Generac Power Systems Guardian Rv 004700 00 Users Manual 0D8351revR

004700-00 to the manual afc584b1-1db2-45a6-8c50-d8102997aa77

2015-02-09

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Owner’s Manual and
Installation Instructions
Air-cooled Recreational
Vehicle Generators
• Model: 004700-0
QUIETPACT 40G

This manual should remain with the unit.

INTRODUCTION
Thank you for purchasing this model of the
QUIETPACT product line by Generac Power Systems
Inc. This model is designed and manufactured to
supply electrical power for recreational vehicles.

READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the 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 personnel to special instructions about a particular operation that may be hazardous if performed incorrectly
or carelessly. Observe them carefully. Their definitions are as follows:

DANGER
After this heading, read instructions that, if not
strictly complied with, will result in personal injury
or property damage.

After this heading, ead instructions that, if not
strictly complied with, may result in personal injury
or property damage.

The operator (driver) is responsible for proper and
safe use of the vehicle and its equipment, and the
safety of all vehicle occupants. We strongly recommend that the operator read this manual and thoroughly understand all instructions before using this
equipment. We also strongly recommend instructing
other occupants in the vehicle to properly start and
operate the generator. This prepares them if they need
to operate the equipment in an emergency.

CONTENTS
This manual contains pertinent owner’s information,
including warranty, electrical diagrams, exploded
views and lists of repair parts for generator model
numbers 004700-0. 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 perform all safety
checks, to make sure that all maintenance for safe
operation is performed promptly, and to have the
equipment checked periodically by an Authorized
Service Dealer. Normal maintenance service and
replacement of parts are the responsibility of the
owner/operator and, as such, are not considered
defects in materials or workmanship within the
terms of the warranty. Individual operating habits
and usage contribute to the need for maintenance
service.

After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:

Proper maintenance and care of the generator ensures
a minimum number of problems and keep operating
expenses at a minimum. See an Authorized Service
Dealer for service aids and accessories.

After this heading, read explanatory statements
that require special emphasis.

HOW TO OBTAIN SERVICE

These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compliance with the special instructions while performing
the service are essential to preventing accidents.

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.

Four commonly used safety symbols accompany the
DANGER, WARNING and CAUTION blocks. The type
of information each indicates follows:

When contacting an Authorized Service Dealer or
factory about parts and service, always supply
complete model number and serial number of
unit as given on its data label, which is located on
generator.

symbol points out important safety informa This
tion that, if not followed, could endanger personal safety and/or property of others.

Model No. ____________

Serial No. ______________

 This symbol points out potential explosion hazard.
 This symbol points out potential fire hazard.
symbol points out potential electrical shock
 This
hazard.

the
the
the
the

AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED SERVICE
DEALER, please call this number:

1-800-333-1322
or locate us on the web at:
www.generac.com

Table of Contents
Recreational Vehicle Generator

Part I – Owner’s Manual
Introduction ...................................... Inside Front Cover
Read This Manual Thoroughly ................................IFC
Contents .................................................................IFC
Operation and Maintenance ....................................IFC
How to Obtain Service ............................................IFC
Authorized Service Dealer Locator Number .............. IFC

Part II – Installation Instructions
Safety Rules .................................................................... 18
Section 1 – General Information ............................... 20
1.1

Purpose and Scope of the Manual ..................... 20

1.2

Safety................................................................. 20

1.3

Standards Booklets ........................................... 20

Safety Rules ...................................................................... 2

1.4

Equipment Description ..................................... 20

Section 1 – General Information ................................. 4

1.5

Generator Engine Operating Speed ................... 20

1.1

Generator Identification ...................................... 4

1.6

Generator AC Connection System ..................... 20

1.2

Generator Applicability ....................................... 5

Section 2 – Installation ................................................ 22

1.3

Safety................................................................... 5

2.1

Location and Support ....................................... 22

1.4

Generator AC Connection System ....................... 5

2.2

Generator Compartments ................................. 23

1.5

Specifications ...................................................... 5

2.3

Cooling and Ventilating Air ................................ 26

Section 2 – Operation .................................................... 7

2.4

Gasoline Fuel System ........................................ 26

2.1

Generator Control Panel....................................... 7

2.5

Exhaust System................................................. 27

2.2

Optional Remote Start/Stop Panel ........................ 7

2.6

Electrical Connections....................................... 28

2.3

Automatic Choke .................................................. 7

2.7

Battery Installation... ......................................... 31

2.4

Before Starting the Engine ................................... 7

2.8

Optional Accessories ......................................... 31

2.5

Starting the Generator ......................................... 8

2.6

Stopping the Generator ........................................ 9

Section 3 – Post-installation Start-up
Adjustments.............................................. 32

2.7

Applying Loads to Generator................................ 9

3.1

Post Installation Tests ....................................... 32

2.8

Do Not Overload the Generator ............................ 9

3.2

Before Initial Start-up........................................ 32

2.9

Protection Systems ............................................... 9

3.3

Initial Start ........................................................ 32

2.10 Additional Information ....................................... 10

3.4

Testing Under Load ........................................... 32

Section 3 – Maintenance .............................................. 11

3.5

Installation Checklist......................................... 33

3.1

Checking the Engine Oil Level ............................ 11

3.2

Changing the Engine Oil and/or Oil Filter .......... 11

3.3

Maintaining the Engine Air Cleaner .................... 12

3.4

Clean Air Intake ................................................. 13

Appendix
Appendix
Appendix
Appendix
Appendix

3.5

Checking the Engine Spark Plug ........................ 13

3.6

Fuel Filter ........................................................... 13

3.7

Spark Arrestor Service....................................... 13

3.8

Cleaning the Generator ...................................... 14

3.9

Battery Maintenance ........................................... 14

1
2
3
4
5

–
–
–
–
–

Notes ...................................................... 34
Troubleshooting ................................... 35
Electrical Data ...................................... 36
Exploded Views and Parts Lists ....... 38
Warranty ................................................ 48

3.10 Major Service Manual......................................... 15
3.11 Exercising the Generator .................................... 15
3.12 Out of Service Procedure.................................... 15
3.13 Adjusting Valve Clearance................................... 15
3.14 RV Generator Service Interval ............................ 16

Safety Rules
Recreational Vehicle Generator



SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe
operation be copied and posted in potential hazard areas of the recreational vehicle.
Safety should be stressed to all operators and potential operators of this equipment.



WARNING:



The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.



WARNING:



This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become
familiar with this manual and with the unit. The generator can operate safely, efficiently and 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 warnings in this manual, and on tags and decals affixed
to the unit, are, therefore, not all-inclusive. If using
a procedure, work method or operating technique
the manufacturer does not specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method or operating technique utilized does not render the generator unsafe.

DANGER
the safe design of this generator,
 Despite
operating this equipment imprudently, neglecting
its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
lethal voltages are generated by
 Potentially
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
of the generator are rotating and/or hot
 Parts
during operation. Exercise care near running
generators.

