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Generac Power Systems 004701-0 Portable Generator User Manual

1. BATTERY RED BLK SC 13 RED 16 e e E 15 le 14A P i Du e 14 SW ax 16 14 FS 0 br PCB sc 0 e 15 gt 56 90 cs 0 gt 15 E 4 3 18A gt SP 5 gt 1 6 7 17 START swt o t 0B Jt7 17 ero XI 4 HTO 85 0 6 gt 66 L LOP Jed 85 85 0 6 J42 gt 0 66 J114 0 18 P PANEL 18 i CONNECTOR ol 1 1 17 2 2 14 14 3 3 18 4 4 BCR 15 5 5 z 14A 15 66 14 15 18 14 17 0 BATTERY CHARGE WINDING 55 STOP RI START ON e 4 N AAAA o POWER WINDING 33 ON 44 228 118 11 FUEL 22 ELECTRONIC cat REMOTE PANEL VOLTAGE OPTIONAL REGULATOR BATTERY CHARGE RECTIFIER T CB1 CIRCUIT BREAKER 30A 2A CB3 CIRCUIT BREAKER 2 5A b 4 CH CHOKE HEATER GASOLINE ONLY CB CS CHOKE SOLENOID ON 3 F1 FUSE 7 5A 9 4 Ti FP FUEL PUMP OR LPG SHUT OFF VALVE 2 6 FS FUEL SOLENOID GASOLINE ONLY GT TERMINAL GROUND 4 DPE WINDING HM METER HOUR OPTIONAL SWITCH HIGH TEMP OIL CLOSES ON HIGH TEMP o
2. METAL LINED Y2 INCH THICK BASE E PLYWOOD F E SS H TUBULAR E SUPPORT FRAME Toc 4 GRADE 5 n BOLTS METAL LINED VEHICLE BOTTOM CHASSIS 2 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a 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 2 inch 13 mm on the left side two 2 inches on the right side and 2 1 2 inch 63 5 mm from the back for air circulation AFTER the compartment has been lined with metal and sound insulation Figure 2 3 Figure 2 3 Clearances Plywood Compartment 1 2 Clearance on Top Insulation in Front s 1 2 Left Side NOTE Refer to Figure 1 2 Major Features and Dimensions 2 2 2 COMPARTMENT CONSTRUCTION The generator compartment should be either con structed of or lined with 26 gauge galvanized steel NOTE Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum s low melting point If the compartment is lined w
3. 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 DIG A fire safety the generator must have been properly installed in compliance with ANSI 119 2 1975 NFPA 501C 1974 Standard for Recreational Vehicles Part Installation of Electrical Systems The generator also must have been installed in strict compliance with the manufacturer s detailed installation instructions After installation do nothing that might render the unit in noncompliance with such codes stan dards and instructions Use this generator to supply electrical power for operating 120 volt single phase 60 Hertz AC elec trical loads These loads can require up to 3 400 watts 3 4 kW of power but cannot exceed 28 3 AC amperes of current at 120 volts caurnoN amp Do not overload the generator Some installa tions may require that electrical loads be alter nated to avoid overloading Applying exces sively high electrical loads may damage the generator and may shorten its li
4. O1 4 CO ON O1 4 O1 4 CO C 0 3916 006942 006939 0 3920 0 3917 0 3918 0 3919 097329 008254 0C5644 041495 0E1742A 047290 048031 008628 047411 022473 0234848 022097 086729 0D3700 022129 022259 075763A 0D7293 064113 0C7561 044456 049813 022237 022131 005443 007423 029451 074908 0D8717 0D9020 0742600144 0E0724 004933 0742600143 029451A 0D8627 0D8628 0D8628A 0D8691 0D7176 0A2115 0D9282 0E0393 007968 0E0014 0E0017 0G7366 0A9973 yao q amp ca Mp m 2 TRAY ENCLOSURE PANEL ENCLOSURE SIDE PANEL REAR DIVIDER PANEL ENCLOSURE ROOF PANEL ENCLOSURE BACK PANEL FRONT DIVIDER COMPARTMENT AIR INTAKE PANEL ENCLOSURE DOOR SHIELD MUFFLER SLIDE LATCH FLUSH SCREW HHTT M4 0 7 X 10mm LP REGULATOR HOSE 3 8 I D SINGLE BRAID 33 LONG HOSE CLAMP BAND 3 8 FOAM FRONT AIR OUT COMPARTMENT SCREW HHC M6 1 0 X 16 WASHER FLAT 4 BUSHING 1 09 SNAP WASHER LOCK 6 1 4 CONTACTOR STARTER NUT FLANGE M6 1 0 NYLOK WASHER LOCK 8 5 16 NUT HEX 5 16 18 BOOT BATTERY CABLE PANEL AIR BOX COVER SCREW M6 1 00 x 20mm WING BOLT CARR 3 8 16 X 1 BRASS 3 8 SPECIAL L WASHER NUT HEX M6 X 1 0
5. EXPLOSION HAZARDS A Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline Fuel lines must be properly installed and fastened and free of leaks There must be no possibility of gasoline vapors entering the vehicle interior It is required that an approved flexible noncon ductive fuel line be installed between the generator fuel connection point and rigid fuel lines 19 Section 1 General Information 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 products 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 prov
6. In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise levels Such a compartment might be constructed as follows Figure 2 6 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 Dd A To prevent fire or explosion do not install any insulation or other absorbent materials on the interior or underside of the compartment floor Seal all compartment door edges to prevent noise leakage around the door perimeter Line the compartment door interior except for air openings with suitable fireproof sound insulation such as 1 inch 25 mm thick fiberglass with 2 pound density Figure 2 6 Typical Noise Abatement PLYWOOD T EXTERIOR 5 8 OR 3 4 THICK SOUND INSOLATION MATERIAL PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS ERGI INSULATION 2 2 5 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items Figure 2 7 Engine exhaust and cooling air outlets Generator cooling air inlet Four holes
7. by Generac Ji Systems Inc Owner s Manual and Installation Instructions Air cooled Recreational Vehicle Generators e Model 004701 0 QUIETPACT 40LP This manual should remain with the unit INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc It has been designed and manu factured 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 starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAUTION and NOTE blocks are used to alert person nel to special instructions about a particular opera tion that may be hazardous if performed incorrectly or carelessly Observe them carefully Their defini tions are as follows A A After this heading read instructions that if not strictly complied with will result in personal injury or property damage WARNING amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution After this heading read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warning
8. Read the vehicle manufacturer s instructions The owner operator should become familiar with the vehicle in which this generator is installed Differences exist between vehicles For example some vehicles may use a transfer switch to isolate dockside power from the generator while other vehicles may use an isolating receptacle Some vehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads 7 OPERATION Section 2 Operation ix Recreational Vehicle Generator 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 th
9. 115 01 17 17 PCB 7 17 17 CLOSEST TO BEARING 01 4 4 J110 66 m o un 55 J12 0 16 18 15 4 RED d J415 2 FIELD 85 0 oF 0 3 8 gt 11 2 BCR 33 22 55 C 2 66 RI 2 OF 44 17 c 66 15 0 18A 18 LY 0 0 OF CONN 1 0 0 1 zi PINE 0 0 0 n ar 7O 2 90 3 4 14 o i 4 14 18 O 15 li 2 14A TC 0 conn 2 m u swt PANEL 15 Swe 18 CONNECTOR 1 0B 11 FS FP Fl 33 GT 15 1 3 14A 11 a 18 77 ul 13 90 Lo 15 i BLACK WHITE 18 14 18 CBI 18A 14A 14A 85 15 15 85 A FILTER MTG LOP 0 HTO SCREW 12 77 GREEN 7 18 E CUSTOMER AC CONNECTION 0 BLACK WHITE GREEN 90 cs ND NEUTRAL CONNECTION 14 CH Mi BY CUSTOMER XXX 39 ums Section 7 Exploded Views and Parts Lists Recreational Vehicle Generator 0 Enclosure Drawing No 0F4589 B Nf 5 Section 7 Exploded Views and Parts Lists LISTS Recreational Vehicle Generator Enclosure Drawing 0F4589 B 0 O1 4 CO
10. Use approved nonflammable insulating materi als in high temperature areas 2 2 5 SOUND INSULATING MATERIALS Once installers have determined that a compartment is properly constructed and metal lined they can add acoustical material This may include additional seal ant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a nonflam mable type One excellent insulating material is a 1 inch 25 mm thick fiberglass having a 2 pound den sity When fiberglass is used its coated side should face toward the compartment interior DANI 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 24 Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compartment
11. WASHER LOCK 3 8 WASHER FLAT 3 8 M10 BLOCK TERMINAL BATTERY POST STUD 3 8 16 X 2 1 4 BRASS TAPE FOAM 1 8 x SCREW HHTT M5 0 8 X 10 CUSTOMER CONNECTION HARNESS FOAM AIR OUT COMPARTMENT SIDE CABLE STARTER ASSEMBLY OIL DRAIN SCREW SWT 1 4 20 X 5 8 W W CABLE BATTERY CONNECTION FOAM TAPE 1 16 X FOAM AIR INTAKE COMPARTMENT FOAM ROOF AIR OUT COMPARTMENT FOAM BACK COMPARTMENT FOAM DOOR PANEL WASHER SELF LOCKING 1 WASHER NYLON 250 HARDWARE CLOTH COMPARTMENT AIR OUT ASSEMBLY CAP amp DIPSTICK NUT HEX JAM 3 8 16 BRASS BOX MUFFLER TAIL PIPE GASKET MUFFLER TAIL PIPE BOX LOGO QP RIVET POP 41 LISTS a Mh Section 7 Exploded Views and Parts Lists Recreational Vehicle Generator Generator Drawing No 0F4590 C ae Section 7 Exploded Views and Parts Lists LISTS Recreational Vehicle Generator Generator Drawing No 0F4590 C 0 gt gt gt CO CO CO C C co 029092 022129 049451 0C8096A 0D8120 066849 066386 0D4217 073159 0D4484H 0D4430H 0D4216 048614 0F9533 022131 027028 0D6832 022145 030231 0C3168 022259 0C8565 0D8048 083512 0D6831 029451 0D6918 0D2558
12. ized personnel away from batteries Damage will result if the battery connections are made in reverse DIG A Do not dispose of the battery a fire The battery is capable of exploding Storage batter ies give off explosive hydrogen gas This gas can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explo sion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equip ment near the battery Discharge static electric ity from body before touching the battery by first touching a grounded metal surface A battery presents a risk of electrical shock and high short circuit current The following pre cautions are to be observed when working on batteries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of the battery Disconnect any charging source prior to connecting or disconnecting battery terminals and Do not use any jumper cables or booster battery to crank and start the generator engine If any battery has discharged remove it for recharging WARNING amp Do not open or mutilate the battery Released electrolyte has been known to be harm
13. pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS A Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking open flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline Section 1 General Information Recreational Vehicle Generator 1 1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA LABEL or information decal 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage 1 Generator Air Intake 10 Fuel Pump Behind Access Panel 2 Engine Start Stop Switch 11 LP Regulator Solenoid 3 Fuse 12 Oil Filter 4 Optional Remote Panel Receptacle Side View 13 Oil Drain Cap 5 Generator AC Output Leads Side View 14 Dipstick 6 Fuel Primer Switch 15 Air Filter Behind Access Panel 7 Circuit Breaker 16 Oil Fill 8 Starter Contactor 17 Spark Plug 9 Fuel Inlet GUARDIAN KW
