 TESTING THE INSTALLATION The manufacturer recommends testing the installa tion to be sure adequate cooling airflow is available to the unit before placing the unit into service If the unit shows signs of overheating enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate NOTE The installation must be tested especially if air is brought in from below the generator set 2 4 GASOLINE FUEL SYSTEM The installation of a gasoline fuel system Figure 2 14 for a recreational vehicle generator set must comply with applicable codes standards and regula tions The entire fuel system must be completely free of leaks There must be no possibility of gasoline vapors entering the vehicle interior Figure 2 14 Generator Fuel System a qu LE SSE SS SS nh 6 FUEL LINE FUEL PUMP FUEL FILTER A 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 Factory installed generator fuel system components include a fuel filter b 12 volt DC electric p
16. c the supporting framework Figure 2 3 All bolts must be long enough so that when tight at least three threads are visible past the retaining lock nuts Refer to the Generator Compartment section for the location of the generator mounting holes Figure 2 3 Typical Generator Restraint METAL LINED Ye INCH THICK BASE PLYWOOD TUBULAR METAL SUPPORT FRAME METAL LINED VEHICLE BOTTOM CHASSIS 2 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compartment that the installer constructs the compartment MUST meet certain spec ifications as outlined in the following sections 2 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a mini mum clearance of 1 2 inch 13 mm on the front and top 1 inch 25 mm on the sides and 1 2 inch 13 mm from the back for air circulation AFTER the compartment has been lined with metal and sound insulation Figure 2 4 NOTE Refer to Figure 1 2 Major Features and Dimensions Figure 2 4 Clearances Plywood Compartment 1 1 2 Clearance on Top 1 Clearance in Back 1 EachSide Insulation INSTALLATION Section 2 Installation Recreational Vehicle Generator 2 2 5 COMPARTMENT CONSTRUCTION The ge
17. construction of a special noise abatement compartment might be considered to reduce noise levels Such a compartment might be constructed as follows Figure 2 7 Use 5 8 inch thick or 3 4 inch thick plywood in the compartment Construct the compartment floor of a double thick ness of 5 8 inch or 3 4 inch plywood 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 combina tion of acoustical materials as mentioned in the sound Insulating Materials section A 191 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 fiberglass with a 2 pound density Figure 2 7 Typical Noise Abatement PLYWOOD 5 8 OR 3 4 THICK EXTERIOR METAL LINER WSS 2 z NSS l 2 EN SS PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION INSTALLATIO Section 2 Installation Recreational Vehicle Generator 2 2 5 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartm
18. sion Do not allow gas vapors to enter the vehicle 19 Recreational Vehicle Generator 1 1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product s installation requirements Give serious consideration to all information and instructions in the manual both for safety and for continued reliable 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 1 2 SAFETY Before handling installing operating or servicing this equipment carefully read the Notice to Installer and Safety Rules on pages 18 and 19 Comply with all safety rules to prevent death personal injury or damage to equipment and or property Str
19. 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 generators manufactured prior to December 31 1997 DO NOT have a transferable warranty Generac RV generators manufactured after January 1 1998 have a transferable warranty to the second owner ONLY for the remainder of the three year limited warranty Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any warranty service All warranty expense allowances are subject to the conditions defined in Guardian s Warranty Policies and Procedures Guide THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING 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
20. 4 GROUND CABLE WASHER LOCK SPECIAL 3 8 BRACKET LP REGULATOR SCREW SWAGE 1 4 28 X 1 2 43 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator Alternator and Panel Model 04164 3 Drawing No 0D1776 D eeu ITEM PART NO 1 0C9675 2 0A5649H 3 0A5646H 4 073159 5 031971 6 0C9674 7 0A6529 8 052858 9 066386 10 066849 11 0A8475 12 0C3818 13 075234 14 022473 15 022097 16 055816 17 090141 18 0A1658 19 074906 20 094039 21 0 9881 22 022129 23 027756 24 086316 25 053650 26 0C4258 27 075244 28 094071 29 094070 30 075476 31 022264 32 065795 33 090987 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator PARTS Ce LISTS Alternator and Panel Model 04164 3 Drawing No 0D1776 D IY DESCRIPTION ha Dw p BR B PO On Pp Ww wo BR BR LOWER BEARING CARRIER ROTOR ASSEM STATOR ASSEM BALL BEARING BALL BEARING UPPER BEARING CARRIER STUD STATOR 8 1 25 FLANGE LOCK NUT BRUSH HOLDER M5 0 8 X 16 LG TAPTITE SPECIAL LOCK WASHER M5 GENERATOR TOP HOUSING RESISTOR1R 5 25 WLVG M6 FLAT WASHER M6 LOCK WASHER M6 1 0 X 70 LG CAPSCREW GROUND CABLE SPECIAL LOCK WASHER M6 M6 1 0 X 20 LG TAPTITE CONTROLLER DECAL UNIT 5 16 M8 LOCK WASHER NYLON WASHER PANEL SHEET METAL 4 PIN CONNECTOR CONDUIT ASSEMBLY ASSEMBLY REMOTE CABLE M5
21. 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 13 OUT OF SERVICE PROCEDURE 5 15 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 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 10W 30 oil having API classification For Service SE 4 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase 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 15 EM Section 5 Maintenance MAINTENANCE Recreational Vehicle Generator 2 O 5 13 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Check the tag the engine for oil viscosity classification Verify that the correct recommend ed oil is
22. It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by an Authorized Service Dealer Normal maintenance service and replacement of parts are the responsibility of the owner operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of the generator ensures a minimum number of problems and keep operating expenses at a minimum See an Authorized Service Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs contact an Authorized Service Dealer for assistance service technicians are factory trained and are capa ble 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 or locate us on the web at www generac com Part Owner s Manual Introduction Inside Front Cover Read This Manual Thoroughly
23. MOUNT WASHER SPRING RETAINER SKID RUBBER MOUNT MOUNT RUBBER SCREW HHC 3 8 16 X 1 2 WASHER LOCK 3 8 NUT HEX 5 16 18 NUT FLANGE 5 16 18 SKID RUBBER MOUNT GASKET EXHAUST MANIFOLD SCREW SHC M8 1 25 X 20MM MANIFOLD EXHAUST EXHAUST PIPE GASKET EXHAUST COVER PLATE ITEM PART NO 33 079246 34 056893 35 0A8407 36 0A8531 37 039253 38 0C1320 39 0A8010 40 0A8010A 41 0A8726 42 0A8250 43 022131 44 075224 45 23897 46 0 6858 47 042633 48 075216 49 049451 50 073106 51 048694 52 063036 53 0 8594 54 001227 55 022152 56 022158 57 001741 58 0742600131 59 024114 60 075763A 61 023152 62 053407 63 0A4456 64 0 9193 65 0 2110 DESCRIPTION 2 po Na NNN SH HSH SH HSH HSH HSH KS SK SH SCREW M6 1 0 X 16MM W LOCK WASHER SCREW CRIMPTITE 4H 0 24 X 1 2 GASKET BLOWER SIDE PLATE BLOWER SIDE SCREW HHC 8 1 25 X 20MM HOUSING BLOWER GASKET BLOWER HOUSING GASKET BLOWER HOUSING GASKET BLOWER PAN CAPSCR HEX HD 3 8 24 X 2 WASHER FLAT 3 8 M10 PULLEY ENGINE WASHER FLAT 10 GASKET COLLECTOR PAN SCREW HHC 3 8 24 X 1 BELT POLY V 4L 40 WASHER PULLEY RETAINER PULLEY ALT SCREEN SLIDE PAN SCREW CRIMPTITE 48 18 X 1 4 PAN SLIDE STARTER CONTACTOR WASHER LOCK 10 NUT HEX 10 32 BOOT STARTER CONTACTOR STARTER CABLE NUT HEX 5 16 24 BOOT BATTERY CABLE SCREW HHC 3 8 16 X 3
24. SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMIS INC BOX 297 WHITEWATER WI 53190 Revision 02 05 Part No OF1118 Revision D 06 15 06 Printed in U S A
25. Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 0 Engine Accessories Model 04164 5 Drawing No 1155 T COM LO T N CN N 9794 N N N lt 00000 g DN Tr rt 5Q Section 6 Exploded Views and Parts Lists Qi Recreational Vehicle Generator Engine Accessories Model 04164 3 Drawing No 1155 TY DESCRIPTION 1 6532 1 MANIFOLD INTAKE 2 091039 1 GASKET MANIFOLD HEAD 3 051753 1 5 6 1 0 X 40MM 4 0 7585 1 SPARK PLUG CHAMP 5 089228 1 GASKET CARB MANIFOLD 6 0A7336B 1 CARBURETOR GN 410 L P 7 090970 1 GASKET CARB AIR FILTER 8 6564 1 BASE AIR FILTER 9 056893 3 CRIMPTITE 10 24 X 1 2 10 0A6566 1 DETENT 11 0A6780 1 SPRING A L BELLCRANK CARB 12 096290 2 STUD CARB MOUNT 90 LG 13 073111 1 FILTER AIR 14 081646 1 PRE CLEANER AIR FILTER 15 0A6563 1 COVER AIR FILTER 16 0C3633 2 KNOB AIR CLEANER 17 0A6581A 1 BREATHER TUBE 18 0C2332 1 DECAL AIRBOX QP55 19 092164 1 ASSEMBLY GOV SPRING ADI BRACKET 20 082025 1 NUT HEX LOCK M5 0 8 NYLON 21 0A7029 1 NYLON WASHER 31 X 26 X 43 22 0A6913 1 ROD LINKAGE GOV LEVER BELLCRANK 23 091161 1 BOLT SHOULDER M6 1 0 X 15MM 24 049813 2 NUT M6 1 0 25 092586 2 WASHER FELT 26 083512 2 8 1 25 X 16MM 27 6778 1 SPRING A L GOV LEVER BELLCRANK 28 0A6785 1 ROD LINK