 GENERAL HAZARDS 
• For safety reasons, the manufacturer recommends
that the installation, initial start-up and maintenance of this equipment is carried out by an
Authorized Service Dealer.
2



• The generator engine releases DEADLY carbon
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death.
Never operate the generator set with the vehicle
inside any garage or other enclosed area. 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) 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.
• Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon
monoxide detector. The exhaust system must be
installed in accordance with the genset installation
manual. Make sure there is ample fresh air when
operating the genset in a confined area.
• The engine exhaust fumes contain carbon monoxide, 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 compliance with applicable codes and standards.
Following installation, do nothing that might render the system unsafe or in noncompliance with
such codes and standards. The generator compartment 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 ventilating air is critical to correct generator operation and is required to expel toxic fumes and fuel
vapors from the generator compartment. Without
sufficient cooling airflow, the engine/generator
quickly overheats, which causes serious damage
to the generator. Do not alter the installation or
permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of
the generator.

Safety Rules
Recreational Vehicle Generator

• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and contact the
nearest Authorized Service Dealer immediately for
parts needing repair or replacement.
• Before performing any maintenance on the generator, 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 conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.

 ELECTRICAL HAZARDS 
• The generator covered by this manual produces
dangerous electrical voltages and can cause fatal
electrical shock. Avoid contact with bare wires, terminals, 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 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.
• In case of accident caused by electric shock, immediately shut down the source of electrical power.
If this is not possible, attempt to free the victim
from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim
from the live conductor. If the victim is unconscious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.

 FIRE HAZARDS 
• For fire safety, the generator must be installed
and maintained properly. Installation always must
comply with applicable codes, standards, laws
and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installation, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regulations.
• Keep a fire extinguisher in the vehicle at all times.
Extinguishers rated “ABC” by the National Fire
Protection Association are appropriate for use on
the recreational vehicle generator electrical system. Keep the extinguisher properly charged and
be familiar with its use. If there are any questions
pertaining to fire extinguishers, consult the local fire
department.

Section 1 – General Information
Recreational Vehicle Generator

1.1

GENERATOR IDENTIFICATION
Please record the following information from the generator DATA DECAL or information decal.
1. Model Number _____________________

2. Serial Number __________________

3. kW Rating _________________________

4. Rated Voltage __________________

Model: 004700-0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Generator Air Intake
Engine Start/Stop Switch
Fuse
Optional Remote Panel Receptacle (Side View)
Generator AC Output Leads (Side View)
Fuel Primer Switch
Circuit Breaker
Starter Contactor
Fuel Inlet
Fuel Pump (Behind Access Panel)

14,16

11.
12.
13.
14.
15.
16.
17.

2 6
7
3

CONTROL CENTER
C .B .
3 0 A

F U E L

S T A R T

S T O P

P R IM E

F U S E
15 A

S E R V IC E

A C C E S S

P A N E L

MAINTENANCE SCHEDULE
CHECK DAILY

AIR FILTER:

CLEAN PREFILTER
EVERY 100 HOURS. *
REPLACE ELEMENT
EVERY 250 HOURS. *

OIL & OIL FILTER:

CHANGE EVERY 100
HOURS. (OR ANNUALLY) *

SPARK PLUGS:

INSPECT & CLEAN
PLUGS EVERY 100
HOURS. REPLACE PLUGS
EVERY 500 HOURS.
(IF NECESSARY)

D
, W
ter
ew a

4
5

10/15

AIR FILTER LOCATED BEHIND PANEL.

OIL LEVEL:

Fuel Filter (Side View)
Oil Filter
Oil Drain Cap
Oil Dipstick
Air Filter (Behind Access Panel)
Oil Fill
Spark Plug

PERFORM MORE OFTEN IN DUSTY CONDITIONS

FUEL FILTER:

CHANGE EVERY 400
HOURS. (OR ANNUALLY)

REPLACEMENT INFORMATION

PREFILTER P/N:
AIR FILTER P/N:
OIL FILTER P/N:
SPARK PLUG P/N:
FUEL FILTER P/N:
OIL CAPACITY WITH FILTER:

TEMPERATURE
32˚F AND HIGHER
10˚F TO 100˚F
0˚F TO 80˚F
-20˚F TO 50˚F

RAC OHVI INDUSTRIAL ENGINE

0D4511
0D3262
070185
072347
0D7515
0.8L/0.84QT

SAE VISCOSITY
30
15W-40
10W-30
5W-30

PACT 40G
RV SERVICE LOCATOR:

WHEN SERVICE OR PARTS ARE NEEDED IN
THE USA OR CANADA, CONTACT THE GENERAC
SERVICE LOCATOR AT 1-800-333-1322.

13 12

9/11

1.800.333.1322

Section 1 – General Information
Recreational Vehicle Generator

1.2

GENERATOR APPLICABILITY

These generators have been designed and manufactured 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 application,
contact an Authorized Service Dealer. Do not use the
unit until advised by a competent authority.

DANGER
fire safety, the generator must have been
 For
properly installed in compliance with ANSI
119.2-1975/NFPA 501C-1974, “Standard for
Recreational Vehicles, Part III – Installation of
Electrical Systems.” The generator also must
have been installed in strict compliance with the
manufacturer’s detailed installation instructions.
After installation, do nothing that might render
the unit in noncompliance with such codes, standards and instructions.
Use this generator to supply electrical power for
operating 120-volt, single-phase, 60 Hertz, AC electrical loads. These loads can require up to 3,600 watts
(3.6 kW) of power, but cannot exceed 30 AC amperes
of current at 120 volts.

not overload the generator. Some installa Do
tions may require that electrical loads be alternated to avoid overloading. Applying excessively
high electrical loads may damage the generator
and may shorten its life. Add up the rated watts
of all electrical lighting, appliance, tool and
motor loads the generator will power at one
time. This total should not be greater than the
wattage capacity of the generator. If an electrical device nameplate gives only volts and amps,
multiply volts times amps to obtain watts (volts
x amps = watts). Some electric motors require
more watts of power (or amps of current) for
starting than for continuous operation.

1.3

SAFETY

Before attempting to use the generator set, carefully read the “Safety Rules” section of this manual.
Comply strictly with these rules to prevent accidents
and damage to equipment and/or property. We suggest copying and posting the “Safety Rules” in potential hazard areas of the vehicle. Stress safety to all
operators and potential operators of this equipment.

1.4

GENERATOR AC
CONNECTION SYSTEM

This generator set is equipped with dual stator AC
power windings. These two-stator windings supply electrical power to customer electrical loads by
means of a two-wire connection system. Note, however, that the neutral is bonded to the frame of the
engine-generator.
The generator may have been installed so that it powers 120-volt AC loads (Figure 1.1). It can be wired to
connect 120-volt AC electrical loads. This procedure
should be done by an Authorized Service Dealer or
other qualified installer.