14. 087680 0D7530 0D9723 0D4511 0D8451 022097 0G3671 090388 0G3671 081105 089476 022531 0D8981 048031E ine Po ppp p BP amp E ss eR E e 7 SCREW IHHC 5 16 24 X 11 1 4 G5 WASHER LOCK M8 5 16 WASHER FLAT 406 1 0 X 1 62 O D FAN 8 CURVE BLADE 16 5MM I D SCREW IHHC 8 1 25 X 260MM SCREW HHTT M5 0 8 X 16 ASSEMBLY BRUSH HOLDER CARRIER REAR BEARING BEARING ROTOR STATOR ADAPTOR ENGINE SCREW HHC 5 16 24 X 3 4 GASKET FRONT DIVIDER WASHER FLAT 3 8 10 NUT LOCK HEX 5 16 18 NYLON INSERT BRACKET ENGINE MOUNTING WASHER FLAT 5 16 SCREW HHC 5 16 18 X 1 1 2 5 16 SPECIAL LOCK WASHER NUT HEX 5 16 18 SCREW SHC 8 1 25 X 18MM VIBRATION MOUNT SCREW HHTT M8 1 2 X 16MM BRACKET ALTERNATOR MOUNTING TAPE ELEC UL FOAM 1 8 X 1 2 DUCT ALTERNATOR AIR GASKET ALTERNATOR DUCT NUT WING M6 1 0 STUD M6 1 0 OFFSET ELEMENT AIR FILTER PRECLEANER AIR WASHER FLAT 281 I D X 1 50 O D WASHER LOCK 6 1 4 MUFFLER SCREW HHTT M6 1 0 X 12MM BOLT CARR 5 16 18 X 2 NUT FLANG 5 16 18 LOCK GASKET EXHAUST SCREW HHC 5 16 18 X 1 3 4 FILTER GASKET RV HOSE CLAMP 3 8 LISTS a Mh Section 7 Exploded Views and Parts Lists Recreational Vehicle Generator Control Panel Drawing No 0F4591 A 44 Section 7 Exploded Views and Parts Lists i urs Re
15. 3 4 Clean Air 12 3 5 Checking the Engine Spark Plug 12 3 6 Clean Spark 12 3 7 Cleaning the 13 3 8 Battery Maintenance ier eite tao eee aee 13 3 9 Major Service Manual see 14 3 10 Exercising the Generator 14 3 11 Out of Service Procedure tenens 14 3 12 Adjusting Valve 14 3 13 RV Generator Service Interval 15 Section 4 Notes iius atis sut un akin 16 Table of Contents 3 F CONTENTS Recreational Vehicle Generator Part II Installation Instructions Safety Rules 18 Section 1 General Information 20 1 1 Purpose and Scope of the Manual 20 122 Safety E 20 1 3 Standards Booklets 20 1 4 Equipment Description eerte 20 1 5 Generator Engine Operating Speed 20 1 6 Generator AC Connection System 20 Section 2 Installation 2 1 Location and Support 2 2 Generator Compartments 23 2 3 Cooling and Ventilating 26 2 4 LP Gas Fuel System eene testet senten een 26 2 5 Exhau
16. ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI A119 2 NFPA 501C available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 available from the State of California Documents Section Box 1015 North Highlands CA 95660 eo 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 1 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to air cooled generators This generator is designed specifically for installing in recreational vehicles This generator operates 120 volts single phase 60 Hertz AC electrical loads that require 28 3 amps 1 5 GENERATOR ENGINE OPERATING SPEED The generator s revolving field rotor is driven by a single cylinder four cycle engine The generator sup plies 120 volts AC at 60 Hertz when the rotor is oper ating at 3 600 rpm 1 6 GENERATOR AC CONNECTION SYSTEM The generator is equipped with dual stator power windings as shown in Figure 1 1 Figure 1 1 120 volt Single Voltage Connection STATOR POWER WINDINGS T2 WHITE GROUNDED NEUTRAL The AC connection system on these air cooled gen erators uses a GROUNDED neutral A separate green ground wire is connected to th
17. Engine Drawing No 0F5791 G Part 2 0 gt O1 OC 4 amp 4 4 d de CO CO Q2 CO CO CO lO lO o lll Oo O gt 65 amp ON dq O amp Q IO 41 Oi amp OQ 0 5800 078621 076389 0G4379 0A8897B 077168 004331 076390 005827 078658 0F0967 089213E 0A7637 0E3811 0D1303 078645 0A7811 072683A 0F0687 089096 088156 048822 078691 045772 045776 074908 078606 076361 002414 099922 0C3733 0C4390 084186 083192 0E0057 078699B 021705B 0C3590 0C3591 0D9853A 083235 080336 0C8754 077161 077160 076307 088403 026073A 088412A 076329 0C3592 049340 045761A ocho AE NY M mU x cL l4 cL cL Doc 5 NA ur cho oL LONG BLOCK ASSEMBLY 220 RV LP CONNECTING ROD ASSEMBLY PISTON PIN RING SET PISTON DIA 75 GEAR COVER ASSEMBLY M8 x 56mm HEAD BOLT PISTON COATED DIA 75 PIN RETAINER RING ASSY CRANKSHAFT GH220 TAPER GOVERNOR PIN WASHER FLAT 1 4 015 CRANKCASE ASSEMBLY GOVERNOR ARM OIL SEAL GOVERNOR GEAR ASSEMBLY GOVERNOR GEAR C RING GOVERNOR SPOOL 1 8 NPT PIPE PLUG CAMSHAFT ASSEMBLY CRANKCASE GASKET VALVE STEM SEAL CYLINDER HEAD GASKET OIL PRESSURE RELIEF COVER OI
18. Nut Tighten Jam Nut to 65 85 inch pounds 7 10 N m 3 13 RV GENERATOR SERVICE INTERVAL HOUES eere ete terrens Clean Spark Arrestor terere Change Engine Oil filter eser Clean Air Pre filter HOUES eet ere Inspect Spark Plugs 250 Hours Replace Paper Air Filter Element HOO HOUIS Replace Spark Plugs 1st 50 Hours then every 500 LIES Adjust Valve Lash Section 3 Maintenance Recreational Vehicle Generator MAINTENANCE 2 0 15 NOTES 16 Section 4 Notes Recreational Vehicle Generator PART Il INSTALLATION INSTRUCTIONS SAFETY RULES Safety Rules Recreational Vehicle Generator DANGER For fire safety installation of a generator into a recreational vehicle must comply strictly with article 551 NFPA 70 ANSI C1 1975 AND ANSI A119 2 1975 NFPA 501C Standard for Recreational Vehicles Part 3 Installation of Electrical Systems In addition installa tion must comply with the manufacturer s instructions and recommendations NOTICE TO INSTALLER These Installation Instructions have been published by the manufacturer to aid in the installation of the products described in this manual The manufac turer assumes that installation personnel are familiar with the procedures for installing such products or similar products manufactured The manufacturer also assumes that personnel have been trained in th
19. 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 50 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 OF4594 Revision D 10 22 07 Printed in U S A
20. 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 is not permanently sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all applicable codes standards and regula tions 2 6 ELECTRICAL CONNECTIONS Be sure to read section Generator AC Connection System 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 instal
21. 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 Figure 3 1 Oil Maintenance Features Oil Dipstick Oil Fill 10 Oil Drain Oil Filter 4 If necessary remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dip stick Full mark DO NOT FILL ABOVE THE FULL MARK caution Ak Never operate the engine with the oil level below the Add mark on the dipstick Doing this could damage the engine 5 Install and tighten the oil fill cap and the dipstick before operating the engine 5 2 CHANGING THE ENGINE OIL AND OR OIL FILTER Change the engine oil after the first 25 hours of operation after the 25 hour break in period sec tion Thereafter change the oil every 100 oper ating 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 follows see Figure 3 1 1 Run the engine until it is thoroughly warmed up at least five minutes then shut OFF the engine 2 Immediately after the engine shuts OFF pull the oil drain cover free of the base Remove the plug from the tube with a 5 16 allen wrench and drain the oil
22. bring fuel from the tank to the carburetor This rocker type switch springs back into its original position when released 2 1 2 START STOP SWITCH To crank and start the engine hold this switch in the START position Release the switch when the engine starts To stop an operating engine press and hold the switch in the STOP position until the engine shuts off The switch center position is the RUN position 2 1 5 FUSE The fuse protects the engine s DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine cannot be cranked If the fuse must be replaced use only an identical replacement AE 2 1 4 MAIN BREAKER The main breaker protects the generator s AC out put circuit against overload and provides a method of turning OFF the generators 120 volt AC output to the vehicle circuits This generator has a 30 amp breaker 2 2 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel is available that allows starting and stopping the generator engine conveniently from inside the vehicle Order part number 0 0429 or OF0430 a remote panel that includes a Start Stop switch a generator run lamp a fuel prime switch and an hourmeter The hourmeter provides a continuous indication of engine generator operating time Use the hourmeter for checking off peri
23. conduit is NOT vapor tight along its entire length From the junction box route power supply wires through approved conduit to either a double pole double throw transfer switch or b approved iso lation receptacle Connecting to a transfer switch or isolation receptacle must prevent vehicle electri cal circuits from being connected to two different power supplies at the same time such as genera tor and dockside power Conductors must be rated 221 F 105 C or must be of a larger conductor size 2 6 5 GENERATOR AC CONNECTIONS Generator AC output leads BLACK hot and WHITE grounded neutral come out of the generator as shown in Figure 2 13 There is also a green lead that connects to ground in the junction box of the recreational vehicle Leads BLACK to WHITE are protected against over load by a 30 amp circuit breaker CB1 Use this line to neutral connection separately to operate 120 volt single phase 60 Hertz AC loads requiring up to 3 400 watts 3 4 kW of power Figure 2 13 Generator AC Output Leads REMOTE PANEL CONNECTOR 500 2 19 11 16 REF AC OUTPUT HARNESS P bJ caution Ak 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 gen erator s rated wattage capacity Ad
24. 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 FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regula tions Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical sys tem Keep the extinguisher properly charged and be familiar with its use If there are any questions
25. for passage of generator mounting bolts INSTALLATION Section 2 Installation Recreational Vehicle Generator Figure 2 7 Compartment Floor Cutout Drawing 0G3723 A 31VIdWN3Ll NOILYTIVISNI 371 71035 A04 WoD 204aua8gs2a14 0 SAWS NVIGSVOD LIVLINOO N3dDU DNI J009 aos q3srno3s SI SNUIIL2031880 ANY 30 3V319 Lda 38 LSAW 5131100 LSQOVHX3 ANY SSNVLNI ATV 1719 L v 1 62 1 T 3 539 7 v L8 S v 1 L8 L 8 1 1 L8 1 8H 1922 maii M 6 sos d 1 1 02 1 L 91 E vl G IS 5 095 Z i Z 91 2 SOLE 9 J N E L 91 81 91 6 4 i 1 T t v 801 ut 1 Lv E 21 1 i 00 99 X04 3ONV3V312 dd NUNC N N LOMI T J dortd5 SOs 3oNVNV31O TNT Ida vey AN 1 1 8 2 1 1 1 3 d10r dO N04 dav L8 1 82 1 LEM n gl e LIE 1 diOv dO 304 adv 2184 CS3HONIJ WW NI 38V SNUISNGWIG d 1 W ad Ma 25 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator DIG A Fuel lines and exhaust piping must not pen etrate into the vehicle living area 2 3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow o