26. This total should be less than the unit s rated wattage amperage capacity 2 74 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The following general rules apply Cut wiring to the required length and allow extra wire for junction box connections Carefully prepare conduit ends to prevent sharp edges from cutting through wiring insulation Route conduit so it does not interfere with genera tor movement If using metallic conduit vapor seal the end of the conduit where it enters the junction box Do this because flexible metallic conduit is not vaporproof along its entire length 2 7 5 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 2 18 An alternate method for isolating different power sources is by using an isolating receptacle Figure 2 19 Whichever method is use be certain that both power sources are NOT connected at the same time 2 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 Section 2 Installation INSTALLATION 1 Recreational Vehicle Generator 2 77 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code NFPA 70 551 7 requires that ground fault circuit interrupters GF
27. at 120 volts or 20 AC amperes at 240 volts for model 02010 2 For model 04164 3 the loads can require up to 4 500 watts 4 5 kW of power but cannot exceed 37 5 amperes of current at 120 volts or 18 8 amperes at 240 volts caution amp A Do not overload the generator Some installa tions may require that electrical loads be alter nated to avoid overloading Applying excessively high electrical loads may damage the genera tor 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 electri cal device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of current for starting than for continuous operation 1 5 SAFETY Before attempting to use the generator set care fully read the Safety Rules section of this manual Comply strictly with these rules to prevent accidents and damage to equipment and or property We sug gest copying and posting the Safety Rules in poten tial hazard areas of the vehicle Stress safety to all operators and potential operators of this equipment Section 1 General Information GENERAL Recreational Vehicle Generator INFORMATION 1 4 GENERATOR AC CONNECTION SYSTEM This generator set is equi
28. breaker or transfer switch 6 STOPPING THE GENERATOR Turn OFF all electrical loads using the means provided such as a main circuit breaker or transfer switch 2 Let generator run at no load for a few minutes to stabilize internal engine generator temperatures 3 Place the Start Stop switch in its STOP position 2 7 APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Before applying electrical loads let the generator stabilize and warm up for a minute or two DO NOT overload the generator 2 71 LETTING THE ENGINE STABILIZE The generator supplies correct rated voltage only at the proper governed speed Some electrical appli ances may be extremely sensitive to voltage Incorrect voltages can damage such appliances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when suf ficient power is not available may shorten engine life Never turn ON electrical loads until after the generator engine has started and stabilized at no load Section 2 Operation OPERATION Recreational Vehicle Generator 1r 2 8 SUMMER WINTER HEAT RISER SYSTEM Under certain weather conditions it is possible for ice to form in the venturi area of the carburetor This condition can be very dangerous because it can pre vent the governor system from functioning properly which results a runaway engine The most common weather condit
29. 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 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 9 BATTERY MAINTENANCE All lead acid batteries will discharge when not in use The generator battery should be inspected as follows 3 9 1 WEEKLY Inspect the battery posts and cables for tightness and corrosion Tighten and clean as necessary Check the battery fluid level of unsealed batteries and if necessary fill with Distilled Water Only Do not use tap water in batteries 5 9 22 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 fr
30. engine is equipped with an automatic choke that consists of two main components a choke solenoid and prechoke 2 3 1 CHOKE SOLENOID During engine cranking Start Stop switch at START a solid state choke module signals the choke sole noid to activate and cycle choke on choke off until the engine starts The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking When the engine starts the choke stops cycling 2 5 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 OPERATION Section 2 Operation o Recreational Vehicle Generator 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 41 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 NOTE Be sure the installation complies with all stan dards and codes liste
31. excess oil and to distribute oil DO NOT TWIST 7 Install the foam precleaner into the cover fol lowed by the paper filter 8 Install the cover foam precleaner and paper fil 9 Tighten the two screws to retain the filter in place Figure 3 2 Engine Air Cleaner PAPER AIR FILTER FOAM PRECLEANER AIR CLEANER CE SS Ln x A 222 Be 2 3 3 2 CLEANING OR REPLACING THE PAPER FILTER Once each year or every 100 hours of operation whichever comes first clean or replace the paper filler The new replacement filter must be flame retardant Service the paper filter more frequently if operating the generator in extremely dusty or dirty conditions Use the following procedure Figure 3 2 1 Follow steps 1 3 in the Cleaning the Foam Precleaner section service the foam precleaner if necessary 2 Remove the paper filter 3 Clean the air filter by tapping it gently on a solid surface If the filter is too dirty replace it with a new one Dispose of the old filter properly 4 Clean the air cleaner cover then reassemble following steps 7 9 in the Cleaning the Foam Precleaner section 54 CLEAN AIR INTAKE Clean all foreign material from the air intake Figure 3 3 at least once every 100 hours of operation Clean more often if necessary Inspect the area around the generator exhaust muf fler periodically and remove all grass leav
32. for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for 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
33. 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 TY RULE Safety Rules Recreational Vehicle Generator WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS A For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the
34. is not permanently sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all applicable codes standards and regula tions 2 ELECTRICAL CONNECTIONS Be sure to read the Generator AC Connection System section 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 2 71 ELECTRICAL JUNCTION BOX Install an approved square electrical junction box with a blank cover o
35. is available Do not allow the unit to overheat during prolonged operation NOTE The generator engine is equipped with a high tem perature switch The switch has normally closed N C contacts When the engine temperature is too high switch contacts close and the engine shuts down automatically THE MANUFACTURER RECOMMENDS TESTING THE GENERATOR FOR ADEQUATE COOLING 35 2 POST CE Section 5 Post installation Start up Adjustments INSTALLATION START UP ADJUSTMENTS Recreational Vehicle Generator 5 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT 1 Generator is properly located Q Generator is properly supported Generator is properly restrained GENERATOR COMPARTMENT Q Compartment construction is proper Q Holes Openings are vapor sealed 1 Compartment size is correct Q Compartment is vapor sealed 1 Sound insulation is correct Floor cutouts are properly completed COOLING AND VENTILATING AIR U Airflow is adequate Q Air inlet opening is correct 1 Compensate for restrictions Q Check that installation has been tested GASOLINE FUEL SYSTEM Q Fuel tank complies with all applicable codes Q Fuel system is properly installed and checked for leaks OPTIONAL LP GAS FUEL SYSTEM Q Fuel system is properly installed and checked for leaks Q Pressure at regulator inlet is correct Q Rated flow of primary regulator is correct 1 parts are properly installed Q Fu
36. life of a part s or engine Failures caused by any external cause or act of God such as oollision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses d or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY
37. manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fire extinguisher in the vehicle at all times Extinguishers rated 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 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 Genera
38. on any forest covered brush covered or grass covered unimproved land a spark arrestor may need to be installed The spark arrestor must be maintained in effective work ing order by the vehicle owner operator For assistance in ordering installing and maintaining spark arrestor exhaust mufflers contact the nearest Authorized Service Dealer Exhaust mufflers supplied by the manufacturer are spark arrestor types The manufacturer s exhaust mufflers for recreational vehicle generators do not have a spark arrestor screen but are of the more effi cient toroid or swirl type To remove carbon and combustion deposits from such mufflers remove the plug from the muffler and run the engine for approxi mately 15 minutes Shut down the engine let the muffler cool and install the plug wanNiNG Be sure to reinstall the muffler plug tightly Engine vibration could cause a loose plug to fall out Without the plug in place hot engine exhaust is directed out the opening This hot exhaust depending on the installation could be directed to areas not able to withstand the extreme heat such as wooden floor boards or other flammable material This could result in a fire 14 3 8 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windings will have an adverse
39. prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the purchaser owner Such use shall not reduce Generac s ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts 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