Figure 1.1 – Connections for 120 Volts Only

1.5

SPECIFICATIONS

1.5.1 FUEL REQUIREMENTS
This generator is equipped with a gasoline fuel system. Depending on the installation, the generator may
have either a separate fuel tank, or it may “share” the
vehicle engine’s fuel tank.
NOTE:
Some installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter
than the vehicle engine’s pickup tube. Such an
arrangement causes the generator engine to “run
out of gas” while adequate fuel for the vehicle
remains in the tank.
To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator. Leaded
REGULAR grade gasoline is an acceptable substitute.
NOTE:
Using unleaded gasoline contributes to longer
engine valve life by reducing lead and carbon
deposits.

Section 1 – General Information
Recreational Vehicle Generator

1.5.5 GENERATOR



The manufacturer does not recommend using
any gasoline containing alcohol (such as “gasohol”). If using any gasoline containing alcohol, it
must not contain more than 10 percent ethanol,
and it must be removed from the generator during storage. Do NOT use any gasoline
containing methanol. If using gasoline with alcohol, inspect more frequently for fuel leaks and
other abnormalities.

1.5.2 FUEL CONSUMPTION
Model
004700-0

No Load

1/2 Load

Full Load

0.24

0.35

0.55

Fuel consumption is in gal/hr.

Rated Maximum Continuous
AC Output (Gasoline)...........................3,600 Watts (3.6 kW)
Rated Voltage ....................................................... 120 Volts AC
Rated Maximum Continuous
AC Current (Gasoline) ....................................... 30 Amperes
Phase .............................................................................. Single
Rotor RPM.......................................................................3,600
Number of Rotor Poles...........................................................2
Engine RPM.....................................................................3,600
Rated AC Frequency....................................................... 60 Hz
Battery Charge Voltage ..........................................14 Volts DC
Battery Charge Current................................ 2 Amperes (max)
Gasoline weight .....................................................170 Pounds
Length....................................................749.8 mm (29.52 in.)
Width .....................................................483.1 mm (19.02 in.)
Height ....................................................342.2 mm (13.47 in.)

1.5.3 ENGINE OIL REQUIREMENTS

1.5.6 EMISSIONS COMPLIANCE PERIOD

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:

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.

• During summer months: SAE 30. An acceptable
substitute is SAE 10W-30.
• During winter months: SAE 5W-30. DO NOT USE
SAE 10-W40.
Crankcase and oil filter capacity is approximately
800 mL or .84 U.S. quarts. Do NOT use special additives. See Sections 3.1 and 3.2 for oil level check and
fill procedures.

1.5.4 ENGINE
Type of Engine................................... GN-220, Single-cylinder
Cooling Method ........................................................Air-cooled
Rated Horsepower .......................................7.8 @ 4,200 rpm
Displacement.................................................................. 220cc
Cylinder Block ......................... Aluminum w/Cast Iron Sleeve
Type of Governor .............................Mechanical, Fixed Speed
Air Cleaner ........................Paper Element w/Foam Precleaner
Starter ....................................................... 12-volt DC Electric
Ignition System ..................... Solid-state w/Flywheel Magneto
Recommended Spark Plug
Champion ................................................................ RC14YC
AC.................................................................................. R45S
Fram Autolite .....................................................................65
Spark Plug Gap....................................... 0.030 inch (76 mm)
Recommended Minimum Battery..............400 Cold-cranking
Amperes

• For engines less than 225 cc displacement, Category
C=125 hours, B=250 hours, and A=500 hours.
• For engines of 225 cc or more, Category C=250
hours, B=500 hours, and A=1000 hours.

Section 2 – Operation
Recreational Vehicle Generator

2.1

GENERATOR CONTROL PANEL

The following features are mounted on the generator
control panel (Figure 2.1):

Figure 2.1 – Generator Control Panel
CONTROL CENTER
S T A R T

F U E L

S T O P

P R IM E

C .B .
3 0 A

FUS E
7. 5 A

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 0F0429 or 0F0430, 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 periodic maintenance requirements
on the unit.

2.3

AUTOMATIC CHOKE

The engine is equipped with an automatic choke that
consists of two main components: a choke solenoid
and prechoke.

2.1.1 FUEL PRIMER

2.3.1 CHOKE SOLENOID

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 bring fuel
from the tank to the carburetor. This rocker type
switch springs back into its original position when
released.

During engine cranking (Start/Stop switch at START),
a solid-state choke module signals the choke solenoid to activate and cycle (choke on/choke off) until
the engine starts. The choke solenoid thus opens
and closes the carburetor choke valve only when the
engine is cranking. When the engine starts, the choke
stops cycling.

2.1.2 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.

2.1.3 FUSE
The fuse protects the engine’s DC control circuit
against electrical overload. If the fuse element has
melted open due to overloading, the engine cannot
be cranked. If the fuse must be replaced, use only an
identical replacement.

2.1.4 MAIN BREAKER
The main breaker protects the generator’s AC output
circuit against overload and provides a method of
turning OFF the generator’s 120-volt AC output to the
vehicle circuits. This generator has 30-amp breaker.

2.3.2 PRECHOKE
The choke system also has a temperature-sensitive
metal strip that adjusts choke valve angle according
to ambient temperatures (i.e., in cold ambient temperatures, choke valve closes more). Once the engine
starts, an element heats the temperature-sensitive
strip to a normal operating condition, opening the
choke valve. This may take about three minutes in
cooler weather.

2.4

BEFORE STARTING THE ENGINE
NOTE:

Instructions and information in this manual
assume the generator has been properly installed,
connected, serviced, tested and adjusted by a
qualified installation technician or installation
contractor.

2.4.1 INSTALLATION
Generator installation must have been properly completed so it complies with all applicable codes, standards and regulations and with the manufacturer's
recommendations.

Section 2 – Operation
Recreational Vehicle Generator

2.4.2 ENGINE LUBRICATION
Have the engine crankcase properly serviced with the
recommended oil before starting. Refer to Section
1.5.4, and Sections 3.1 and 3.2 for oil servicing procedures and recommendations.

attempt to crank or start the engine before
 Any
it has been properly serviced with the recommended oil may result in an engine failure.

2.4.3 FUEL SUPPLY
The engine must have an adequate supply of proper
fuel to operate. Before starting it, check that sufficient fuel is available.
NOTE:
Depending on the installation, the generator may
have either a separate fuel tank, or it may “share”
the vehicle engine’s fuel tank.

2.4.4 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. Without sufficient cooling
and ventilating airflow, the engine/generator quickly
overheats, which causes it to shut down and may
damage the generator.

2.4.5 ENGINE EXHAUST GAS
Before starting the generator engine, be sure there is
no way for exhaust gases to enter the vehicle interior
and endanger people or animals. Close windows,
doors and other openings in the vehicle that, if open,
might permit exhaust gases to enter the vehicle.