26. generator while the vehicle is parked over high grass weeds brush leaves or any other combustible substance Such materials can ignite and burn from the heat of the exhaust system The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down 2 9 5 EFFECTS OF MOISTURE AND DIRT Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt cor rosive vapors road splash etc Permitting dirt and moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor 3 1 CHECKING THE ENGINE OIL LEVEL For oil capacities and requirements see Engine Oil Requirements section Check the engine crankcase oil level at least every eight hours of operation or before using it 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
27. has started and stabilized at no load 2 7 NOT OVERLOAD THE GENERATOR Read the rated wattage amperage capacity of the generator on the generator data label see Generator Identification Applying electrical loads in excess of the unit s rated capacity will cause the engine generator to automati cally shut down To avoid overloading add up the wattage of all con nected electrical lighting appliance tool and motor loads This total should not be greater than the generator s rated wattage capacity Most lighting appliance tool and motor loads indicate their required watts on their nameplate or data plate For light bulbs simply note the wattage rating of the bulb If a load does not show its rated wattage multiply that load s rated VOLTS times AMPS to obtain WATTS Induction type motors such as those that run the vehicle s furnace fan refrigerator air conditioner etc need about 2 1 2 time more watts of power for starting than for running for a few seconds during motor starting Be sure to allow for this when con necting electrical loads to the generator First fig ure the watts needed to start electric motors in the system To that figure add the running wattages of other items that will be operated by the generator Do not apply heavy electrical loads for the first two or three hours of operation 2 8 PROTECTION SYSTEMS 2 8 1 LOW OIL PRESSURE SWITCH This switch Figure 2 2 has normall
28. nothing that might ren der the system unsafe or in noncompliance with such codes and standards The generator com partment must be completely vapor sealed from the vehicle interior There must be no possibility of exhaust fumes entering the vehicle interior Never operate this equipment with a leaking or defective exhaust system Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed flow of cooling and ven tilating air is critical to correct generator opera tion and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which causes serious damage to the generator Do not alter the installation or permit even partial blockage of ventilation provi sions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement Before performing any 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 Nev
29. of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall not be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission related part covered by the ECS Warranty 7 Throughout the ECS Warranty Period Generac shall maintain a supply of warranted emission related parts sufficient to meet the expected demand for such emission related parts 8 Any Generac authorized and approved emission related replacement part may be used in the performance of any ECS Warranty maintenance or repairs and will be provided without charge to the purchaser owner Such use shall not reduce Generac s ECS Warranty obligations 9 Unapproved add on modified counterfeit and or 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 t
30. or maintain this equipment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators 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 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 fume
31. removal unless the generator is to be removed from under neath the supporting framework The location must provide easy access to frequent ly serviced components such as filters oil drains spark plugs and other common maintenance parts The location must provide sufficient room to allow minimum clearances as outlined in Generator Compartments If sound insulation is to be used on the compartment walls and ceiling the mini mum recommended applies to the space between the generator and such insulation The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense If mounting the generator in an enclosed compart ment the base of the generator must rest flat on the floor without any gaps When using a suspended mounting system ensure the base of the generator is flush with the sur rounding bodywork If the unit is mounted higher in the structure heated air may recirculate into the generator causing it to overheat 2 1 2 GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding The metal framework on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams These beams should consist of a 1 1 2 inch square 11 gauge steel tub ing OR b 1 1 2 inch 11 gauge angle iron A typical
32. seeee 14 Volts DC Battery Charge Current sss 2 Amperes max Gasolin welght 25 nene nas ee cesis 170 Pounds Lenati orere ia eni Ne aE 749 8 mm 29 52 in TE 483 1 mm 19 02 in Height sie redis mi 342 2 mm 13 47 in Maximum wattage and current are subject to and limited by such factors as fuel Btu content ambient temperature altitude engine condition etc Maximum power decreases about 3 5 for each 1 000 feet above sea level and will also decrease about 1 for each 6 C 10 above 16 C 60 ambient temperature 1 5 6 EMISSIONS COMPLIANCE PERIOD For non handheld engines the Emissions Compliance Period referred to on the Emissions Compliance Label indicates the number of operating hours for which the engine has been shown to meet Federal emission requirements For engines less than 225 cc displacement Category 125 hours 250 hours and 500 hours For engines of 225 cc or more Category 250 hours 500 hours and A 1000 hours 2 1 GENERATOR CONTROL PANEL The following features are mounted on the generator control panel Figure 2 1 Figure 2 1 Generator Control Panel N H C CONTROL CENTER START FUEL 30A jte STOP PRIME Fuse 75 n 2 1 1 FUEL PRIMER Before starting a cold engine if it has not been started in more than two weeks press this switch for approximately 10 to 15 seconds to
33. with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor which can be damaging to the generator windings caution Do NOT use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also con taminate the generator fuel system 3 8 BATTERY MAINTENANCE lead acid batteries will discharge when not in use The generator battery should be inspected as follows 3 8 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 MAINTENANCE 2 0 Section 3 Maintenance Recreational Vehicle Generator 3 8 2 EVERY SIX MONTHS Have the state of charge and condition checked This should be done with an automotive type bat tery hydrometer NOTE Servicing of the battery is to be performed or supervised by personnel knowledgeable of batter ies and the required precautions Keep unauthor
34. 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 003979 085953 0D8739A 0D9689 0E7019 083512 082025 092984 094820 089739 091848 091848 0D8778 008803 040946 009235 070185 096437 043182 008397 008591 077091 0 7095 077075 0C2824 045764 0E9406A 0G3662 0G4695B 0A6344 0G6502 Se ING ae a a ck atk NX SIND x M SPRING ANTI LASH WASHER CARB WEAR ASSEMBLY BRACKET GOVERNOR ADJUST ELBOW 90D STREET 1 8NPT SPRING GOVERNOR SCREW HHTT M8 1 2 x 16mm NUT HEX LOCK M5 0 8 NYLOCK TOP WRAPPER PLUG EXPANSION LOWER WRAPPER GASKET OIL PSI PAD 04701 1 ONLY ADAPTER OIL FILTER SCREW SHC M6 1 0 X 22mm SCREW SHC M6 1 0 X 35MM G12 9 04701 1 ONLY SWITCH OIL 5 PSI FILTER OIL THERMAL SWITCH 305F WASHER LOCK M3 ROD CHOKE CONTROL SOLENOID CHOKE PIN COTTER SCREW PRHMS 4 40 x 1 1 8 LONG COVER CHOKE COIL SCREW TAP R 10 32 X 9 16 SCREW HHTT M4 0 7 X 8 BP OIL COOLER 220 CLAMP HOSE OETIKER STEPLESS 17 HOSE 3 8 X 16 25 BRAID WRAP BARBED EL 90 1 8 NPT X 3 8 OIL FILTER SPACER 220RV 47 Section 7 Exploded Views and Parts Lists GN 220 H SH Engine Drawing No 0F5791 G Part 2 Recreational Vehicle Generator LISTS PARTS Ce Section 7 Exploded Views and Parts Lists LISTS Recreational Vehicle Generator GN 220 H SH
35. AE 10 W40 Crankcase and oil filter capacity is approximately 800 mL or 84 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 4 ENGINE Type GN 220 Single cylinder Cooling Methodi cos rere enmt Air cooled Rated Horsepower 7 8 4 200 rpm DISplacemietit 220 Cylinder Block s Aluminum w Cast Iron Sleeve of GIOVeEBOE rores Mechanical Fixed Speed Air Cleaner ee Paper Element w Foam Precleaner iriure 12 volt DC Electric Ignition System Solid state w Flywheel Magneto Recommended Spark Plug loto oo T RC14YC AG P UI R45S Fram Autolite 65 Spark Plug Gap see 0 030 inch 76 mm Recommended Minimum Battery 400 Cold cranking Amperes 1 5 5 GENERATOR Rated Maximum Continuous AC Output Gasoline 3 400 Watts 3 4 kW Rated Voltage te ert eerie etse 120 Volts AC Rated Maximum Continuous AC Current Gasoline 28 3 Amperes pr Single Rotor RPM eee eee oreet ogre Ren nonni p d 3 600 Number of Rotor teda 2 Engine RPM 3 600 Rated AC Frequency eruit rera ia 60 Hz Battery Charge Voltage
36. AFETY RULES carefully before install ing operating or servicing this equipment Become familiar with this Owner s Manual and with the unit The generator can operate safely efficiently and reliably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique uti lized does not render the generator unsafe A A Despite the safe design of this generator operat ing this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capa ble persons to operate or maintain this equip ment A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator Parts of the generator are rotating and or hot during operation Exercise care near running generators N GENERAL HAZARDS For safety reasons the manufacturer recommends that the installation initial start u