40. 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 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 MAINTENANCE 2 Section 3 Maintenance Recreational Vehicle Generator 3 10 MAJOR SERVICE MANUAL To obtain a service manual for the generator con tact the nearest Authorized Service Dealer or go to www generac com Make sure to identify the MODEL NUMBER and SERIES 5 11 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement The drive belt and pulleys are warranted for the life of the generator Drive belt tension was properly adjusted before the unit was shipped from the factory If suspecting that the drive belt tension is incorrect contact an Authorized Service Dealer 5 12
41. used in the engine see the Engine Oil Requirements section If necessary drain and refill with the proper oil Check the state of the battery Fill all cells of unsealed batteries to the proper level with 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 Clean and wipe the entire generator Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly Turn OFF all electrical loads Add fuel if neces sary and then start the engine Allow the unit to warm up thoroughly Apply electrical loads to at least 50 percent of the units rated wattage capacity When the engine is thoroughly warmed up shut it down The generator is now ready for service 16 PART Il INSTALLATION INSTRUCTIONS SAFETY RULES Safety Rules Recreational Vehicle Generator N DANGER For fire safety installation of a generator into a recreational vehicle must comply N strictly with article 551 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 ma
42. vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area The engine exhaust fumes contain carbon mon oxide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Thus the exhaust system must be installed properly in strict compliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards The generator com partment must be completely vapor sealed from the vehicle interior There must be no possibility of exhaust fumes entering the vehicle interior Never operate this equipment with a leaking or defective exhaust system Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ven tilating air is critical to correct generator opera tion and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or permit even partial blockage of ventilation provi sions as this can seriously aff
43. 08 2 BREATHER GASKET 12 080309 1 13 080338 1 OIL BREATHER SEPARATOR 14 0D4788 1 PIPE PLUG 3 8 15 083897 2 TAPPET SOLID 16 072694 2 PIVOT BALL STUD 17 003998 2 NUT HEX M8 1 0 G8 18 078672 1 SEAL VALVE STEM 19 078694 1 PUSH ROD GUIDE PLATE 20 083907 2 ROCKER ARM 21 021714 1 CYLINDER HEAD W VALVE SEATS AND GUIDES 22 0D2274 2 VALVE SPRING RETAINER 23 086515 4 VALVE SPRING KEEPER 24 086516 1 EXHAUST VALVE 25 086517 1 INTAKE VALVE 26 089673 2 WASHER VALVE SPRING 27 0 4391 2 VALVE SPRING 28 0A9877 1 CAMSHAFT ASSEMBLY 29 0E3812 2 CRANKSHAFT SEAL 30 076361 1 THRUST WASHER 31 0A5776 1 PRESSURE RELIEF BALL 32 0A7811 1 GOVERNOR SPOOL 33 078645 1 GOVERNOR RETAINER C RING 34 078691 1 COVER OIL PRESSURE RELIEF 35 074908 1 5 0 8 X 10MM TAPTITE 36 0A7975 1 GOVERNOR GEAR ASSEMBLY 37 5771 1 OIL PRESSURE SPRING 38 0B2104 1 SPRING WASHER 39 0 9667 1 OIL SUMP ASSEMBLY 40 078658 1 GOVERNOR ARM R PIN 41 078659 2 THRUST WASHER 42 0A7628 1 GOVERNOR ARM RC45 43 089288C 1 CRANKCASE SUB ASSEMBLY 44 0E3341 1 BALANCER 45 086025 1 SET GEROTOR 46 0D9853B 2 PUSH ROD 47 0 9666 1 CRANKSHAFT ASSEMBLY 48 090747 1 BREATHER VALVE ASSEMBLY 49 0C3150 1 ROCKER COVER GASKET 50 092362 1 ROCKER COVER W FILL 51 068527 4 M6 1 0 X 20MM HEX HEAD SCREW AND LOCKWASHER 52 083921 1 BEARING TUBE SHAFT 53 077158 1 OIL SCREEN PICKUP ASSEMBLY 54 076329 1 OIL FILL PLUG 55 0 0057 1 O RING 56 093064 1 OIL FILL CAP ASSEMBLY 49 Cp
44. 08 X 110 LG PPHMS SPACER PLASTIC 4 0 7 X 16 LG CAPSCREW 8 M4 LOCK WASHER BATTERY CHARGE RECTIFIER M3 0 5 X 12 LG PPHMS ITEM PART NO 34 086317A 35 075235 36 082737 37 049813 38 055440 39 043182 40 045771 41 053623 42 0234845 43 083049 44 022152 45 051716 46 090144 47 090145 48 025105 49 086315 50 090734 51 022985 52 032300 53 022676 54 087798 55 092113 56 075210 57 0A8475A 58 051715 59 090157 60 090156 61 074908 62 031791 63 023897 64 002724 65 031879 DESCRIPTION 1 3 4 4 2 2 4 1 1 1 5 d 1 1 4 1 4 Po N PANEL SUPPORT BRACKET M5 0 8 X 30 LG CAPSCREW VIBRATION MOUNT M6 1 0 HEX NUT M5 08 X 25 LG HEX HD CAPSCR M3 LOCK WASHER HEX NUT M8 C BREAKER 2 5A ON BUSHING REGULATOR VOLTAGE LOCKWASHER 10 M5 0 8 HEX NUT C BREAKER 20A C BREAKER 30A ALL UNITS 6 32 SCREW W LOCK WASHER PANEL COVER M4 0 7 X 12 LG CAPSCR W LOCK WASHER amp FLAT WASHER 6 FLAT WASHER FUSE HOLDER FUSE AGC 15A SWITCH S P D T START STOP SWITCH S P D T FUEL PUMP TERMINAL BLOCK SPECIAL LOCK WASHER M4 M4 0 7 HEX NUT DECAL CB RATING 30A DECAL CB RATING 20A M5 0 8 X 10 LONG TAPTITE CLAMP HOSE 10 M5 FLAT WASHER BOOT ROCKER SWITCH WASHER FLAT 4 45 us Section 6 Exploded Views and Parts Lists 0 Recreational Vehicle Generator 0 Engine Sheet Metal Model 02010 2 and 04164 3 Drawing 0D1760 E LO
45. 1 inches water column Gas pressure at the outlet side of the secondary regulator how ever is a negative pressure and can draw flame inside a line or fitting and cause an explosion 2 6 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used A properly installed exhaust system must be vapor tight quiet and completely safe A DX 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 caution amp A 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 2 6 1 MU
46. AGE BELLCRANK CARB 29 0A6753 1 BELLCRANK GOV RODS 30 0A8222 1 SPRING GOVERNOR 31 086681 1 NUT GOVERNOR LEVER 32 020753 1 HHCS M6 1 0 X 60MM 33 022473 2 M6 FLAT WASHER 34 022097 4 M6 LOCK WASHER 35 0A6582 1 TUBE WINTER INLET 36 0 6503 1 GROMMET 1 16 1 1 2 37 0A6569 1 GROMMET AIR IN OUT 38 0A7660 1 VALVE WINTER SUMMER 39 0A6568 1 GROMMET WINTER SUMMER VALVE 40 0A6567 1 SPRING DETENT 41 091916 1 LEVER GOVERNOR ARM 42 083532 1 BOLT HEX HD WASHER LOCK WASHER M6 1 0 X 30MM 51 Section 7 Warranty WARRANTY Recreational Vehicle Generator CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and the United States Environmental Protection Agency EPA together with Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine New utility and lawn and garden equipment engines must be designed built and equipped to meet stringent anti smog standards for the state of California and the federal government Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modification or improper maintenance of your engine Your emission control system may include parts such as the carburetor ignition and exhaust systems Generac will repair your engine at no cost to you for diagnosis replacement parts an
47. APHRAGM TWIN REGULATOR CAP DIAPHRAGM SUPPORT COVER TWIN REGULATOR SCREW HHTT M4 0 7 X 8 BP BARBED STR 1 2 X 1 2 NPT CONNECTION 3 4 NPT 3 8 45D JET LP GN220 ENGINE PARTS waz 00 41 us Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator 0 Base and Pulleys Model 04164 5 Drawing No 0F1124 B de ae ITEM PART NO 1 2 057822 3 074994 4 022145 5 022129 6 045771 7 066849 8 022473 9 062684 10 0A8475 11 077603 12 0C2368 13 051730 14 029459 15 075215 16 052858 17 073146 18 075209 19 075242 20 075237 21 0A6479 22 046911 23 025017 24 022237 25 022259 26 081105 27 0 8614 28 090239 29 040976 30 0A8341 31 077643 32 090859 Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator PARTS Ce LISTS Base and Pulleys Model 04164 3 Drawing No 0F1124 B IY DESCRIPTION 1 2 16 co 12 Po FPN ASSEMBLY REGULATOR SEE E V 0 1125 8 HOSE CLAMP HOSE 1 2 I D PETROLEOM WASHER FLAT 5 16 M8 WASHER LOCK 8 5 16 NUT HEX M8 1 25 SCREW TAPTITE M5 0 8 X 16MM LONG WASHER FLAT 1 4 M6 GROUNDING LUG LOCK WASHER SPECIAL 410 SAFETY BOLT SCREW HHC 5 16 18 X 3 5 BASE MOUNTING SCREW HHC 8 1 25 X 60MM SPRING BELT TENSION WASHER SPRING CENTER NUT TOP LOCK FL M8 1 25 SLIDE NYLON SUPPORT NYLON SLIDE SPRING GENERATOR
48. ARB SIDE 34 131 074260 1 ASSEMBLY WIRE STARTER 16 35 090892 1 SUPPORT OIL FILTER 36 091159 1 BUSHING RUBBER 37 091160 1 WASHER RUBBER 38 091161 1 BOLT SHOULDER M6 1 0 X 15MM 39 049821 2 BOLT SOCKET HD CAPSCR M8 1 25 X 30MM 40 086999 1 GASKET OIL FILTER SUPPORT 41 0A8584 1 SWITCH OIL PRESSURE 10 PSI 42 075281 1 SWITCH OIL TEMPERATURE 43 0C1085 2 SCREW PHILIPS PAN HD MACH M3 0 5 X 8 44 043182 2 LOCK WASHER M3 45 070185B 1 FILTER OIL 46 0 9649 1 ENGINE LONG BLOCK GN410VSRV 47 082774 1 KEY WOODRUFF 4 X 19 DIA 48 0C2308 1 COVER 49 0A1658 1 SPECIAL LOCK WASHER M6 50 090388 1 6 1 00 12 51 075474 1 BOOT TEMPERATURE SWITCH 52 001624 1 BOOT OIL PRESSURE SWITCH 53 0C4373 1 SPACER ENDFRAME 47 Cp Section 6 Exploded Views and Parts Lists Recreational Vehicle Generator OG GN 410 Engine Model 02010 2 and 04164 3 Drawing No 0 9615 aa Section 6 Exploded Views and Parts Lists Cp Recreational Vehicle Generator GN 410 Engine Model 02010 2 and 04164 3 Drawing No 0 9615 TY DESCRIPTION 1 021533 1 PISTON RING SET 2 0 3221 1 CONNECTING ROD 5 0 1466 1 PISTON PIN 4 071983 2 PISTON RETAINER 5 021713 1 CYLINDER HEAD GASKET 6 0A1442 8 FLANGED HEX HD CAPSCREW 8 1 25 X 42 7 021742 4 M10 1 5 X 105 HHFL 8 0 2985 1 PISTON 9 076701 1 CRANKCASE GASKET 10 045756 2 M6 1 0 X 10 TAPTITE THD FORMING 11 0803
49. ATING 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 ea Recreational Vehicle Generator A 1091 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 2 2 4 ACOUSTICS For additional noise abatement the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement com partment NOTE Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compartment In addition to the effective use of sound insulating materials