DANGER
generator engine releases DEADLY carbon
 The
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even
death. Never operate the generator set with
the vehicle inside any garage or other enclosed
area. 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) 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.
8

DANGER
sleep in the vehicle while the genset is
 Never
running unless the vehicle has a working carbon
monoxide detector. The exhaust system must be
installed in accordance with the genset installation manual. Make sure there is ample fresh air
when operating the genset in a confined area.

2.5

STARTING THE GENERATOR
NOTE:

Read the vehicle manufacturer’s instructions.
The owner/operator should become familiar with
the vehicle in which this generator is installed.
Differences exist between vehicles. For example,
some vehicles may use a transfer switch to isolate
dockside power from the generator, while other
vehicles may use an isolating receptacle. Some
vehicles may be equipped with a DC converter,
which allows the generator to power certain DC
lighting and other DC loads.
To start the generator from either the generator control panel or from the optional remote panel, proceed
as follows:
1. Turn OFF electrical loads using the means provided in the vehicle (such as a main line circuit
breaker or transfer switch).
NOTE:
If starting from the generator control panel, turn
OFF loads by setting the generator’s main circuit
breaker to the OFF (or open) position. If starting
from a remote panel, turn OFF loads using the
means provided in the vehicle (such as a main
circuit breaker). Electrical load circuits will be
turned ON after the generator has started, stabilized and warmed up.
2. If the engine has not been started in more than
two weeks, press the Fuel Pump Primer switch
and hold it for about 10 to 15 seconds to prime
the fuel system. However, if the engine is warm,
skip Step 2.
3. Hold the engine Start/Stop switch in the START
position to crank the engine. Release the switch
when the engine starts.

the engine does not start after it has been
 Ifcranking
for 15 seconds, release the Start/Stop
switch, wait one minute and try again. Holding
the switch for longer than 15 seconds can damage the starter motor.
4. Let the engine run at no-load for a few minutes to
stabilize and warm up.
5. Turn ON electrical loads using the means provided (such as a main circuit breaker or transfer
switch).

Section 2 – Operation
Recreational Vehicle Generator

2.6

STOPPING THE GENERATOR

1. Turn OFF all electrical loads using the means
provided (such as a main circuit breaker or
transfer switch).
2. Let generator run at no-load for a few minutes, to
stabilize internal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position.

2.7

APPLYING LOADS TO GENERATOR

When applying electrical loads to the generator,
observe these guidelines:
• Before applying electrical loads, let the generator
stabilize and warm up for a minute or two.
• DO NOT overload the generator.

2.7.1

LETTING THE ENGINE STABILIZE

The generator supplies correct rated voltage only at
the proper governed speed. Some electrical appliances may be extremely sensitive to voltage. Incorrect
voltages can damage such appliances.
If electrical loads are applied at reduced operating
speeds, such loads imposed on the engine when sufficient power is not available may shorten engine life.
Never turn ON electrical loads until after the generator
engine has started and stabilized at no-load.

2.8

DO NOT OVERLOAD THE
GENERATOR

Read the rated wattage/amperage capacity of the generator on the generator data label (see Section 1.1).
Applying electrical loads in excess of the unit’s rated
capacity will cause the engine/generator to automatically shut down.

• Induction type motors (such as those that run the
vehicle’s furnace fan, refrigerator, air conditioner,
etc.) need about 2-1/2 time more watts of power for
starting than for running (for a few seconds during
motor starting). Be sure to allow for this when connecting electrical loads to the generator. First, figure the watts needed to start electric motors in the
system. To that figure, add the running wattages of
other items that will be operated by the generator.
• Do not apply heavy electrical loads for the first two
or three hours of operation.

2.9

PROTECTION SYSTEMS

2.9.1 LOW OIL PRESSURE SWITCH
This switch (Figure 2.2) has normally closed (N.C.)
contacts that are held open by engine oil pressure during cranking and operating. Should oil pressure drop
below a preset level, switch contacts close, and the
engine automatically shuts down. The unit should not
be restarted until oil is added.

2.9.2 HIGH TEMPERATURE SWITCH
This switch (Figure 2.2), which has normally open
(N.O.) contacts, is mounted near the oil filter. The
contacts close if the temperature should exceed
approximately 284º F (140º C), initiating an engine
shutdown.

Figure 2.2 – Low Oil Pressure and
High Temperature Switches
High Temperature Switch
Low Oil Pressure
Switch

To avoid overloading, add up the wattage of all connected electrical lighting, appliance, tool and motor
loads. This total should not be greater than the
generator’s rated wattage capacity.
• Most lighting, appliance, tool and motor loads
indicate their required watts on their nameplate or
data plate. For light bulbs, simply note the wattage
rating of the bulb.
• If a load does not show its rated wattage, multiply
that load’s rated VOLTS times AMPS to obtain
WATTS.

Section 2 – Operation
Recreational Vehicle Generator

2.9.3 FIELD BOOST
The Controller Circuit Board houses a field boost
diode and resistor that are not part of the automatic
choke circuit. These two components are part of
a “field boost” circuit (Figure 2.3). 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

2.9.4 OVERVOLTAGE PROTECTION
A solid-state voltage regulator (Figure 2.4) controls
the generator’s AC output voltage. This regulator supplies an excitation current to the rotor. By regulating
the rotor’s excitation current, the strength of its magnetic field is regulated and, in turn, the voltage delivered to connected electrical loads is controlled. When
the AC frequency is 60 Hertz, voltage is regulated at
120 volts (voltage-to-frequency ratio is 2-to-1).

Figure 2.4 – Solid State Voltage Regulator

The voltage regulator also incorporates a “voltage
surge protection circuit.” This circuit prevents troublesome surges in the generator AC output voltage.
Voltage surge is a common cause of damage to electronic equipment.

2.10 ADDITIONAL INFORMATION
2.10.1 25-HOUR BREAK-IN PERIOD
The first 25 hours of operation is the break-in period
for the generator. Properly breaking in the generator is essential to minimize fuel consumption and
provide maximum engine performance. During this
25-hour break-in period, follow this procedure:
• Run the unit at varying electrical loads to help seat
the engine piston rings properly.
• Check the engine oil level frequently. Add oil if
needed. It is normal for the generator engine to
consume more oil than is normal until the piston
rings have properly seated.
• For the 75-hour operation following the break-in
period, avoid light electrical loads. Load the generator at 50 percent (or more) of its rated wattage capacity. Repeated light loads during these 75
hours can cause improper seating of engine piston
rings, resulting in blowby and high oil consumption.
• After operating the unit for 25 hours, complete the
tasks recommended under Section 2.10.2.

2.10.2 25-HOUR CHECK-UP
After the 25-hour break-in period, contact an
Authorized Service Dealer for the following maintenance. 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.
Inspect the entire electrical system.
Inspect the engine exhaust system.