37. Drawing No 0F5791 G Part 1 Recreational Vehicle Generator LISTS PARTS 0 Ce FNI 6 le Wed 710 20 10 IH IOOO ITEM PART NO QTY DESCRIPTION 0D8433 001069 090695F 0G6468 081810 083312 0D8400 0C8917D 0C8798A 045756 082774 022129 081990 0D9004A 0E7585 082981 093231 0C1085 0D7666A 090051 080316 090948 078631 0F5759A 091846 0D7558 078643 0D8372 0C2756 0D7458 lx Wy ND i ah sk po a Section 7 Exploded Views and Parts Lists Recreational Vehicle Generator PARTS Cy LISTS GN 220 H SH Engine Drawing No 0F5791 G Part 1 0 GUARD FAN SCREW HHTT M6 1 0 X 8mm 04701 1 ONLY BLOWER HOUSING BLOWER HOUSING 04701 1 ONLY NUT HEX M16 1 5 WASHER M16 CONICAL ASSEMBLY CHOKE SOLENOID BRACKET FLYWHEEL WITH RING GEAR BACKPLATE ELECTRIC START SCREW HHTT M6 1 0 X 10mm KEY WOODRUFF 4 x 19D 5 16 M8 LOCK WASHER SCREW SHC 8 1 25 X 40mm STARTER ASSEMBLY SPARKPLUG TAPTITE M6 1 0 x 30mm ASSEMBLY IGNITION COIL ADV W DIODE SCREW PPHM M3 0 5 X 8mm BREATHER TUBE GASKET MANIFOLD HEAD SCREW HHFC M6 1 0 X 30mm INTAKE MANIFOLD GASKET CARBURETOR MANIFOLD CARBURETOR LP WITH CHOKE NO IDLE PORT GASKET CARB ADAPTOR ADAPTOR CARB BOLT CARB MOUNT M6 1 0 x 75mm GASKET CARB TO AIRBOX ASSEMBLY GOVERNOR LEVER ROD GOVERNOR 31 32
38. F WADA 4 e IM IGNITION MAGNETO 7 FIELD L1 LIGHT RUN OPTIONAL WHITE BLACK LOP SWITCH LOW OIL PRESSURE CLOSES ON LOW PRESSURE ENGINE CONTROLLER R1 RESISTOR 1 25W 2 SC STARTER CONTACTOR 999 120 30 ES SM STARTER MOTOR SW1 SWITCH START STOP NEUTRAL CONNECTION SW2 SWITCH FUEL PRIMER BY CUSTOMER SP SPARK PLUG TC TERMINAL CONN 4 TAB 38 Section 6 Electrical Data Recreational Vehicle Generator Electrical Schematic and Wiring Diagram Drawing No 0D8063 D ELECTRICAL DATA SUPPLIED BY CUSTOMER O o SUPPLIED BY CUSTOMER 12 BATTERY 77 SM 16 77 zo 118 4 62 ELECTRONIC 4 VOLTAGE 18 REGULATOR 228 16 56 0 2 0 3 15 15 2 14 o 56 0 JH 90 2 225 Ji4 O1 18 4
39. FC Contents E IFC Operation and Maintenance oe cis ette IFC How to Obtain Service eoe coder egeret aa IFC Authorized Service Dealer Locator Number IFC Pew 2 Section 1 General Information 4 1 1 Generator Identification oed rte tenir eene 4 1 2 Generator Applicability eene nene 5 1 9 ege 5 1 4 Generator AC Connection System 5 1 5 Specifications ooo eerte vri eese tue caer en ea pdd tete 5 Section 2 Operation ree 6 2 1 Generator Control Panel 4 terree 6 2 2 Optional Remote Start Stop Panel 7 2 3 Before Starting the 7 2 4 Starting the 7 2 5 Stopping the Generator 8 2 6 Applying Loads to 8 2 7 Do Not Overload the Generator 8 2 8 Protection Systems sis e 8 2 9 Additional Information 9 Section 3 10 3 1 Checking the Engine Oil Level 10 3 2 Changing the Engine Oil and or Oil Filter 11 3 3 Maintaining the Engine Air Cleaner 11
40. HESE 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 AN Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can dam age the other engine 2 5 1 SPARK ARRESTOR This spark arrestor assembly meets code and stan dard requirements of the U S Forest Service Use only mufflers and parts approved by the manufactur er Any person s installing an unapproved muffler or an unapproved exhaust system part or modifying an exhaust system in any way that might cause a hazard is liable for any damage injury or warranty expense that might be caused by such unapproved installation or modification Failure to provide and maintain a spark arrestor may be in violation of the law If this generator is used on any forest covered brush covered or grass covered unimproved land provide a spark arrestor The vehi cle owner or operator must maintain this device in good condition In the state of California the preced ing is required by law Section 4442 of the California Public Resources Code Other states may have simi lar laws Federal laws apply on federal lands When installing replacing the tailpipe or spark arres tor components verify that the tailpipe has a hole to s
41. L PRESSURE SPRING 11 32 BALL M5 FORM SCREW M6 1 0 x 12mm SCREW GOVERNOR GEAR THRUST WASHER SCREW HHFC M8 1 25 X 35mm SPRING WASHER VALVE RETAINER VALVE SPRING VALVE SPRING WEAR WASHER GEROTER SET O RING SLEEVE SEAM DWL CYLINDER HEAD ASSEMBLY EXHAUST VALVE INTAKE VALVE PUSH ROD TAPPET OIL PICK UP ASSEMBLY ROCKER COVER GASKET PIVOT BALL STUD GN 191 220 ROCKER ARM ROCKER ARM JAM NUT PUSH ROD GUIDE PLATE 1 4 NPT PIPE PLUG ROCKER COVER ASSEMBLY PLASTIC OIL FILL PLUG VALVE SPRING KEEPER BARBED ELBOW 90 1 4 NPT X 3 8 STUD M8 1 25 10mm X 30mm ag Section 7 Exploded Views and Parts Lists Recreational Vehicle Generator Regulator Drawing No 0F5819 PARTS Or OG ee LO 50 Section 7 Exploded Views and Parts Lists i urs Recreational Vehicle Generator Regulator Drawing No 0F5819 0 CO C 005694 04795 0 5022 0C6070 0C4680 0C4647 0C4643 0D3973 0D7020A 026073 0D3308 070728 0C5764 0C4643A 0C5764 0C5968 0C5759 0C5761 0C6069 0C6731 0C6067 0C4706 0C6068 0C5762 045764 0C5760K Y eL elo mA meals mes Gm edis ms m CASTING TWIN REGULATOR HOUSING SCREW PPHM SEMS M4 0 7 X 10 SOLENOID COIL 12VDC SPRING SOLENOID PLUNGER PLUNGER
42. LP REG ASSY GASKET SOLENOID INLET TWIN REGULATOR NO HOLE PLUG EXPANSION 16MM TWINREG BARBED STR 1 2NPT X 3 8 W VS PLUG STD PIPE 1 8 STEEL SQ HD WASHER FLAT 3 2MM ID X 10MM OD SCREW PFILHM M3 0 5 X 5 SPRING REGULATOR 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 DIAPHRAGM TWIN REGULATOR CAP DIAPHRAGM SUPPORT COVER TWIN REGULATOR SCREW HHTT 4 0 7 X 8 BP JET LP 51 Section 8 Warranty WARRANTY Recreational Vehicle Generator CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and the United States Environmental Protection Agency EPA together with Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine New utility and lawn and garden equipment engines must be designed built and equipped to meet stringent anti smog standards for the state of California and the federal government Generac will warrant the 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 diagno
43. N Recreational Vehicle Generator ape 2 8 4 OVERVOLTAGE PROTECTION A solid state voltage regulator Figure 2 4 controls the generator s AC output voltage This regulator sup plies an excitation current to the rotor By regulating the rotor s excitation current the strength of its mag netic field is regulated and in turn the voltage deliv ered to connected electrical loads is controlled When the AC frequency is 60 Hertz voltage is regulated at 120 volts voltage to frequency ratio is 2 to 1 Figure 2 4 Solid State Voltage Regulator JO e e 11 ECL SENSING 4 _ TO ROTOR 10 DIRECT CURRENT E57 STATOR gt 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 9 ADDITIONAL INFORMATION 2 9 1 25 HOUR BREAK IN PERIOD The first 25 hours of operation is the break in period for the generator Properly breaking in the genera tor is essential to minimize fuel consumption and provide maximum engine performance During this 25 hour break in period follow this procedure Run the unit at varying electrical loads to help seat the engine piston rings properly Ch
44. REAKERS FOR AIR CONDITIONERS GFCI BREAKERS POWER SUPPLY CORD Figure 2 15 Installation With Isolation Receptacle DOCKSIDE POWER RECEPTACLE JUNCTION POWER SUPPLY CORD FLEXIBLE VEHICLE AC DISTRIBUTION PANEL INSTALLATION Section 2 Installation Recreational Vehicle Generator 2 6 6 POWER SUPPLY CORD The power supply cord must comply with all appli cable codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected 2 6 7 GROUND FAULT CIRCUIT INTERRUPTERS The National Electrical Code NFPA 70 551 7 requires that a ground fault circuit interrupters GFCIs be installed on all external and some internal electrical receptacles Contact the dealer for recom mendations 2 7 BATTERY INSTALLATION 271 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 with a larger capacity may be needed 2 72 BATTERY CABLES Using batt
45. T2 WHITE GROUNDED NEUTRAL 1 5 SPECIFICATIONS 1 5 1 FUEL REQUIREMENTS These generators are equipped with a liquefied petro leum LP gas fuel system LP gas is usually aupplied as a liquid in pressure tanks These generators require 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 use of an independent heat source may be needed to be sure the fuel sufficiently vapor izes in the storage tank LP gas may consist of propane butane or a mixture of the two gases Propane vaporizes at tempertures as low as 20 F 29 C but butane returns to its liquid state when the temperature drops below about 32 F 0 For that reason a higher ratio of propane is desired in the gas mixure when temperatures drop below freezing 1 52 FUEL CONSUMPTION Model 1 2 Load Full Load 004701 0 0 73 Fuel consumption is in gal hr OPERATION Section 2 Operation Recreational Vehicle Generator 1 5 5 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum Institute API Service Classification SF 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 S
46. TH THE VICTIM Use a nonconducting imple ment such as a rope or board to free the victim from the live conductor If the victim is uncon scious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury SAFETY RULES Safety Rules Recreational Vehicle Generator FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installa tion do nothing that might alter a safe installation and render the unit in noncompliance with the aforementioned codes standards laws and regula tions Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system Keep the extinguisher properly charged and be familiar with its use If ther are any questions per taining to fire extinguishers consult the local fire department
47. ark 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 3 6 CLEAN SPARK ARRESTOR The engine exhaust muffler has a spark arrestor screen Inspect and clean the screen every 50 hours of operation or once each year whichever comes first NOTE If using the generator on any forest covered brush covered or grass covered unimproved land it must equipped with a spark arrestor The spark arrestor must be maintained in good condition by the owner operator Clean and inspect the spark arrestor as follows Remove the screen retaining bracket by removing the screw Figure 3 5 Slide the spark arrestor screen out from the tail pipe Inspect screen and replace if torn perforated or otherwise damaged DO NOT USE a defective screen If screen is not damaged clean it with com mercial solvent Replace the screen and the retaining bracket Figure 3 5 Spark Arrestor TAILPIPE P N 0E0683 _ SPARK ARRRESTOR SCREEN P N 089680 RETAINING SCREW P N 056892 5 7 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible Protect the unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and mois ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact
48. creational Vehicle Generator Control Panel Drawing No 0F4591 A gt 0 9719 075210 092234 065795 023484 023484R 075234 057159 054502 087798 092113 032300 0A9611 090145 0E2314 0A1658 075235 047411 049226 051716 075476 022264 051715 0A2053 022473 022097 049813 055440 049815 038750 051714 008794 025105 028739 008308 0 5025 023484 043182 031879 a Pm PRO d RP PP PO PP Aa la la la la la la la ol REGULATOR VOLTAGE TERMINAL BLOCK CONTROLLER BATTERY CHARGER RECTIFIER BUSHING SNAP 1 BUSHING SNAP 1 1 4 RESISTOR 1 OHM 25W CIRCUIT BREAKER 2 0 AMP 60HZ CIRCUIT BREAKER 3 0 AMP 50 7 SWITCH SWITCH S P D T ON MOM ON HOLDER FUSE FUSE 7 5A CIRCUIT BREAKER 30 X 1 60HZ CIRCUIT BREAKER 15A 2 POLE 50HZ LOCK WASHER SPECIAL SCREW HHC 5 0 8 X 30MM SCREW HHC M6 1 0 X 16MM WASHER LOCK M5 NUT HEX M5 0 8 SCREW PPHM 4 0 7 X 16MM WASHER LOCK 48 M4 NUT HEX M4 0 7 SCREW HHC M6 1 0 X 65MM WASHER FLAT 1 4 WASHER LOCK M6 1 4 NUT HEX M6 1 0 SCREW HHC M5 0 8 X 25MM SCREW HHC 5 0 8 X 16MM SCREW HHC M6 1 0 X 30MM NUT HEX M3 0 5 PANEL CONTROL SCREW RHM 46 32 X 1 4 SIMS TIE WRAP UL 4 NOT SHOWN DECAL NOT SHOWN HARNESS NOT SHOWN BUSHING SNAP 1 09 WASHER LOCK M3 WASHER FLAT M3 45 Section 7 Exploded Views and Parts Lists GN 220 H SH Engine
49. d 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 water Wrap the foam precleaner in a clean cloth and gently squeeze it dry 6 Saturate the foam precleaner in clean engine oil Gently squeeze it in a clean cloth to remove excess oil and to distribute oil DO NOT TWIST 7 Install the foam precleaner into the cover fol lowed by the paper filter 8 Install the cover foam precleaner and paper filter 9 Tighten the two screws to retain the filter in place p Figure 3 2 Engine Air Cleaner 11 MAINTENANCE 2 09 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 Section 5 Maintenance Recreational Vehicle Generator 1 Follow steps 1 3 in Cleaning the Foam Precleaner service the foam precleaner if
50. d the watts or amperes of all lighting appliance tool and motor loads the generator will operate at one time This total should be less than the unit s rated wattage amperage capacity 2 6 4 CONDUIT Route the connections between the generator and the junction box through approved flexible conduit The following general rules apply 2 6 5 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 ISOLATING DIFFERENT POWER SOURCES Connections from the junction box must terminate in a double pole double throw transfer switch Figure 2 14 An alternate method for isolating different power sources is by using an isolating receptacle Figure 2 15 Whichever method is used be certain that both power sources are NOT connected at the same time Section 2 Installation INSTALLATION Ps Recreational Vehicle Generator Figure 2 14 Transfer Switch Isolation Method JUNCTION BOX VEHICLE FLEXIBLE WIRING CONDUIT DOUBLE VEHICLE POLE DISTRIBUTION DOUBLE PANEL THROW SWITCHING 30 AMP DEVICE MAIN BREAKER HACR B
51. e Air inlet opening is correct Compensate for restrictions Check that installation has been tested OPTIONAL LP GAS FUEL SYSTEM Fuel system is properly installed and checked for leaks Pressure at regulator inlet is correct Q Rated flow of primary regulator is correct All parts are properly installed Fuel system is properly tested adjusted EXHAUST SYSTEM Exhaust system complies with all applicable codes Exhaust system is properly and safely installed DATE OF INSTALLATION z INSTALLATION START UP ADJUSTMENTS Recreational Vehicle Generator ELECTRICAL CONNECTIONS Connections comply with local code requirements and all National Electrical Codes Junction box is properly installed Wiring meets all standards All connections are correct Conduit is properly installed and sealed Generator is properly bonded to the vehicle BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Cables are clean and tight Cables are connected properly Proper ventilation is provided Terminals are coated with anti corrosion grease and terminal covers are positioned OPTIONAL ACCESSORIES Check that remote start stop panels if used are installed properly Check that hourmeter kit if used is installed properly Check that any other options and accessories if used a
52. e Generac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Facility is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility All 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 Co
53. e manufacturer s application for certification c The ECS Warranty only pertains to emissions related parts on your engine as follows 1 Any warranted emissions related parts that are not scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the ECS Warranty Period If any such part fails during the ECS Warranty Period it shall be repaired or replaced by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that is scheduled only for regular inspection as specified in the Owner s Manual shall be warranted for the ECS Warranty Period A statement in such written instructions to the effect of repair or replace as necessary shall not reduce the ECS Warranty Period Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the first scheduled replacement point for 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
54. e recreational vehicle s junction box NOTE Do NOT connect loads in excess of circuit breaker ratings SONVNALNIVW Q3uInO3H T1V SS300V HOOQ 1NOHH E lt z INFORMATION ei ove S 5 5 5 E Bla EIS o 2 4 SS3NHVH __ 1ndl1no OV adu 9 2 2 Els 61 Lovet og o 2 009 pos S o HOLO3NNOO o gt 310W3H c 5 1 e c 9 o m 5 Lez 5 zz 889 ove vu L698 g La b9Uel ri _ Lg i 1006 62 t Lte 2 jee 91 6 _ Let el e 969 9 6 959 8 2 0 Loue el Q NOLLO3NNOO sss Lv O3N 3 p 1 i d e b i i S 5 9 96 1 8 6 1 d Y e NOLLOSNNOO i pons i 1v8 SOd Lows 8 Lever 8 face lt ELIZ da Lvl 1 ses LOL vi La
55. e recommended installation procedures for these products and that such training includes a use of common hand tools b use of special tools and c use of any tools and or equipment from other sup pliers The manufacturer cannot possibly know of and advise the recreational vehicle trade of all conceiv able methods procedures or techniques by which to perform an installation Nor can the manufacturer anticipate every possible hazard that might result from each installation method procedure or tech nique The manufacturer has not undertaken any such wide evaluation If using a procedure work method or operating technique the manufacturer does not specifically recommend ensure that it is safe for others Also make sure the procedure work method or operating technique utilized does not ren der the generator unsafe Information illustrations specifications etc con tained in these Installation Instructions are based on the latest information available at the time of publica tion Every effort has been expended to be sure that such data is both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time without prior notice A AN Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate
56. e switch when the engine starts caution Ak AN If the engine does not start after it has been cranking for 15 seconds release the Start Stop switch wait one minute and try again Holding the switch for longer than 15 seconds can dam age the starter motor 4 Letthe engine run at no load for a few minutes to stabilize and warm up 5 Turn ON electrical loads using the means pro vided such as a main circuit breaker or transfer switch 2 5 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 6 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 6 1 LETTING THE ENGINE STABILIZE The generator supplies correct rated voltage only at the proper governed speed Some electrical appli ances may be extremely sensitive to voltage Incorrect voltages can damage such appliances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when suf ficient power is not available may shorten engine life Never turn ON electrical loads until after the genera tor engine
57. eck the engine oil level frequently Add oil if needed It is normal for the generator engine to consume more oil than is normal until the piston rings have properly seated For the 75 hour operation following the break in period avoid light electrical loads Load the gen erator at 50 percent or more of its rated watt age capacity Repeated light loads during these 75 hours can cause improper seating of engine piston rings resulting in blowby and high oil consump tion After operating the unit for 25 hours complete the tasks recommended under 25 Hour Check up MAINTENANCE Section 3 Maintenance Recreational Vehicle Generator 2 9 2 25 HOUR CHECK UP After the 25 hour break in period contact an Authorized Service Dealer for the following main tenance The vehicle owner is responsible for any charges Change the engine crankcase oil and oil filter Check the oil level Inspect the cooling and ventilation openings Check the engine carburetor adjustments Check the engine ignition system nspect the entire electrical system Inspect the engine exhaust system 2 9 5 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 9 4 OPERATION IN HIGH GRASS OR BRUSH Never operate the
58. ecurely fasten the spark arrestor components see Figures 2 11 and 2 12 Use only manufacturer supplied hardware Substitution of parts may cause damage to the screen or a loose fit to the tailpipe Figure 2 11 Spark Arrestor TAILPIPE P N 0E0683 NV SPARK ARRRESTOR s SCREEN P N 089680 RETAINING SCREW P N 056892 Figure 2 12 Spark Arrestor Installation 27 4 1 08 LD 7 5 5 7 32 DRILL BOTTOM SIDE ONLY INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator 2 5 2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76 mm between exhaust system parts and any combus tible material such as wood felt cotton organic fibers or other like material If the 3 inch 76 mm clearance cannot be maintained locate insulate or shield the exhaust part s so that the temperature of any combustible material is not raised more than 117 F 65 C above the ambient air tempera ture 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 f 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
59. emperature 3 Replace temperature switch switch 4 Defective engine control board 4 Replace control board 5 Overheated engine 5 Check that the airflow openings are adequate The Start Stop switch is l Defective Start Stop switch 1 Replace switch set to Stop but the engine 2 Open Disconnected 18 wire 2 Reconnect or close wire continues to run between Start Stop switch and engine control board 3 Open Disconnected 0 wire 3 Reconnect or close wire between Start Stop switch and engine control board 4 Defective engine control board 4 Replace control board There is no AC output from 1 Main line circuit breaker open 1 Reset circuit breaker the generator to ON or closed 2 Fault with vehicle circuit 2 Reset and replace if necessary breaker and or fuses 3 Transfer switch set to NORMAL 3 Set switch to GENERATOR 4 Start switch not held long 4 Stop then restart the engine enough to flash the field Hold Start switch for at least 2 seconds 5 Generator internal failure 5 Contact an Authorized Service Dealer 36 Section 5 Notes Recreational Vehicle Generator NOTES 37 Section 6 Electrical Data Recreational Vehicle Generator ELECTRICAL DATA Electrical Schematic and Wiring Diagram Drawing No 0D8063 D