50. Air Intake 2 Engine Start Stop Switch 3 Fuse 4 Optional Remote Panel Receptacle behind control panel 5 Generator AC Output Leads behind control panel 6 Fuel Primer Switch 7 Circuit Breaker 8 Circuit Breaker 9 Starter Contactor 1O Fuel Solenoid 11 Demand Regulator 12 Oil Filter 13 Oil Drain Cap 14 Oil Dipstick 15 Data Decal 16 Oil Fill 17 Spark Plug 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 a competent authority A DIE A For fire safety the generator must have been properly installed in compliance with ANSI 119 2 1975 NFPA 501C 1974 Standard for Recreational Vehicles Part III Installation of Electrical Systems The generator also must have been installed in strict compliance with the manufacturer s detailed installation instructions After installation do nothing that might render the unit in noncompliance with such codes stan dards and instructions Use this generator to supply electrical power for operating 120 240 volt single phase 60 Hertz AC electrical loads These loads can require up to 4 800 watts 4 8 kW of power but cannot exceed 40 AC amperes of current
51. CIs on all external and some internal electrical recepta cles be installed Contact the manufacturer or dealer for recommendations Figure 2 18 Transfer Switch Isolation Method 2ND AIR FROM 20 AMP CONDITIONER HACR BREAKER JUNCTION BOX _ VEHICLE FLEXIBLE E WIRING CONDUIT 5 E EE VEHICLE AC e DISTRIBUTION amp DOUBLE PANEL THROW SWITCHING 30 AMP gt DEVICE MAIN BREAKER LLL f CONDITIONERS gt POWER SUPPLY CORD ES GFCI BREAKERS Figure 2 19 Installation With Isolation Receptacle FLEXIBLE CONDUIT JUNCTION VEHICLE AC DISTRIBUTION PANEL DOCKSIDE POWER RECEPTACLE 77 POWER SUPPLY CORD 33 INSTALLATION Section 2 Installation Recreational Vehicle Generator 2 8 BATTERY INSTALLATION 2 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 0 C use a battery rated 70 amp hours and capable of delivering 400 cold cranking amperes For prevailing ambient temperatures below 32 0 C use a battery rated 95 amp hours and capable of delivering 400 cold cranking amperes NOTE If the battery is to be used to power other vehicle accessories as well as start the generator a bat tery w
52. Compartment section If sound insulation is to be used on the compartment walls and ceiling the minimum recommended applies to the space between the generator and such insulation The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense 2 1 2 GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding The metal framework on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams These beams should consist of a 1 1 2 inch square 11 gauge steel tub ing OR b 1 1 2 inch 11 gauge angle iron A typical supporting frame with horizontal support tubing is shown in Figure 2 1 The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another method is to suspend the 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 ee 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 con
53. DELS ONLY 814170 CS CHOKE SOLENOID GASOLINE MODELS ONLY 77 66 l Fl FUSE 15A FUEL PUMP DR LPG SHUT OFF VALVE GT TERMINAL GROUND 4 i METER HOUR DPTIONAL 55 HTO SWITCH HIGH TEMP DIL CLOSES ON HIGH TEMP IM IGNITION MAGNETO R1 1 LIGHT RUN OPTIONAL ON SWITCH LOW OIL PRESSURE CCLDSES ON LOW PRESSURED PCB ENGINE CONTROLLER 4 RI RESISTOR 1 OHM 25W SC STARTER CONTACTOR i i SM STARTER MOTOR POWER WINDING i SW SWITCH START STOP 33 SW2 SWITCH FUEL PRIMER SP1 SPARK PLUG 81 CYL 44 TERMINAL CONN 4 E 3 CONNECTOR ELECTRONIC VOLTAGE n REGULATOR RED 4 T1 e 6 T3 DPE WINDING OF O Wn OF 4 FIELD WHITE BLACK RED E 120V 30A NEUTRAL CONNECTION BY CUSTOMER ical Data ion 5 Electr Recreational Vehicle Generator Sect Electrical Schematic and Wiring Diagram Drawing 0D1754 A ELECTRICAL DATA lt YSAWOLSND NOILIGNNOD Vall 3N NOILISNNOD IV NBWOLSNQ 1 t F f 1 G8 V8I 8l 81 gt 40123 ND2 now T3Nvd BRE e ccu oS 99r IO 0 i 8l 0 v8 l 10 OX 0 30 M 1 Es 30 10 W M 3425 OL 8 v ADV l8 DIW 331 113 H O eo 4 38 dtt 99
54. FFLERS 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 installed The vehicle owner or operator must maintain this device in good condition In the state of California the preceding is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands 2 6 2 OF EXHAUST SYSTEM Two types of exhaust systems for these generators are available from the manufacturer They include the following Out the bottom exhaust system dimensions are 15 16 O D model 9742 Out the side exhaust system dimensions 1 1 4 O D 18 gauge model 4172 NOTE No matter what type of exhaust kit best fits the recreational vehicle the mounting base has open ings for either bottom out or side out exhaust systems Use the cover plate provided with the g
55. TIONS When installing an LP gas system consider seriously the following items 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 Usea length of approved flexible fuel hose between the gaseous fuel solenoid valve and rigid gas pip ing The flexible line should be at least six 6 inches longer than necessary 2 5 5 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 INSTALLATION Section 2 Installation Recreational Vehicle Generator 2 5 4 PRIMARY REGULATOR Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regu lator Mount the primary regulator at the gas ta
56. The contacts close if the temperature should exceed approximately 293 F 145 C initiating an engine shutdown 10 Figure 2 4 Low Oil Pressure and High Temperature Switches HIGH TEMPERATURE ENGINE OIL OIL PRESSURE FILTER SWITCH 2 9 5 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 5 During engine cranking only a positive DC battery voltage is deliv ered through the diode resistor brushes and slip rings and the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Figure 2 5 Field Boost Circuit e St P eL 77 CONTROLLER CIRCUIT CLOSEST TO BOARD BEARING N FIELD GRND 2 9 4 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 6 controls the generator s AC output voltage This regulator sup plies an excitation current to the rotor By regulating the rotor s excitation current the strength of its mag netic field is regulated and in turn the voltage deliv ered to connected electrical loads is controlled When the AC frequency is 60 Hertz voltage is regulated at 120 volts v
57. add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 2 Air Induction System including 1 1 Gasoline carburetor assembly and its a Intake pipe manifold internal components if so equipped b Air cleaner a Fuel filter if so equipped 3 Ignition System including b Carburetor gaskets a Spark plug c Fuel pump if so equipped b Ignition module 1 2 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 7 Warranty WARRANTY Recreational Vehicle Generator GENERAC POWER SYSTEMS THREE YEAR LIMITED WARRANTY FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS NOTE ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES For a period of 3 three years of operation from the date of original sale Generac Power Systems Inc Ge
58. an 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 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 injur
59. ated 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 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
60. cables etc into the vehicle liv ing area must be sealed vapor tight with silicone rubber base sealant 23 INSTALLATION Section 2 Installation 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 e Seams and joints of the galvanized steel whether used as a liner or for the compartment itself must be lapped and mechanically secured Such seams may be manufactured welded bolted riveted or screwed Manufactured lock seams are shown in Figure 2 6 Installer constructed compartments typically utilize a standard lap joint Figure 2 6 Types of Lock Seams FOLD LOCKED STANDING DOUBLE LOCK DOUBLE SEAM 1 GORDON SEAM LOCK SEAM STANDARD LAP JOINT After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material See the Sound Insulating Materials section A DI A Do not install any flammable material directly above or around the compartment Heat trans ferred through the compartment structure may be sufficient to ignite char or discolor seat cush ions fiberboard and other flammable materials Use approved nonflammable insulating materials in high temperature areas 2 2 5 SOUND INSUL
61. d in the Standards Booklets section of this manual 2 4 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommended oil before starting Refer to the Engine Oil Requirements section and Checking the Engine Oil Level and Changine the Engine Oil and or Oil Filter sections for oil servicing procedures and rec ommendations caution amp Any attempt to crank or start the engine before it hase been properly serviced with the recom mended oil may result in an engine failure 2 4 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 4 4 COOLING AND VENTILATING AIR Air inlet and outlet openings in the generator com partment must be open and unobstructed for con tinued proper operation Without sufficient cooling and ventilating airflow the engine generator quickly overheats which causes it to shut down and may damage the generator 2 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 gases to enter the vehicle A 1191 A
62. d labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility 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 no
63. d to supply fuel from a tank to the generator must comply with applicable codes stan dards and regulations The following general rules apply to rigid fuel lines Rigid lines should be of annealed seamless drawn aluminum or steel e Lines and fittings must comply with SAE 4512 Standard Automotive Fittings or with ANSI 126 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 es 2 4 2 2 Flexible Fuel Line Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines This prevents breaking of the line caused by vibration shifting settling or movement The follow ing rules apply The flexible hose must comply with SAE J1737 3OR7 Standard for Fuel and Oil Hose It must be approved for use with gasoline and low perme ability The hose should be at least 6 inches 152 mm longer than is needed to prevent the hose from rupturing if the generator shifts or settles 2 5 LP GAS FUEL SYSTEM DIG A LP gas is highly EXPLOSIVE The gas is heavier than air and tend