2.10.3 ATTENTION REQUIRED
AFTER SUBMERSION
If the recreational vehicle generator has been submerged in water, it MUST NOT be started and operated. Following any submersion in water, have an
Authorized Service Dealer thoroughly clean and dry
the generator.

Section 3 – Maintenance
Recreational Vehicle Generator

2.10.4 OPERATION IN HIGH GRASS
OR BRUSH

3.1

Never operate the generator while the vehicle is
parked over high grass, weeds, brush, leaves or any
other combustible substance. Such materials can
ignite and burn from the heat of the exhaust system.
The generator exhaust system becomes extremely
hot during operation and remains hot for a long time
after it has shut down.

For oil capacities and requirements, see “Engine
Oil Requirements,” Section 1.5.4. Check the engine
crankcase oil level at least every eight hours of operation, or before each use. To check the engine oil level,
proceed as follows (see Figure 3.1):

2.10.5 EFFECTS OF MOISTURE AND DIRT
Keep the generator set as clean and dry as possible.
Protect the unit against excessive dust, dirt, corrosive
vapors, road splash, etc. Permitting dirt and moisture to accumulate on generator windings will have
an adverse effect on the insulation resistance of those
windings.
When moisture is 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.

CHECKING THE ENGINE OIL
LEVEL

1. Be sure the generator is as level as possible.
2. Remove the dipstick and wipe it dry with a clean,
lint-free cloth.
3. Install and tighten the dipstick cap; then, remove
it again. The oil level should be at the dipstick
“Full” mark.
4. If necessary, remove the oil fill cap on the rocker
cover and slowly add oil until it reaches the dipstick “Full” mark. DO NOT FILL ABOVE THE
“FULL” MARK.

operate the engine with the oil level
 Never
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.

3.2

CHANGING THE ENGINE OIL
AND/OR OIL FILTER

• Change the engine oil after the first 25 hours of
operation (after the 25-hour break-in period, see
Section 2.10.1). Thereafter, change the oil every
100 operating hours. Change the oil more frequently if operating consistently under heavy load
or at high ambient temperatures.

Figure 3.1 – Oil Maintenance Features
CONTROL CENTER
C .B .
3 0 A

F U E L

S T A R T

S T O P

P R IM E

FUS E
7.5 A

S E R V IC E

A C C E S S

P A N E L

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE
OIL LEVEL:

CHECK DAILY

AIR FILTER:

CLEAN PREFILTER
EVERY 100 HOURS. *
REPLACE ELEMENT
EVERY 250 HOURS. *

OIL & OIL FILTER:

CHANGE EVERY 100
HOURS. (OR ANNUALLY) *

SPARK PLUGS:

INSPECT & CLEAN
PLUGS EVERY 100
HOURS. REPLACE PLUGS
EVERY 500 HOURS.
(IF NECESSARY)

FUEL FILTER:

CHANGE EVERY 400
HOURS. (OR ANNUALLY)

GENERAC
OHVI POWERED

GEN
ER A
C

To Re

REPLACEMENT INFORMATION
PREFILTER P/N:
AIR FILTER P/N:
OIL FILTER P/N:
SPARK PLUG P/N:

ve
mo

, W
ter
P owe
ew a
r S y s t e m s , I n c . - W h it

PERFORM MORE OFTEN IN DUSTY CONDITIONS

0D7515

OIL CAPACITY WITH FILTER:

0.8L/0.84QT

TEMPERATURE
32˚F AND HIGHER
10˚F TO 100˚F
0˚F TO 80˚F
-20˚F TO 50˚F

GENERAC OHVI INDUSTRIAL ENGINE

0D4511
0D3262
070185
072347

FUEL FILTER P/N:

SAE VISCOSITY
30
15W-40
10W-30
5W-30

QUIETPACT 40G
RV SERVICE LOCATOR:

WHEN SERVICE OR PARTS ARE NEEDED IN
THE USA OR CANADA, CONTACT THE GENERAC
SERVICE LOCATOR AT 1-800-333-1322.

1.800.333.1322

Oil Dipstick/Oil Fill

Oil Drain

Oil Filter
11

Section 3 – Maintenance
Recreational Vehicle Generator

• Change the engine oil filter after the first 25 hours
of operation, and every 100 operating hours thereafter.
To change the oil and/or oil filter, proceed as follows
(see Figure 3.1):
1. Run the engine until it is thoroughly warmed up
(at least five minutes) then shut OFF the engine.
2. 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 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 underneath to catch excess oil.
5. Apply a light coating of clean engine oil to the gasket 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 recommended oil (see Section 1.5.4). Periodically use
the dipstick to check the oil level and continue to
fill the crankcase until the oil reaches the dipstick
“Full” mark. DO NOT FILL ABOVE THE “FULL”
MARK.
9. Install and tighten the oil fill cap and the dipstick
before 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.

3.3

MAINTAINING THE ENGINE
AIR CLEANER

3.3.1 CLEANING THE FOAM PRECLEANER
Clean and re-oil the foam precleaner every three
months or every 25 hours of operation, whichever
occurs first. Service the foam precleaner more frequently if operating the generator in extremely dusty
or dirty conditions. Use the following procedure
(Figure 3.2):
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover, foam precleaner and paper filter.
3. Remove the foam precleaner from the cover.
12

4. Wash the foam precleaner in liquid detergent and
water.
5. Wrap the foam precleaner in a clean cloth and
gently squeeze it dry.
6. Saturate the foam precleaner in clean engine
oil. Gently squeeze it in a clean cloth to remove
excess oil and to distribute oil (DO NOT TWIST).
7. Install the foam precleaner into the cover, followed by the paper filter.
8. Install the cover, foam precleaner and paper filter.
9. Tighten the two screws to retain the filter in place.

Figure 3.2 – Engine Air Cleaner

3.3.2 CLEANING OR REPLACING
THE PAPER FILTER
Once each year or every 100 hours of operation
(whichever comes first), clean or replace the paper
filter. The new replacement filter must be flame
retardant. Service the paper filter more frequently if
operating the generator in extremely dusty or dirty
conditions. Use the following procedure (Figure 3.2):
1. Follow steps 1-3 in Section 3.3.1; service the
foam precleaner if necessary.
2. Remove the paper filter.
3. Clean the air filter by tapping it gently on a solid
surface. If the filter is too dirty, replace it with a
new one. Dispose of the old filter properly.
4. Clean the air cleaner cover then reassemble following steps 7-9 in Section 3.3.1.

Section 3 – Maintenance
Recreational Vehicle Generator

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 muffler periodically and remove all grass, leaves, dirt,
etc., from this area.

3.6

FUEL FILTER

Remove and replace the fuel filter (Figure 3.5) once
each year or every 400 hours of operation, whichever
comes first. Fuel filter is removed with a 15/16” deep
well socket.