60. ent away from any source of heat sparks or flame NEG BAT CONNECTION Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage 2 8 OPTIONAL ACCESSORIES A plug in receptacle Figure 2 17 is provided on the generator set Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit starting and stopping the generator engine from any convenient location inside the vehicle Section 3 Post installation Start up Adjustments POST Figure 2 17 Remote Panel Plug in Receptacle 6 14A 14A 4 15 4 lt 18 m is 5 2 17 B RE 1 0 o D 12 00 WIRE WIRE No LENGTH mm FUNCTION 0 WHITE 12 0 305 GROUND 14 RED 12 0 305 ENGINE RUN SIGNAL 15 ORANGE 12 0 305 12 VDC 305 305 305 17 YELLOW 12 0 305 START 18 BROWN 12 0 305 STOP 14A BLUE 12 0 305 PRIME P N 0D9099 B 2 8 1 REMOTE START STOP PANEL A remote mounted Start Stop panel Figure 2 18 is available that allows the user to start and stop the generator engine conveniently
61. er 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 The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle have the generator properly grounded bonded either by solid mounting to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT disconnect the bonding conductor if so equipped DO NOT reconnect the bonding conduc tor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum SAFETY RULES Safety Rules Recreational Vehicle Generator In case of accident caused by electric shock imme diately shut down the source of
62. ery 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 following chart CABLE LENGTH i CABLE SIZE 16 to 20 4 5 to 6 For warm weather use No 2 cable up to 20 feet 2 7 3 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or to the lug on the starter contactor Figure 2 16 NOTE Check to be sure the battery cable boot for the starter cable has been installed 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connection Figure 2 16 3 Connect cables so the connectors are clean and tight Figure 2 16 Connecting Battery Cables 712 9 9 2 13 16 POS 34 3 7 1 3 8 39 6 69 6 pone C 2 3 4 2 7 4 BATTERY COMPARTMENT Install the generator battery in its own vented com partment Place the battery compartm
63. f air for cooling ventilating and engine combustion be supplied to the generator set Without sufficient airflow the engine generator quickly overheats Such overheating can cause serious operating difficulties and also may cause fire and personal injury The installer must make sure that sufficient air is avail able to the generator for cooling ventilating and combustion The installer also must provide for a path for exhausting the cooling air to the exterior of a compartment if so equipped 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 bottom right side of the generator Figure 2 8 This airflow cools the engine generator and elec tronic components The second part of the cooling system a suction fan draws air that is heated from a hot engine into a collector compartment at the left side of the unit This heated air although cooler than exhaust muffler is then deflected out the bottom toward the ground Figure 2 8 Airflow Through Engine Generator 2 3 2 TESTING THE INSTALLATION The manufacturer recommends testing the installa tion to be sure adequate cooling airflow is available to the unit before plac
64. fe Add up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one time This total should not be greater than the wattage capacity of the generator If an electrical device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of cur rent for starting than for continuous operation 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 CONNECTION SYSTEM This generator set is equipped with dual stator AC power windings These two stator windings sup ply electrical power to customer electrical loads by means of a two wire connection system Note how ever that the neutral is bonded to the frame of the engine generator The generator may have been installed so that it pow ers 120 volt AC loads Figure 1 1 Figure 1 1 Connections for 120 Volts Only T1 DS CB1 0O RED mui 120V 30 AMP STATOR POWER WINDINGS
65. from inside the vehicle The remote panel includes a Start Stop switch hour meter generator run lamp a fuel prime switch and a wire harness The hourmeter should be used in conjunction with the maintenance operations found in Part I of this manual Figure 2 18 Optional Remote Panel 2 INSTALLATION START UP ADJUSTMENTS Recreational Vehicle Generator 5 1 POST INSTALLATION TESTS The air cooled generator set was factory tested and adjusted It should not be required to adjust the unit any further except under special circumstances warninc amp Do not make any unnecessary adjustments Factory settings are correct for most applica tions When making adjustments however be careful to avoid overspeeding the engine 3 2 BEFORE INITIAL START UP Before starting complete the following 1 Check the engine crankcase oil level and if nec essary fill to the dipstick FULL mark cross hatched area with the recommended oil Do not fill above the FULL mark 2 Check the fuel supply Gas fuel lines must have been properly purged and leak tested in accor dance with applicable fuel codes All fuel shutoff valves in the fuel supply lines must be open DG A AN If a liquid propane LP gas fuel system has been installed it must be properly tested for leaks before operating the system in compliance with ANSI A119 2 NFPA 501C No leakage is permit ted Be s
66. ful to the skin and eyes and to be toxic The electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following procedures are to be observed Wear full eye protection and protective clothing Where electrolyte contacts the skin wash it off immediately with water MAINTENANCE S O Section 3 Maintenance Recreational Vehicle Generator Where electrolyte contacts the eyes flush thoroughly and immediately with water and seek medical attention and Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or water The bicar bonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried 3 9 MAJOR SERVICE MANUAL To obtain a service manual for the generator contact the nearest Authorized Service Dealer Make sure to identify the MODEL NUMBER and SERIES 3 10 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 11 OUT OF SERVICE PROCEDURE 5 11 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
67. 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 Ps Section 2 Installation Recreational Vehicle Generator 2 4 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 tank outlet or in the supply line from the gas tank The following rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inch es water column Do NOT exceed 14 inches water column The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit NOTE Recommended MINIMUM flow rate for these air cooled generators is 40 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 40 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 4 5 GASEOUS CARBURETION LP gas vapors should be supplied to the secondary regulator inlet at abo
68. he use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 2 Air Induction System including 1 1 Gasoline carburetor assembly and its a Intake pipe manifold internal components if so equipped b Air cleaner a Fuel filter if so equipped 3 Ignition System including b Carburetor gaskets a Spark plug c Fuel pump if so equipped b Ignition module 1 2 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 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 8 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 sal
69. ide 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 Stress safety to all installers operators and service technicians who work on this equipment 1 3 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The following standards booklets latest revision are available from the sources indicated 1 Standard 501 Standard for Recreational Vehicles available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 70 Handbook of the National Electric Code available same as Item 1 3 ANSI C1 1975 and
70. ing the unit into service If the unit shows signs of overheating enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate NOTE Test the installation especially if bringing in air from below the generator set 2 4 LP GAS FUEL SYSTEM A LP gas is highly EXPLOSIVE The gas is heavier than air and tends to settle in low areas Even the slightest spark can ignite it and cause and explosion Only competent qualified people should be allowed to install test adjust or ser vice an LP gas fuel system Install the optional fuel system in compliance with applicable codes standards and regulations After the installation do not do anything that might render the 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 4 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 9 Dd A Use only approved components in the fuel sup ply system All components must be properly installed in accordance with applicable codes Improper in
71. into a suitable container Loosening the oil fill cap will allow the crankcase to drain faster 3 After the oil has drained replace the plug onto the end of the oil drain tube Retain the cover in the base 4 With the oil drained remove the old oil filter by turning it counterclockwise Place a towel under neath to catch excess oil 5 Applya light coating of clean engine oil to the gas ket of the new filter Fill the filter until saturated with clean oil 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 Remove the oil fill cap on the oil fill tube and slowly add the proper type and amount of recom mended oil see Specifications Periodically use the dipstick to check the oil level and continue to fill the crankcase until the oil reaches the dipstick Full mark DO NOT FILL ABOVE THE FULL MARK MAINTENANCE 29 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 Section 3 Maintenance Recreational Vehicle Generator 3 3 MAINTAINING THE ENGINE AIR CLEANER 3 3 1 CLEANING THE FOAM PRECLEANER Clean an
72. ith 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 4 If constructing a compartment line the exterior underside of the compartment floor with 26 gauge galvanized steel INSTALLATION he Section 2 Installation Recreational Vehicle Generator Figure 2 4 Typical Compartment Construction CROSS SECTION VIEW METAL LINING Era FIREPROOF EM SOUND INSULATION T kt METAL LINING EE VAPOR SEALED PLYWOOD AT ALLTIMES METAL f e All 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 inte rior 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 e Holes and openings made in the compartment walls to allow for the passage of electrical conduit conductors hoses cables etc into the vehicle liv ing area must be sealed vapor tight with silicone rubber base sea