64. de for a path for exhausting the cooling air to the exterior of a compartment if so equipped A DX A Never use discharged cooling air for heating or permit such air to enter the vehicle interior This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases 2 3 1 GENERATOR AIRFLOW Engine operation drives cooling fans for the two stage cooling air system A pressure fan draws cooling air into the top of the generator Figure 2 9 This airflow cools the engine generator and electronic components The second part of the cooling system a suction fan draws air that is heated from a hot engine into a col lector pan at the base of the unit This heated air although cooler than exhaust muffler is then deflected out the bottom toward the ground Figure 2 9 Airflow Through Engine Generator LFA Ll 2 52 COOLING AIR INLET OPENINGS The minimum size of the air inlet opening whether the generator is housed in a conventional compart ment or not is at least 100 square inches see Figure 2 10 This rule applies whether inlet air is brought in through an opening in the compartment door an opening in the vehicle skirt through duct Work o
65. deposits Section 1 General Information INFORMATION Recreational Vehicle Generator GENERAL caution amp N 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 5 2 OPTIONAL PROPANE FUEL SYSTEM This generator is equipped with a liquid propane LP gas fuel system LP gas is usually supplied as a liquid in pressure tanks The generator requires a vapor withdrawal type fuel system This type of gaseous fuel system uses the vapors forming above the liquid fuel in the storage tank Air temperature around the storage tank must be high enough to sustain adequate fuel vaporization In colder climates it may be necessary to use an inde pendent heat source to be sure the fuel sufficiently vaporizes in the storage tank LP gas may consist of propane butane or a mixture of the two gases Propane vaporizes at temperatures as low as 20 F 29 C but butane returns to its liquid state when the temperature drops below about 32 F O C For that reason a higher ratio of propane is desired in the gas mixture when temperatures drop below freezing 1 5 5 FUEL CONSUMPTION
66. e engine Start Stop 3 Replace Start Stop switch switch 4 Defective starter contactor 4 Replace contactor 5 Defective starter motor 5 Replace starter motor 6 Low or defective battery 6 Charge or replace battery The engine cranks but 1 Out of fuel 1 Replenish fuel will not start 2 Defective fuel pump 2 Replace fuel pump 3 Open 14 wire from 3 Check connections and engine control board insulation of 14 wires 4 Flooded engine 4 Wait 5 10 minutes before trying o Defective spark plug s 5 Clean re gap or replace plug s 6 Fuel line shut off closed 6 Open fuel line shut off 7 Plugged fuel filter 7 Clean or replace fuel filter The engine starts hard 1 Air cleaner 1 Check clean or replace air cleaner and runs rough plugged or damaged 2 Defective spark plug s 2 Clean or replace plug s The engine starts but shuts 1 Engine oil level low 1 Check oil and add oil as needed down when the Start Stop 2 Defective low oil 2 Replace pressure switch switch is released pressure switch 3 Defective high temperature 3 Replace temperature switch switch 4 Defective engine control board 4 Replace control board Overheated engine o Check that the airflow openings are adequate The Start Stop switch is l Defective Start Stop switch 1 Replace switch set to Stop but the engine 2 Open Disconnected 718 wire 2 Reconnect or close wire continues to run between Start Stop switch and engine control board
67. e engine has been shown to meet Federal emission requirements For engines less than 225 cc displacement Category C 125 hours B 250 hours A 500 hours For engines of 225 cc or more Category 250 hours B 500 hours and 1000 hours 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 Figure 2 1 Generator Control Panel FUSE MAIN START BREAKER V 20A p JS STOP FUEL PRIMER 2 1 1 FUEL PRIMER Before starting a cold engine if it has not been started in more than two weeks this switch must be pressed for approximately 10 to 15 seconds to bring fuel from the tank to the carburetor This rocker type switch springs back into its original position when released It is not necessary to press the primer switch for LP units 2 1 2 START STOP SWITCH To crank and start the engine hold this switch in the START 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 FUSE The fuse protects the engine s DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine cannot be cranked If the fuse must be re
68. ect 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 leakage oil leakage etc A ELECTRICAL HAZARDS N The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires 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
69. ed to the diaphragm opens a valve to permit gas glow through the carburetor Figure 2 16 LP Gas Carburetion Diagram AIR GAS AT FLOW POSITIVE PRESSURE LOW PRESSURE AREA es INSTALLATION Section 2 Installation Recreational Vehicle Generator 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 2 5 6 FUEL SUPPLY LINES LP gas lines must be accessible but protected against possible damage Do NOT connect electrical wiring to any LP gas fuel line or run wiring alongside the lines Route gas lines away from hot engine exhausts Retain gas lines with metal clamps that do not have sharp edges e Install an approved length of flexible hose betwee
70. ehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads To start the generator from either the generator con trol panel or from the optional remote panel proceed as follows 1 Turn OFF electrical loads using the means pro vided in the vehicle such as a main line circuit breaker or transfer switch NOTE If starting from the generator control panel turn OFF loads by setting the generator s main circuit breaker to the OFF or OPEN position If starting from a remote panel turn OFF loads using the means provided in the vehicle such as a main circuit breaker Electrical load circuits will be turned ON after the generator has started stabi lized and warmed up 2 If the engine has not been started in more than two weeks press the Fuel Pump Primer switch and hold it for about 10 to 15 seconds to prime the fuel system However if the engine is warm skip Step 2 3 Hold the engine Start Stop switch in the START position to crank the engine Release the switch when the engine starts caution amp If the engine does not start after it has been cranking for 15 seconds release the Start Stop switch and try again Holding the switch for longer than 15 seconds can damage the starter motor 4 Letthe engine run at no load for a few minutes to stabilize and warm up 5 Turn ON electrical loads using the means pro vided such as a main circuit
71. el system is properly tested adjusted DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER 36 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 Q Junction box is properly installed Q Wiring meets all standards 1 connections are correct Q Conduit is properly installed and sealed Q Generator is properly bonded to the vehicle BATTERY INSTALLATION 1 Recommended battery is installed Recommended cables are installed Cables are clean and tight Cables are connected properly Proper ventilation is provided COOCOO Terminals are coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES Q Check that remote start stop panels if used are installed properly Q Check that hourmeter kit if used is installed properly 1 Check that any other options and accessories if used are installed properly POST INSTALLATION TESTS Q Check that all tests are completed properly Section 4 Troubleshooting TROUBLESHOOTING Recreational Vehicle Generator TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank 1 Fuse blown 1 Replace fuse 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defectiv
72. enerator to cover the opening NOT used 2 6 5 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 65 C above the ambient air tem perature 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 INSTALLATION Section 2 Installation Recreational Vehicle Generator 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 opened or
73. ent for the following items Figure 2 8 Engine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts See the Generator Restraint section A Dita A Fuel lines and exhaust piping must not penetrate into the vehicle living area Figure 2 8 Compartment Floor Cutout 586 2317 32 11 341 Ke 564 22 2 1 L4 213 MOUNTING HOLES 5 pO ENT i 263 10 3 85 3 37 114 4 674 7 96 3 8 178 7 07 60 12 471 480 18 9 348 13 77 a e Y 211 8 371 e THIS HOLE IS OPTIONAL FOR MOUNTING GENERATOR Les 642 25 37 THIS IS THE MINIMUM PENING NEEDED IN THE COMPARTMENT FLOOR FOR OUTLET AIR 25 INSTALLATIO Section 2 Installation Recreational Vehicle Generator 2 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 provi