Figure 3.5 – Fuel Filter

Figure 3.3 – Cleaning Air Intake

POS

FUEL

NEG

USTC

3.7
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 questionable.
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).

Figure 3.4 – Setting the Spark Plug Gap

CLEAN SPARK ARRESTOR

The engine exhaust muffler has a spark arrestor
screen. Inspect and clean the screen every 50 hours
of operation or once each year, whichever comes
first.
NOTE:
If using the generator on any forest-covered,
brush-covered or grass-covered unimproved land,
it must equipped with a spark arrestor. The spark
arrestor must be maintained in good condition by
the owner/operator.
Clean and inspect the spark arrestor as follows:
• Remove the screen retaining bracket by removing
the screw.
• Slide the spark arrestor screen out from the tail
pipe.
• Inspect screen and replace if torn, perforated or
otherwise damaged. DO NOT USE a defective
screen. If screen is not damaged, clean it with commercial solvent.
• Replace the screen and the retaining bracket.

Figure 3.6 - Spark Arrestor

TAILPIPE
P/N 0E0683

can occur if the wire terminal does not
 Sparking
fit firmly on the spark plug terminal end. If necessary, re-form the wire terminal to obtain a
tight fit.

SPARK ARRRESTOR
SCREEN P/N 089680
RETAINING
SCREW P/N 056892
13

Section 3 – Maintenance
Recreational Vehicle Generator

3.8

CLEANING THE GENERATOR

Keep the generator set as clean and dry as possible.
Protect the unit against excessive dust, dirt, corrosive
vapors, road splash, etc. Permitting dirt and moisture to accumulate on generator windings will have
an adverse effect on the insulation resistance of those
windings.
When moisture is allowed to remain in contact with
windings, some of the moisture will be retained in
voids and cracks in the insulation. This causes a
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.

NOT use a forceful spray of water to clean
 Do
the generator. Water will enter the generator
interior and cause problems, and may also contaminate the generator fuel system.

3.9

BATTERY MAINTENANCE

All lead-acid batteries will discharge when not in
use. The generator battery should be inspected as
follows:

DANGER
not dispose of the battery in a fire. The
 Do
battery is capable of exploding. Storage batteries give off explosive hydrogen gas. This gas can
form an explosive mixture around the battery
for several hours after charging. The slightest
spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery
and cause blindness or other injury. Any area
that houses a storage battery must be properly
ventilated. Do not allow smoking, open flame,
sparks, or any spark producing tools or equipment near the battery. Discharge static electricity from body before touching the battery by
first touching a grounded metal surface.
presents a risk of electrical shock
 Aandbattery
high short circuit current. The following precautions 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.

3.9.1 WEEKLY
• Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
• Check the battery fluid level of unsealed batteries
and, if necessary, fill with Distilled Water Only. Do
not use tap water in batteries.

not open or mutilate the battery. Released
 Do
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
electrolyte is a dilute sulfuric acid that is
 The
harmful to the skin and eyes. It is electrically

3.9.2 EVERY SIX MONTHS
• Have the state of charge and condition checked.
This should be done with an automotive-type battery hydrometer.
NOTE:
Servicing of the battery is to be performed or
supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.
Damage will result if the battery connections are
made in reverse.

•
•
•
•

conductive and corrosive. The following
procedures are to be observed:
Wear full eye protection and protective clothing;
Where electrolyte contacts the skin, wash it off
immediately with water;
Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or water. The bicarbonate 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.

Section 3 – Maintenance
Recreational Vehicle Generator

3.10 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.

3.11 EXERCISING THE GENERATOR
The manufacturer recommends that the generator be
started and operated at least once every seven days.
Let the unit run for at least 30 minutes to “exercise”
the engine.

3.12 OUT OF SERVICE PROCEDURE
3.12.1 REMOVAL FROM SERVICE
If the generator cannot be exercised every seven days,
and it is to be out of service longer than 30 days, prepare the generator for storage as follows:
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
Note:
Using a fuel additive such as STA-BIL fuel stabilizer, 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
SF.”
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.

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 necessary 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
unit’s rated wattage capacity.
8. When the engine is thoroughly warmed up, shut
it down.
9. The generator is now ready for service.

3.13 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:
1. 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 3.7).

Figure 3.7 — Adjusting Valve Clearance

3.12.2 RETURN TO SERVICE
To return the unit to service after storage, proceed
as follows:
1. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recommended oil is used in the engine (see Section 1.5.4). If
necessary, drain and refill with the proper oil.
2. Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with distilled water. DO NOT USE TAP WATER IN THE
BATTERY. Recharge the battery to 100 percent
state of charge, or, if defective, replace the battery.
3. Clean and wipe the entire generator.
15

Section 3 – Maintenance
Recreational Vehicle Generator

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 3.8).

Figure 3.8 — Tightening Jam Nut

3.14 RV GENERATOR SERVICE
INTERVAL
50 Hours ................................ Clean Spark Arrestor
100 Hours ...........................Change Engine Oil/filter
100 Hours .................................. Clean Air Pre-filter
100 Hours ................................ Inspect Spark Plugs
250 Hours ............ Replace Paper Air Filter Element
400 Hours ...................................Replace Fuel Filter
500 Hours ................................Replace Spark Plugs
1st 50 Hours-then
every 500 Hrs. .......................... Adjust Valve Lash

PART II –
INSTALLATION
INSTRUCTIONS

DANGER

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!!

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, installation
must comply with the manufacturer’s instructions and recommendations.

NOTICE TO INSTALLER
These Installation Instructions have been published
by the manufacturer to aid in the installation of the
products described in this manual. The manufacturer assumes that installation personnel are familiar
with the procedures for installing such products, or
similar products manufactured. The manufacturer
also assumes that personnel have been trained in
the recommended installation procedures for these
products and that such training includes (a) use of
common hand tools, (b) use of special tools, and (c)
use of any tools and/or equipment from other suppliers.
The manufacturer cannot possibly know of and
advise the recreational vehicle trade of all conceivable methods, procedures or techniques by which to
perform an installation. Nor can we anticipate every
possible hazard that might result from each installation method, procedure or technique. The manufacturer has not undertaken any such wide evaluation.
Therefore, people who use a method, procedure or
technique that the manufacturer does not specifically
recommend must first completely satisfy themselves
that their safety, the safety of the vehicle's occupants
and the product's safety is not endangered by the
method, procedure or technique selected.
Information, illustrations, specifications, etc., contained in these Installation Instructions are based on
the latest information available at the time of publication. Every effort has been expended to be sure that
such data is both accurate and current. However, the
manufacturer reserves the right to change, alter or
otherwise improve this product at any time without
prior notice.