73. lant If flexible metal conduit is used it must be sealed internally at the end where it terminates inside the compartments electrical junction box NOTE Flexible metal conduit due to its unique construc tion is NOT vapor tight along its entire length Seams and joints of the galvanized steel whether used as a liner or for the compartment itself must be lapped and mechanically secured Such seams may be manufactured welded bolted riveted or screwed Manufactured lock seams are shown in Figure 2 5 Installer constructed compartments typically utilize a standard lap joint After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material 23 INSTALLATION Ps Section 2 Installation Recreational Vehicle Generator Figure 2 5 Types of Lock Seams ACME LOCK Jn FOLD LOCKED STANDING OFF SET DOUBLE LOCK DOUBLE SEAM E GORDON SEAM LOCK SEAM STANDARD LAP JOINT DIG A Do not install any flammable material directly above or around the compartment Heat trans ferred through the compartment structure may be sufficient to ignite char or discolor seat cush ions fiberboard and other flammable materials
74. led to prevent damage from road shock INSTALLATION Ta 2 6 1 Section 2 Installation Recreational Vehicle Generator Wiring must be of adequate size have approved insulative qualities and be properly supported Conduit and wire openings into the generator com partment if used must be vapor sealed to prevent entry of flammable explosive or poisonous gases into the vehicle ELECTRICAL JUNCTION BOX Install an approved square electrical junction box with a blank cover on the interior or exterior wall of the area planned for installation of the generator NOT on the generator Route the generator s AC output leads into this junction box through approved flexible conduit This is the point of first termination for generator AC output leads 2 6 2 WIRING Wiring should be of stranded copper to reduce the chance that vibration may cause breakage Wire gauge size should be large enough to handle at least 115 percent of the installed generator s rated maximum current Neutral conductors must be the same size as other leg wires Route power supply conductors from generator AC output leads white black and the green ground wire through approved flexible conduit to the elec trical junction box on the compartment wall If flexible metal conduit is used between the gen erator and the compartment junction box the con duit end that terminates the compartment junction box must be vapor sealed Flexible metal
75. may damage the generator 2 3 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 Dd AN 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 Dd A AN Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installa tion manual Make sure there is ample fresh air when operating the genset in a confined area 2 4 STARTING THE GENERATOR NOTE
76. n insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mount ing to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum If the vehicle electrical circuits can be powered by any other source of electricity such as a dockside power receptacle there must be no possibility of connecting the different power sources to the vehi cle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operat ing Failure to isolate the vehicle circuits from the dockside power supply when the generator is running may result in damage to the generator or serious injury or death to dockside utility power workers due to backfeed of electrical energy In case of accident caused by electric shock imme diately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WI
77. nd SUE ia o Lowe vi gt did TIVL Y 19099 INI 91 1918190 9 HIV oiv S 6cv eN S yly fs LZ T NE _ usnwHxa 13TNI E 9 ole TE 3 8 5 21 09 O u YOLVYANAD HO MOVE b NI SNOILOANNOO amp uw T v Lee 9 sz Ly SI SLANGTAM 81 916 m len ev mm rg N3dO TIY SNOLLOnH1SSO ANY JO HV31O 193 vere 38 ISNW 5197110 15 ANY S39V INI TIY dd 3l LLL dO 21 INSTALLATION Ps 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
78. 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 Cleanthe air cleaner cover then reassemble follow ing steps 7 9 in Cleaning the Foam Precleaner 3 4 CLEAN AIR INTAKE Clean all foreign material from the air intake Figure 3 3 at least once every 100 hours of operation Clean more often if necessary Inspect the area around the generator exhaust muf fler periodically and remove all grass leaves dirt etc from this area Figure 3 3 Cleaning Air Intake lll 3 5 CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine Remove the spark plug and check the condition Replace the spark plug if worn or if reuse is question able 12 2 Clean spark plug by scraping or washing using a wire brush and commercial solvent Do not blast the spark plug to clean 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 030 inch 0 76 mm by carefully bending the ground electrode Figure 3 4 caution Sparking can occur if the wire terminal does not fit firmly on the sp
79. ner also shall be responsible for any and or all damages or losses incurred while the engine is being transported shipped for inspection or warranty repairs If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the fol lowing address ATTENTION WARRANTY DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 297 WHITEWATER WI 53190 Part 1 52 Section 8 Warranty Recreational Vehicle Generator WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1997 and later model year engines a Applicability This warranty shall apply to 1997 and later model year engines The ECS Warranty Period shall begin on the date the new engine or 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 engin
80. ntrol Board part numbers 0A6060 and 0A3369 and inverter if applicable with regard to the generator Oylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Manifolds Generac RV generators manufactured prior to December 31 1997 DO NOT have a transferable warranty Generac RV generators manufactured after January 1 1998 have a transferable warranty to the second owner ONLY for the remainder of the three year limited warranty Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any warranty service All warranty expense allowances are subject to the conditions defined in Guardian s Warranty Policies and Procedures Guide THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Guardian generators that utilize non Generac replacement parts Costs of normal maintenance adjustments installation and start up Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts 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 exhaus
81. odic maintenance requirements on the unit 2 5 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 3 1 INSTALLATION Generator installation must have been properly com pleted so it complies with all applicable codes stan dards and regulations and with the manufacturer s recommendations 2 3 2 ENGINE LUBRICATION Have the engine crankcase properly serviced with the recommended oil before starting Refer to the Specifications Checking the Engine Oil Level and Changing the Engine Oil and or Oil Filter sections for oil servicing procedures and recommendations caution A Any attempt to crank or start the engine before it has been properly serviced it with the recom mended oil may result in an engine failure 2 3 3 FUEL SUPPLY The engine must have an adequate supply of proper fuel to operate Before starting it check that suffi cient fuel is available Section 2 Operation OPERATION Recreational Vehicle Generator ix 2 3 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
82. onable amount of time not to exceed 30 days Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California and federal law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty 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 ow
83. orm 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 the Authorized Service Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact an Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting an Authorized Service Dealer about parts and service always supply the complete model number and serial number of the unit as given on its data label which is located on the generator Model No Serial No AUTHORIZED SERVICE DEALER LOCATION To locate the nearest AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 or locate us on the web at www guardiangenerators com Part Owner s Manual Introduction Inside Front Cover Read This Manual Thoroughly I
84. p and main tenance of this equipment is carried out by an Authorized Service Dealer The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentra tions can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coherently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weak ness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired Never sleep in the vehicle while the genset is run ning unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in 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
85. pre pare the generator for storage as follows 1 Start the engine and let it warm up 2 Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down NOTE Using a fuel additive such as STA BIL fuel stabi lizer or an equivalent will prevent gum deposits from forming in the engine s fuel system 3 While the engine is still warm from running drain the oil completely Refill the crankcase with SAE 10W 30 oil having API classification For Service SE 4 Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase 5 Remove the spark plug and pour two or three tablespoons of clean fresh engine oil into the spark plug threaded openings Reinstall and tighten the spark plug 6 Remove the battery and store it in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor 7 Clean and wipe the entire generator 14 3 11 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Check the tag on the engine for oil viscosity and classification Verify that the correct recommend ed oil is used in the engine see Specifications If necessary drain and refill with the proper oil 2 Check the state of the battery Fill all cells of unsealed batteries to the proper level with dis tilled water DO NOT USE TAP WATER IN THE BATTERY Recharge the battery to 100 percent state of charge or if defec