74. erator set was factory tested and adjusted It should not be required to adjust the unit any further except under special circumstances wanNiNG amp Do not make any unnecessary adjustments Factory settings are correct for most applications When making adjustments however be careful to avoid overspeeding the engine 5 2 BEFORE INITIAL START UP Before starting complete the following 1 Check the engine crankcase oil level and if nec essary fill to the dipstick FULL mark cross hatched area with the recommended oil Do not fill above the FULL mark 2 Check the fuel supply Gas fuel lines must have been properly purged and leak tested in accor dance with applicable fuel codes fuel shutoff valves in the fuel supply lines must be open A A A If a liquid propane LP gas fuel system has been installed it must be properly tested for leaks before operating the system in compliance with ANSI A119 2 NFPA 501C No leakage is permitted Be sure no gasoline fuel vapors enter the vehicle interior 2 INSTALLATION START UP ADJUSTMENTS Recreational Vehicle Generator 5 5 INITIAL START When absolutely certain that the unit has been prop erly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s main circuit breakers to their OFF or open position 2 Refer to Part I section Starting the Generator
75. es dirt etc from this area MAINTENANCE 2 Section 3 Maintenance Recreational Vehicle Generator Figure 3 3 Cleaning Air Intake CLEAN THESE AREAS 5 5 CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine Clean by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug to clean 2 Remove the spark plug and check the condition Replace the spark plug if worn or if reuse is 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 caution amp 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 Figure 3 4 Setting the Spark Plug Gap SET PLUG GAP AT 0 030 inch 0 76 mm i ES 43 MAINTENANCE 2 O Section 5 Maintenance Recreational Vehicle Generator 56 FUEL FILTER GASOLINE ONLY Remove and replace the fuel filter Figure 3 5 once each year or every 100 hours of operation whichever comes first Figure 3 5 Fuel Filter Fuel Filter 5 7 SPARK ARRESTOR MUFFLER If the generator is not equipped with a spark arres tor exhaust muffler and is to be used
76. ess safety to all installers operators and service technicians who work on this equipment 1 5 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The following standards booklets latest revision are available from the sources indicated 1 NFPA Standard 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 A119 2 NFPA 501C available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 available from the State of California Documents Section PO Box 1015 North Highlands CA 95660 eo Section 1 General Information 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 1 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to air cooled generators These generators are designed specifically for installing in recreational vehicles They operate 120 volt single phase
77. ions leading to this problem are temperatures in the range of 25 F to 35 4 C to 1 7 C along with high humidity This ice formation also can be attributed to the load being applied during these weather conditions Generators running with no load or light loads applied usually have the most problems The Summer Winter Lever Figure 2 3 should be in the WINTER position for ambient temperatures below 40 4 4 C and in the SUMMER position for ambient temperatures above 40 F 4 4 C Figure 2 3 Heat Riser System WINTER POSITION SUMMER POSITION When the heat riser is in the SUMMER down posi tion Figure 2 2 air is drawn into the air cleaner from the upper intake tube When the heat riser is in the WINTER up position air is drawn from the lower intake tube which is positioned to draw the heated air near the exhaust manifold To prevent carburetor icing the owner operator should physically position the heat riser to the prop er position dependent on the temperature OPERATION Section 2 Operation o Recreational Vehicle Generator 2 8 1 DO NOT OVERLOAD THE GENERATOR Read the rated wattage amperage capacity of the gen erator on the generator data decal see Generator Identification Applying electrical loads in excess of the unit s rated capacity will cause the engine generator to automati cally shut down To avoid overloading add up the wattage of all con nected elec
78. ith a larger capacity may be needed 2 8 2 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes starting problems For the best cold weather starting the voltage drop between battery terminals and the generator connection point should not exceed 0 12 volts per 100 amperes of cranking current These generators are rated at about 100 DC amperes of cranking current Select battery cables based on a cable length and b prevailing ambient temperatures Generally the longer the cable and the colder the weather the larger the cable size must be as shown in the chart CABLE LENGTH in Feet meters O to 10 O to 3 CABLE SIZE 11 to 15 3 4 to 4 5 16 to 20 4 5 to 6 For warm weather use No 2 cable up to 20 feet 2 8 5 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or to the lug on the starter contactor Figure 2 20 NOTE Check to be sure the battery cable boot for the starter cable has been installed 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connection Figure 2 20 3 Connect cables so the connectors are clean and tight Figure 2 20 Connecting Battery Cables SIDE VIEW OF GENERATOR STARTER CONTACTOR GROUND LUG NEGATIVE CABLE BATTERY 2 8 4 BATTERY COMPARTMENT
79. move the oil fill cap on the rocker cover and slowly add the proper type and amount of recommended oil see section Engine Oil Requirements Periodically use the dipstick to check the oil level and continue to fill the crank case until the oil reaches the dipstick Full mark DO NOT FILL ABOVE THE FULL MARK 9 Install and tighten the oil fill cap and the dipstick before operating the engine 10 Start the engine and check for leaks NOTE Check the oil level and fill to the FULL mark after checking for leaks The filter will retain some oil 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 2 Turn the two screws counterclockwise to loosen Remove the cover foam precleaner and paper filter Remove the foam precleaner from the cover Wash the foam precleaner in liquid detergent and c E Pu Figure 3 1 Oil Maintenance Features water 02 NS N RI OIL DIPSTICK N zt OIL DRAIN HOSE RETAINING CLIP OIL DRAIN CAP 12 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
80. n 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 2 5 7 EXCESS FLOW VALVE LP gas tanks should have an excess flow valve according to NFPA 501C Paragraph 3 4 4 This valve and the gas lines must be carefully sized so the valve will close when a fuel line is severed or broken Consult the Natural LP Gas Association for informa tion 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 2 5 8 LEAKAGE TESTS Do not place the generator into service until the gas system has been properly tested for leaks To test the system a separate source of 12 volts DC is needed to open the gaseous fuel solenoid valve 3Q The leak test must comply fully with NFPA Paragraph 318 connections 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 A 1091 A Gaseous fuel lines between the tank and the sec ondary regulator are under a positive pressure about 1
81. n the interior or exterior wall of the area planned for installation of the generator NOT on the generator Route the generators AC output leads into this junction box through approved flexible conduit This is the point of first termination for generator AC output leads 371 INSTALLATION Section 2 Installation Recreational Vehicle Generator 272 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 genera tor and the compartment junction box the conduit end that terminates the compartment junction box must be vapor sealed Flexible metal conduit is NOT vapor tight along its entire length From the junction box route power supply wires through approved conduit to either a double pole double throw transfer switch or b approved isola tion receptacle Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being connected to two different power supplies at
82. nce or being careless can cause pos sible injury or death Permit only responsible and capable persons to operate or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to ren der 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 N 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
83. nerac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Facility is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac generators sold and rated for Recreational Vehicle RV applications as Generac has defined Recreational Vehicle generator applications The factory recommends exercising the unit one half hour every month WARRANTY SCHEDULE COMMERCIAL APPLICATIONS YEAR ONE 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components WARRANTY SCHEDULE CONSUMER PERSONAL APPLICATIONS YEARS ONE AND TWO 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components YEAR THREE 100 one hundred percent only on selected part s and labor listed Any labor and part s not listed and removal and reinstallation are the owner s responsibility Rotor Stator Computer Control Board part numbers
84. nerator 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 f the compartment is lined with galvanized steel it may be constructed of any material The manu facturer recommends that the compartment be constructed of 1 2 inch thick plywood not strand board with the floor made of a double thickness of 1 2 inch plywood with the grain of the wood at cross section for added strength Figure 2 5 Figure 2 5 Typical Compartment Construction CROSS SECTION VIEW METAL LINING FIREPROOF SOUND INSULATION METAL LINING VAPOR SEALED AT ALL TIMES SS METAL LINING pom PLYWOOD f constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel seams splices and joints of the compart ment walls unless vapor tight by design should be caulked to prevent poisonous flammable or explosive vapors from entering the vehicle interior NOTE Caulking must be done so that the caulking mate rial will stay in place permanently Pressing such materials as putty tape onto joints and seams is NOT acceptable A high quality silicone rubber base sealant is recommended Holes and openings made in the compartment walls to allow for the passage of electrical conduit conductors hoses