 GENERAL HAZARDS 
• For safety reasons, the manufacturer recommends
that the installation, initial start-up and maintenance of this equipment is carried out by an
Authorized Service Dealer.
• The engine exhaust fumes contain carbon monoxide, 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 compliance with applicable codes and standards.
Following installation, do nothing that might render the system unsafe or in noncompliance with
such codes and standards. The generator compartment 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 ventilating air is critical to correct generator operation and is required to expel toxic fumes and fuel
vapors from the generator compartment. Without
sufficient cooling airflow, the engine/generator
quickly overheats, which causes serious damage
to the generator. Do not alter the installation or
permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of
the generator.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Before performing any maintenance on the generator, 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 conditions from leaking exhaust gases, fuel leakage,
oil leakage, etc.
• Never insert any tool or other object through openings in the generator interior, even if the unit is not
running. Serious injury or damage to the equipment may occur.

Safety Rules
Recreational Vehicle Generator

 ELECTRICAL HAZARDS 

 FIRE HAZARDS 

• The generator covered by this manual produces
dangerous electrical voltages and can cause fatal
electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running.
Ensure all appropriate covers, guards and barriers
are in place before operating the generator. If work
must be done around an operating unit, stand on
an insulated, dry surface to reduce shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• During installation onto the vehicle, properly
ground (bond) the generator either by solid mounting 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 vehicle circuits at the same time. The dockside (utility)
power source must be positively isolated from the
vehicle circuits whenever the generator is operating. Failure to isolate the vehicle circuits from
the dockside power supply when the generator is
running may result in damage to the generator or
serious injury or death to dockside (utility) power
workers due to backfeed of electrical energy.
• In case of accident caused by electric shock, immediately shut down the source of electrical power.
If this is not possible, attempt to free the victim
from the live conductor. AVOID DIRECT CONTACT
WITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim
from the live conductor. If the victim is unconscious, apply first aid and get immediate medical
help.
• Never wear jewelry when working on this equipment. Jewelry can conduct electricity resulting in
electric shock, or may get caught in moving components causing injury.

• For fire safety, the generator must be installed
and maintained properly. Installation always must
comply with applicable codes, standards, laws
and regulations. Adhere strictly to local, state and
national electrical and building codes. Comply
with regulations the Occupational Safety and
Health Administration (OSHA) has established.
Also, ensure that the generator is installed in
accordance with the manufacturer’s instructions
and recommendations. Following proper installation, do nothing that might alter a safe installation
and render the unit in noncompliance with the
aforementioned codes, standards, laws and regulations.
• Keep a fire extinguisher in the vehicle at all times.
Extinguishers rated “ABC” by the National Fire
Protection Association are appropriate for use on
the recreational vehicle generator electrical system. Keep the extinguisher properly charged and
be familiar with its use. If there are any questions
pertaining to fire extinguishers, consult the local fire
department.

 EXPLOSION HAZARDS 
• Do not smoke around the generator. Wipe up any
fuel or oil spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
• Gasoline is extremely FLAMMABLE and its vapors
are EXPLOSIVE. Do not permit smoking, open
flame, sparks or any source of heat in the vicinity
while handling gasoline. Comply with all laws governing the storage and handling of gasoline.
• Fuel lines must be properly installed and fastened,
and free of leaks. There must be no possibility of
gasoline vapors entering the vehicle interior.
• It is required to install an approved, flexible, nonconductive fuel line between the generator fuel connection point and rigid fuel lines.

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
product's installation requirements. Give serious
consideration to all information and instructions in
the manual, both for safety and for continued reliable
operation of the equipment.
Because of the different recreational vehicle models and the variations between the models, it would
be extremely difficult, if not impractical, to provide
detailed instructions for every possible installation.
For that reason, instructions and illustrations in this
manual are general in nature. Illustrations are not
intended to serve as detailed installation blueprints.
The installation should comply strictly with all applicable codes, standards and regulations pertaining
to the installation and use of this product. If any
portion of this manual appears to be in conflict with
such codes, standards or regulations, the applicable
codes, standards or regulations must take precedence over the manual.

1.2

SAFETY

Before handling, installing, operating or servicing this
equipment, carefully read the “Notice to Installer”
and “Safety Rules”. Comply with all safety rules to
prevent death, personal injury or damage to equipment and/or property. Stress safety to all installers,
operators and service technicians who work on this
equipment.

1.3

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 30.0 amps.

1.5

GENERATOR ENGINE
OPERATING SPEED

The generator’s revolving field (rotor) is driven by a
single-cylinder, four-cycle engine. The generator supplies 120 volts AC at 60 Hertz when the rotor is operating 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

BLACK

STANDARDS BOOKLETS

Installation, use and servicing of this equipment
should comply strictly with published standards, as
well as the manufacturer's recommendations. The
following standards booklets (latest revision) are
available from the sources indicated:
1. NFPA Standard 501C, “Standard for Recreational
Vehicles,” available from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.
2. NFPA 70, “NFPA Handbook of the National
Electric Code,” available same as Item 1.
3. ANSI C1-1975 and ANSI 119.2-1975, available
from the American National Standards Institute,
1430 Broadway, New York, NY 10018.
4. ANSI A119.2/NFPA 501C, available from the
Recreational Vehicle Association, 1896 Preston
White Drive, Reston, VA 22090.
5. California Administrative Code, Title 25, available
from the State of California, Documents Section,
P.O. Box 1015, North Highlands, CA 95660.
20

• The AC connection system on air-cooled generators uses a GROUNDED neutral.
• A separate green ground wire is connected to the
recreational vehicle’s junction box.
NOTE:
Do NOT connect loads in excess of circuit breaker
ratings.

476.4
[ 18 3/4"]

376.5
[ 14 13/16"]

55.5
[ 2 3/16"]

429.5
[ 16 15/16"]

TAIL PIPE
EXIT

342.2
[ 13 1/2"]

29
[ 1 1/8"]

48.1
[ 1 7/8"]

416
[ 16 3/8"]

HOT AIR
EXHAUST

TYP.
6.7
[ 1/4"]

222.7
[ 8 3/4"]

50.8
[2"]
210
[ 8 1/4"]

369.7
[ 14 9/16"]

343.4
[ 13 1/2"]

300.7
[ 11 13/16"]

101
[ 4"]

82.5
[ 3 1/4"]

423.2
[ 16 11/16"]

736.4
[ 29"]

OIL DRAIN

FRONT DOOR ACCESS FOR
ALL REQUIRED MAINTENANCE

REF.
749.8
[ 29 1/2"]

688.3
[ 27 1/8"]

83.5
[ 3 5/16"]

170
[ 6 11/16"]

176.6
[ 6 15/16"]

5/16"-18 WELDNUTS
(6 PLACES)

36.5 [ 1 7/16"]

AIR
INTAKE

60
[ 2 3/8"]

79
[ 3 1/8"]

717.7
[ 28 1/4"]

VIEW FROM TOP

63.5
[ 2 1/2"]

223.5
[ 8 13/16"]

118
[ 4 5/8"]

360.5
[ 14 3/16"]

414.5
[ 16 5/16"]

REF.
483.1
[ 19"]

BATTERY
CONNECTIONS

AC OUTPUT
HARNESS

FUEL FILTER

REMOTE PANEL
CONNECTOR

NOTE: ALL AIR INTAKES AND EXHAUST OUTLETS MUST BE
KEPT CLEAR OF ANY OBSTRUCTIONS. ALL OPEN AREA
IS REQUIRED FOR COOLING.