86. r 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 34 3 4 TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 per cent of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling airflow is available Do not allow the unit to overheat during prolonged operation NOTE The generator engine is equipped with a high tem perature switch The switch has normally closed N C contacts When the engine temperature is too high switch contacts close and the engine shuts down automatically THE MANUFACTURER RECOMMENDS THAT THE GENERATOR BE TESTED FOR ADEQUATE COOL ING Section 3 Post installation Start up Adjustments POST 3 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT Generator is properly located Generator is properly supported Generator is properly restrained GENERATOR COMPARTMENT Compartment construction is proper Q Holes Openings are vapor sealed Compartment size is correct Compartment is vapor sealed Sound insulation is correct Floor cutouts are properly completed COOLING AND VENTILATING AIR Airflow is adequat
87. re installed properly POST INSTALLATION TESTS Check that all tests are completed properly NAME OF INSTALLER SIGNATURE OF INSTALLER 35 TROUBLESHOOTING Section 4 Troubleshooting Recreational Vehicle Generator TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank 1 Fuse blown 1 Replace fuse 2 Loose corroded or defective 2 Tighten clean or replace battery cables as necessary 3 Defective engine Start Stop 3 Replace Start Stop switch switch 4 Defective starter contactor 4 Replace contactor 5 Defective starter motor 5 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 solenoid 2 Replace fuel solenoid 3 Open 14 wire from 3 Check connections and engine control board insulation of 14 wires 4 Flooded engine 4 Wait 5 10 minutes before trying 5 Defective spark plug s 5 Clean re gap or replace plug s 6 Fuel line shut off closed 6 Open fuel line shut off The engine starts hard l Air cleaner 1 Check clean or replace air cleaner and runs rough plugged or damaged 2 Defective spark plug s 2 Clean re gap or replace plug s The engine starts but shuts 1 Engine oil level low 1 Check oil and add oil as needed down when the Start Stop 2 Defective low oil 2 Replace pressure switch switch is released pressure switch 3 Defective high t
88. s 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 damage to the equipment or a serious injury may occur A ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate covers guards and barriers are in place before operating the generator If work must be done around an operating unit stand on a
89. s 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 personal 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 generator model numbers 004701 0 In addition the latter portion of this manual contains information necessary for the proper installation of these generators OPERATION AND MAINTENANCE It is the operator s responsibility to perf
90. sis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted If dur ing such warranty period any emission related component or system on your engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility 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 reas
91. st System simne onse ode sees ere 28 2 6 Electrical Connections eerte toit roe Pera as 29 2 7 Battery Installation eene tede etri idee 2 8 Optional Accessories Section 3 Post installation Start up Adjustments issis 33 3 1 Post Installation Tests esee 33 3 2 Before Initial Start up ce etre 33 9 9 Inilial Start eve Rente tv dg 33 3 4 Testing Under Load 34 3 5 Installation Checklist cesses 35 Section 4 Troubleshooting 36 Section 5 Notes one nitens 37 Section 6 Electrical 38 Section 7 Exploded Views and Parts Lists 40 Section 8 Warranty essere 52 SAFETY RULES Safety Rules Recreational Vehicle Generator SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe operation be copied and posted near the unit s installation site Safety should be stressed to all operators and potential operators of this equipment WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these S
92. stallation 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 9 Typical Propane Gas Fuel System CARBURETOR REGULATOR SOLENOID PRIMARY REGULATOR VAPOR WIDTHDRAWAL TANK 2 4 SOME IMPORTANT CONSIDERATIONS 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 Use a length of approved flexible fuel hose between the gaseous fuel solenoid valve and rigid gas pip ing The flexible line should be at least 6 inches longer than necessary 2 4 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
93. 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 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 sider using additional tubing angle brackets or other supports to give the supporting frame suf ficient strength Figure 2 1 Typical Horizontal Support Frame SUPPORT TUBING 2 1 4 GENERATOR RESTRAINT Use four 5 16 18 hardened steel bolts Grade 5 to fasten the generator to the supporting frame or the support tubing These bolts must pass through a the generator mounting base b the compartment floor if a compartment is used and c the support ing framework Figure 2 2 All bolts must be long enough so that when tight at least three threads are visible past the retaining lock nuts Refer to Generator Compartments for the location of the generator mounting holes Figure 2 2 Typical Generator Restraint
94. ted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism riot or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages 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 cud or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s Overtime labor Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR
95. tive replace the battery 3 Clean and wipe the entire generator 4 Reconnect the battery Observe battery polarity Damage may occur if the battery is connected incorrectly 5 Turn OFF all electrical loads Add fuel if neces sary and then start the engine 6 Allow the unit to run for several minutes to warm up 7 Apply electrical loads to at least 50 percent of the units rated wattage capacity 8 When the engine is thoroughly warmed up shut it down 9 The generator is now ready for service 5 12 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation adjust the valve clearance in the engine When adjusting valve clearance the engine should be at room temperature and the piston should be at Top Dead Center TDC of its compression stroke both valves closed Correct clearance is 0 001 0 003 inch 0 03 0 07mm Adjust valve clearance as follows l Loosen the rocker arm jam nut Use an allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Figure 3 6 Figure 3 6 Adjusting Valve Clearance Loosen Jam Nut 2 When valve clearance is correct hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut with a crows foot Tighten the jam nut to 65 85 inch pounds torque After tightening the jam nut recheck valve clearance to make sure it did not change Figure 3 7 Figure 3 7 Tightening Jam
96. ttings 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 Dd A Gaseous fuel lines between the tank and the secondary regulator are under a positive pres sure about 11 inches water column Gas pres sure at the outlet side of the secondary regula tor however is a negative pressure and can draw flame inside a line or fitting and cause an explosion 2 5 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used A properly installed exhaust system must be vapor tight quiet and completely safe Dd A AN The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability to think coher ently b vomiting c twitching muscles d throbbing temples e dizziness f headaches g weakness and h sleepiness IF FEELING ANY OF T
97. ulator valve off its seat and permit gas to flow 2 4 6 FUEL SUPPLY LINES LP gas lines must be accessible but protected against possible damage Do NOT connect electrical wiring to any LP gas fuel line or run wiring alongside the lines Route gas lines away from hot engine exhausts Retain gas lines with metal clamps that do not have sharp edges Install an approved length of flexible hose between the gaseous fuel solenoid valve and rigid fuel supply lines The flexible line must be nonmetal lic nonorganic and nonconductive It must be approved for use with LP gas 2 4 7 EXCESS FLOW VALVE LP gas tanks should have an excess flow valve according to 501 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 4 8 LEAKAGE TESTS Do not place the generator into service until the gas system has been properly tested for leaks To test the system a separate source of 12 volts DC is needed to open the gaseous fuel solenoid valve The leak test must comply fully with NFPA Paragraph 318 connections hoses valve regulators fi
98. ure no gasoline fuel vapors enter the vehicle interior 3 3 INITIAL START When absolutely certain that the unit has been prop erly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator s main circuit breakers to their OFF or open position 2 Refer to Part I section Starting the Generator for cranking and starting instructions The engine may require more cranking for initial starting since the fuel lines have to be primed use of the primer switch will shorten this time 3 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 33 z POST Section 3 Post installation Start up Adjustments INSTALLATION START UP ADJUSTMENTS Recreational Vehicle Generator 6 Turn off all electrical loads by setting the gener ator s main circuit breakers to their OFF or open position 7 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine NOTE The generato
99. ut 11 inches water column posi tive pressure The engine pistons draw air in dur ing the intake stroke Figure 2 10 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 attached to the diaphragm opens a valve to permit gas glow through the carburetor Figure 2 10 LP Gas Carburetion Diagram AIR GAS AT FLOW POSITIVE ri PRESSURE M GAS AT Low pressure PRESSURE AREA 27 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 reg
100. y 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 8 2 HIGH TEMPERATURE SWITCH This switch Figure 2 2 which has normally open N O contacts is mounted near the oil filter The contacts close if the temperature should exceed approximately 284 F 140 C initiating an engine shutdown Figure 2 2 Low Oil Pressure and High Temperature Switches High Temperature Switch LowOilPressure Switch 2 8 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 3 During engine cranking only a positive DC battery voltage is delivered through the diode resistor brushes and slip rings to the generator rotor Application of this voltage to the rotor flashes the field whenever it is started Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce pickup voltage in the stator windings Figure 2 3 Field Boost Circuit 9 SC 16 CONTROLLER CIRCUIT CLOSEST TO BOARD BEARING l4 4 0 N FIELD GRND Section 2 Operation OPERATIO

Generac Power Systems 004701-0 Portable Generator User Manual

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