85. ng Amperes 1 5 6 GENERATOR Rated Maximum Continuous AC Output Gasoline 4 800 Watts 4 8 kW AC Output LP 4 500 Watts 4 5 kW Rated M 120 Volts AC Rated Maximum Continuous AC Current Gasoline 5 3 ee Een ane 40 Amperes AC Current LP Pul 37 5 Amperes lici m Single Rotor FRE erm 3 600 Number Ol Rotor Od 2 ol od uu Mete toTc cC 2 571 Raed AC Frente y aca 60 Hz Pantery Charge VOW AGG 14 Volts DC Battery Charge 2 Weight 198 Pounds E lJpC C 200 Pounds RR Uc 25 5 inches 648 mm E M 18 88 inches 479 mm QU Rau 16 75 inches 425 mm units are reconnectable to 120 and or 240 volt dual voltage output Units are no longer listed per RVIA ANSI when recon nected for dual voltage output If reconnected for dual voltage the ampere rating for 240 volts is 20 AC amperes for model 02010 2 and 18 8 AC amperes for model 04164 3 1 5 7 EMISSIONS COMPLIANCE PERIOD For non handheld engines the Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which th
86. ng the engine 11 MAINTENANCE 2 O Section 5 Maintenance Recreational Vehicle Generator 5 2 CHANGING THE ENGINE OIL AND OR OIL FILTER Change the engine oil after the first 25 hours of operation Thereafter change the oil every 100 operating hours Change the oil more frequently if operating consistently under heavy load or at high ambient temperatures Change the engine oil filter after the first 25 hours of operation and every 100 operating hours there after To change the oil and or oil filter proceed as fol lows see Figure 3 1 1 Run the engine until it is thoroughly warmed up at least five minutes then shut OFF the engine 2 Immediately after the engine shuts OFE pull the oil drain hose free of its retaining clip Remove the cap from the hose and drain the oil into a suitable container Loosening the oil fill cap will allow the crankcase to drain faster 3 After the oil has drained replace the cap onto the end of the oil drain hose Retain the hose in the clip 4 With the oil drained remove the old oil filter by turning it counterclockwise o Apply a light coating of clean engine oil to the gasket of the new filter 6 Screw the new filter on by hand until its gasket lightly contacts the oil filter adapter Then tighten the filter an additional 3 4 to one turn 7 Remove the dipstick and wipe it dry with a clean lint free cloth This will be used later to check the oil level 8 Re
87. ngs 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 5 1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements see section Engine Oil Requirements Check the engine crank case oil level at least every eight hours of operation or before use To check the engine oil level proceed as follows see Figure 3 1 1 Be sure the generator is as level as possible 2 Remove the dipstick and wipe it dry with a clean lint free cloth 3 Install and tighten the dipstick 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 cauroN 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 operati
88. nk outlet or in the supply line from the gas tank The following rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column Do NOT exceed 14 inches water column The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommended MINIMUM gas flow rate for all air cooled 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 2 5 5 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 2 16 This air passes through a carburetor venturi which creates a low pressure that is proportional to the quantity of air being pumped The low pressure from the carburetor venturi acts on the regulator diaphragm to pull the diaphragm toward the source of low pressure A lever attach
89. nufac turer assumes that installation personnel are famil iar with the procedures for installing such products or similar products that are manufactured The manufacturer also assumes that personnel have been trained in the recommended installation procedures for these products and that such training includes a use of common hand tools b use of special tools and c use of any tools and or equipment from other suppliers The manufacturer cannot possibly know of and advise the recreational vehicle trade of all conceivable methods procedures or techniques by which to per form an installation Nor can the manufacturer antic ipate every 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 a
90. ny time without prior notice A DIG A A Despite the safe design of this generator operat ing this equipment imprudently neglecting its maintenance or being careless can cause pos sible 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 ren der 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 N For safety reasons the manufacturer recommends that the installation initial start up and main tenance of this equipment is carried out by an Authorized Service Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust system must be installed properly in strict com pliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards The generator com partment must be completely vapor sealed from the vehicle interior There must be no possibility of exhaust fumes entering the vehicle interior Never operate this equipment with a leaking or defective exhaust system Keep hands feet clothing etc a
91. oltage to frequency ratio is 2 to 1 Figure 2 6 Solid State Voltage Regulator 1 5 CE SENSING cE 4 TO ROTOR 0 DIRECT CURRENT 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 10 ADDITIONAL INFORMATION 2 10 1 ATTENTION REQUIRED AFTER SUBMERSION If the recreational vehicle generator has been sub merged in water it MUST NOT be started and oper ated Following any submersion in water have an Authorized Service Dealer thoroughly clean and dry the generator 2 10 2 OPERATION IN HIGH GRASS OR BRUSH Never operate the generator while the vehicle is parked over high grass weeds brush leaves or any other combustible substance Such materials can ignite and burn from the heat of the exhaust system The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down MAINTENANCE 2 Section 3 Maintenance Recreational Vehicle Generator 2 10 3 EFFECTS OF MOISTURE AND DIRT Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windi
92. om batteries Damage will result if the battery connections are made in reverse A DIG A Do not dispose of the battery in a fire The bat tery is capable of exploding Storage batteries give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly venti lated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery Discharge static electricity from body before touching the battery by first touching a grounded metal surface A battery presents a risk of electrical shock and high short circuit current The following precau tions are to be observed when working on bat teries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery 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 amp Do not open or mutilate the battery Released electrolyte has been known to be harmful to the
93. plaxed use only an identical replacement 2 1 4 MAIN BREAKER The main breaker protects the generator s AC output circuit against overload and provides a method of turning OFF the generator s 120 240 volt AC output to the vehicle circuits The generator has one 20 amp breaker and one 30 amp breaker Section 2 Operation OPERATION Recreational Vehicle Generator X NOTE If the generator has been reconnected for dual volt age AC output 120 240 volts install line break ers having an amperage rating that is different than that stated in the Generator AC Connection System section The replacement line breakers consist of two separate breakers one 20 amp and one 30 amp with a connecting piece between the breaker handles so that both breakers will oper ate at the same time If the unit is reconnected for dual voltage it is no longer RVIA listed 22 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel Figure 2 2 is available that allows 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 and a wire harness Figure 2 2 Optional Remote Panel Models 004057 and 004184 2 5 AUTOMATIC CHOKE caso tine onty The
94. pped with dual stator AC power windings These two stator windings sup ply electrical power to customer electrical loads by means of a dual two wire connection system Note however that the neutral is grounded The generator may have been installed so that it pow ers 120 volt AC loads Figure 1 1 It can be wired to connect both 120 and or 240 volt AC electrical loads This procedure should be done by an Authorized service Dealer or other qualified installer Figure 1 1 Connections for 120 Volts Only T1 RED 6 7 BLACK 120V 30 AMP 120V 20 AMP CB1 0O STATOR POWER WINDINGS T2 WHITE T2 WHITE GROUNDED NEUTRAL 1 5 SPECIFICATIONS 1 5 1 FUEL REQUIREMENTS This generator is equipped with a gasoline fuel sys tem Depending on the installation the generator may have either a separate fuel tank or it may share the vehicle engine s fuel tank NOTE Some installations using a shared fuel tank have a generator fuel pickup tube that is shorter than the vehicle engine s pickup tube Such an arrangement causes the generator engine to run out of gas while adequate fuel for the vehicle remains in the tank To reduce lead and carbon deposits use high qual ity UNLEADED gasoline with the generator Leaded REGULAR grade gasoline is an acceptable substi tute NOTE Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon
95. r by any other means eee NOTE Screening louvers or expanded metal that cover air openings restrict airflow Compensate for this by making the actual air opening proportionately larger See the Compensating for Restrictions sec tion Figure 2 10 Air Inlet in Compartment Door 555 59 QS XXX XXX XXX XO QS X DOO XXX XX CC 0X 0X0 0 90 00000 S 55 SS Xx 100 SQUARE INCHES UNRESTRICTED MINIMUM OPENINGS 5 XY RRR 950440 lt gt lt gt lt gt SS lt gt lt gt lt gt lt gt lt gt lt gt 4 lt gt lt gt lt gt lt gt K lt S lt gt lt gt SD lt gt lt gt XXX XXX 55 5 5555 555 5 550 99 XXX 555555555555 5555 5 5 5 6005005000560 0 0 00 00 0 0 0 0 0 0 555555555 555555555555 5555 5 559 X 5 x 5 5 XXX OOO ODO OOO COCO OV DADO OOOO Oe XXX XXX XXX 0X0 SKK KR Koo 59 Xx 5555550 Q 599955 5 sure to meet the minimum clearances illus trated in Figure 2 4 When the unit is installed on a suspended mounting system one of several different methods of supplying airflow may be used as follows Provide a door in the vehicle skirt having an air inlet opening Figure 2 11
96. require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential to preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks The type of information each indicates follows This symbol points out important safety informa tion that if not followed could endanger per sonal safety and or property of others This symbol points out potential explosion haz ard This symbol points out potential fire hazard This symbol points out potential electrical shock hazard The operator driver is responsible for proper and safe use of the vehicle and its equipment and the safety of all vehicle occupants We strongly 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 this generator model In addition the latter portion of this manual contains information necessary for the proper instal lation of these generators OPERATION AND MAINTENANCE
97. s 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 2 5 1 PARTS NOT INCLUDED IN FUEL SYSTEM The propane fuel system does NOT include such items as a gas tank b gas piping c fittings d valves and e primary regulator used to store the gaseous fuel and deliver it to the gaseous fuel sole noid Figure 2 15 A DX A Use only approved components in the fuel sup ply system All components must be properly installed in accordance with applicable codes Improper installation or use of unauthorized components may result in fire or an explosion Follow approved methods to test the system for leaks No leakage is permitted Do not allow fuel vapors to enter the vehicle interior Figure 2 15 Typical Propane Gas Fuel System CARBURETOR V oe LOCKOFF SOLENOID PRIMARY REGULATOR WIDTHDRAWAL TANK 2 5 2 SOME IMPORTANT CONSIDERA
98. sider using additional tubing angle brackets or other supports to give the supporting frame sufficient strength Figure 2 1 Typical Horizontal Support Frame SUPPORT TUBING 2 1 5 SUSPENDED MOUNTING If the generator will be suspended below the hori zontal support tubing the suspension method used with the vehicle frame members must a be able to support the weight of the generator AND b provide sufficient restraint for the generator One typical sus pended mounting system is shown in Figure 2 2 The location of a suspended mounting system must be carefully planned keeping the following general rules in mind Protect the generator against road splash and debris Baffles or splash guards may be required to protect certain areas of the generator To make sure the gen erator is adequately protected road test the installa tion through mud water and slush Figure 2 2 Typical Suspended Mounting System GENERATOR MOUNTING HOLES FOR 3 8 16 BOLTS BOTH SIDES SUPPORT VEHICLE GENERATOR FRAME SUPPORT FRAME The installer must make certain that the selected location will permit adequate cooling and ventilat ing airflow to be supplied 2 1 4 GENERATOR RESTRAINT Use four 3 8 16 hardened steel bolts Grade 5 to fasten the generator to the supporting frame or the support tubing These bolts must pass through a the generator mounting base b the compartment floor if a compartment is used and
99. sponsible 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 55190 Part 1 52 Section 7 Warranty Recreational Vehicle Generator WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1997 and later model year engines a Applicability This warranty shall apply to 1997 and later model year engines The ECS Warranty Period shall begin on the date the new engine or 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
100. t 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 is provided to you by Generac pursuant to California and federal law See also the 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 re
101. the same time such as generator and dockside power e Conductors must be rated 221 105 C or must be of a larger conductor size 2 73 GENERATOR AC CONNECTIONS Generator AC output leads T1 red T2 white and T3 black come out of the generator as shown in Figure 2 17 Leads T1 red and T3 black are hot while T2 white is the grounded neutral lead There is also a green lead that connects to ground in the junction box of the recreational vehicle Figure 2 17 Generator AC Output Leads 3e Line red to T2 white is protected against overload by a 30 amp circuit breaker Use this line to neutral connection separately to operate 120 volt single phase 60 Hertz AC loads requiring up to 3 600 watts 3 6 kW of power Line T3 black to T2 white also is protected against overload by a 20 amp circuit breaker CB2 Use this line to neu tral connection separately to operate similar loads However be sure the total unit load does not exceed the maximum rating of the generator The neutral line T2 white on all units is a grounded neutral caution amp Do NOT connect electrical loads in excess of any circuit breaker rating or problems with circuit breaker tripping will develop which causes a loss of AC output Also do NOT exceed the generator s rated wattage capacity Add the watts or amperes of all lighting appliance tool and motor loads the generator will operate at one time
102. tor 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 1 77771 SS cS Ry NI rs Be 25 hours Every 100 hours Sarum or ocea year Change it RV Service Locator 1 800 333 1322 ww guardlangenerators com 17 J Oo Q J 18 A Baca A X 8 Ez LES 2 Bien ee 577 yo o 11 us 15 GJE eS 2 PRIMEPACT a Maintenance Sch Shears Eney 25 hours fry 100 hours fonus ormone RV Service Locator 1 800 333 1322 wm guardiangenerators com 7 2 lt gt AAH SY y 14 4 Rated Voltage Model 02010 2 1 Generator Air Intake 2 Engine Start Stop Switch 3 Fuse 4 Optional Remote Panel Receptacle behind control panel 5 Generator AC Output Leads behind control panel 6 Fuel Primer Switch 7 Circuit Breaker 8 Circuit Breaker 9 Starter Contactor 10 Fuel Inlet 11 Fuel Pump 12 Fuel Filter 13 Oil Filter 14 Oil Drain Cap 15 Oil Dipstick 16 Data Decal 17 Oil Fill 18 Spark Plug Model 04164 3 1 Generator
103. trical 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 time more watts of power for starting than for running for a few seconds dur ing motor starting Be sure to allow for this when connecting electrical loads to the generator First figure the watts needed to start electric motors in the system To that figure add the running watt ages of other items that will be operated by the generator Do not apply heavy electrical loads for the first two or three hours of operation 2 9 PROTECTION SYSTEMS 2 9 LOW OIL PRESSURE SWITCH This switch Figure 2 4 has normally closed N C contacts that are held open by engine oil pressure dur ing cranking and operating Should oil pressure drop below a preset level switch contacts close and the engine automatically shuts down The unit should not be restarted until oil is added 2 92 HIGH TEMPERATURE SWITCH This switch Figure 2 4 which has normally open N O contacts is mounted near the oil filter
104. ts that these rules for safe operation N be copied and posted in potential hazard areas of the recreational vehicle Safety should be stressed to all operators and potential operators of this equipment e WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm e WARNING e 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 ensurethat it is safe for others Also make sure the procedure work method or operating technique utl ized does not render the generator unsafe A DIG A A Despite the safe design of this generator operat ing this equipment imprudently neglecting its maintena
105. ump 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 27 INSTALLATION Section 2 Installation Recreational Vehicle Generator 2 1 1 FUEL TANK Either the generator must share the vehicle engine s fuel tank or a separate fuel tank must be installed for the generator set 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 A 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 2 4 2 GENERATOR FUEL SUPPLY LINE 2 4 2 1 Rigid Fuel Lines Those lines use
106. way 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 Before performing any maintenance on the gen erator disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or first Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc Never insert any tool or other object through open ings in the generator interior even if the unit is not running Serious injury or damage to the equip ment could occur A ELECTRICAL HAZARDS N The generator covered by this manual produces dangerous electrical voltages and c
107. y 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 conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury SAFETY RULES Safety Rules Recreational Vehicle Generator FIRE HAZARDS A For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regu lations Keep a fire extinguisher in the vehicle at all times Extinguishers r

Guardian Technologies 02010-2 Portable Generator User Manual

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