Section 1 – General Information
Recreational Vehicle Generator

Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-G)

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 reinforce.
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 framework that is part of the recreational vehicle, as
outlined in Section 2.1.2.
• The location must provide an access opening
that is large enough to permit generator removal
(unless the generator is to be removed from underneath the supporting framework).
• The location must provide easy access to frequently serviced components, such as filters, oil drains,
spark plugs and other common maintenance
parts.
• The location must provide sufficient room to allow
minimum clearances as outlined in Section 2.2. If
sound insulation is to be used on the compartment
walls and ceiling, the minimum recommended
applies to the space between the generator and
such insulation.
• The location must provide adequate cooling and
ventilating airflow for the generator without a great
deal of work and expense.
• If mounting the generator in an enclosed compartment, the base of the generator must rest flat on
the floor without any gaps.
• When using a suspended mounting system, ensure
the base of the generator is flush with the surrounding bodywork. If the unit is mounted higher
in the structure, heated air may recirculate into the
generator causing it to overheat.

2.1.2 GENERATOR SUPPORT
The generator must be securely attached to a metal
framework that has been made part of the vehicle
frame structure by bolting or welding. The metal
framework on which the generator will rest and
which will restrain the generator set should consist
of at least two horizontal beams. These beams should
consist of (a) 1-1/2-inch square, 11-gauge steel tubing OR (b) 1-1/2-inch, 11-gauge angle iron. A typical
supporting frame with horizontal support tubing, is
shown in Figure 2.1.

The generator can be installed so that it sits on top
of the horizontal support tubing if the vehicle design
permits. Another method is to suspend the generator below the horizontal support tubing by means of
suitable, structurally sound metal framework. The
following general rules apply:
• Vehicle construction MUST be capable of supporting the weight of the generator.
• Whether the generator is mounted above the horizontal support tubing or suspended below the tubing, the supporting frame used must be structurally sound.
• If the generator cannot be bolted directly to the
supporting frame or support tubing, consider
using additional tubing, angle brackets or other
supports to give the supporting frame sufficient
strength.

Figure 2.1 – Typical Horizontal Support Frame

2.1.3 SUSPENDED MOUNTING
If the generator will be suspended below the horizontal support tubing, the suspension method used
with the vehicle frame members must (a) be able to
support the weight of the generator AND (b) provide
sufficient restraint for the generator. One typical suspended mounting system is shown in Figure 2.2. The
location of a suspended mounting system must be
carefully planned, keeping the following general rules
in mind:
• Protect the generator against road splash and
debris. Baffles or splash guards may be required to
protect certain areas of the generator. To make sure
the generator is adequately protected, road test the
installation through mud, water and slush.

Figure 2.2 – Typical Suspended Mounting System

GENERATOR
SUPPORT FRAME
(MODEL 004718-0)

GENERATOR MOUNTING
HOLES FOR 5/16" - 18
BOLTS (6 PLACES)

Section 2 – Installation
Recreational Vehicle Generator

• The installer must make certain that the selected
location will permit adequate cooling and ventilating airflow to be supplied.

2.1.4 GENERATOR RESTRAINT
Use four 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 supporting framework (Figure 2.3). All bolts must be long
enough so that when tight, at least three threads are
visible past the retaining lock nuts. Refer to Section
2.2 for the location of the generator mounting holes.

Figure 2.3 – Typical Generator Restraint

NOTE:
Refer to “Figure 1.2 – Major Features and
Dimensions”.

2.2.2 COMPARTMENT CONSTRUCTION
• The generator compartment should be either constructed of, or lined with, 26-gauge galvanized
steel.
NOTE:
Aluminum is NOT an acceptable alternative to
galvanized steel due to aluminum’s low melting
point.
• If the compartment is lined with galvanized steel,
it may be constructed of any material. The manufacturer recommends that the compartment be
constructed of 1/2-inch thick plywood (not strandboard), with the floor made of a double thickness
of 1/2-inch plywood with the grain of the wood at
cross section for added strength (Figure 2.5).

Figure 2.5 – Typical Compartment Construction

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 specifications as outlined in the following sections:

2.2.1 COMPARTMENT SIZE
Plan the compartment size carefully. Provide a minimum clearance of 1/2 inch (13 mm) on the front and
top, 1/2 inch (25 mm) on the sides, and 1/2 inch (13
mm) from the back for air circulation AFTER the
compartment has been lined with metal and sound
insulation (Figure 2.4).

Figure 2.4 – Clearances
Plywood
Compartment
1/2" Clearance on Top
1" Clearance
in Back

1" Each Side
Insulation

1/2"
in Front

ed
end
mm )
eco m 12"
R
nce inimu
ara
Cle w (M
18" Belo

• If constructing a compartment, line the exterior
(underside) of the compartment floor with 26gauge galvanized steel.
• All seams, splices and joints of the compartment
walls (unless vapor tight by design) should be
caulked to prevent poisonous, flammable or explosive vapors from entering the vehicle interior.
NOTE:
Caulking must be done so that the caulking material will stay in place permanently. Pressing such
materials as putty tape onto joints and seams is
NOT acceptable. A high quality silicone rubber base
sealant is recommended.
23

Section 2 – Installation
Recreational Vehicle Generator

• Holes and openings made in the compartment
walls to allow for the passage of electrical conduit,
conductors, hoses, cables, etc., into the vehicle living area must be sealed vapor tight with silicone
rubber base sealant.
• If flexible metal conduit is used, it must be sealed
internally at the end where it terminates inside the
compartment’s electrical junction box.
NOTE:
Flexible metal conduit, due to its unique construction, is NOT vapor tight along its entire length.
• Seams and joints of the galvanized steel (whether
used as a liner or for the compartment itself) must
be lapped and mechanically secured. Such seams
may be manufactured, welded, bolted, riveted or
screwed. Manufactured lock seams are shown in
Figure 2.6. Installer constructed compartments
typically utilize a standard lap joint.

Figure 2.6 – Types of Lock Seams

mable type. One excellent insulating material is a 1inch (25 mm) thick fiberglass having a 2-pound density. When fiberglass is used, its coated side should
face toward the compartment interior.

DANGER
not install sound insulation or any absorbent
 Do
material on the compartment floor interior. Such
materials will become soaked with combustible
or explosive vapors and
liquids and will become a fire hazard.
Using a combination of sound insulating materials
can often reduce noise more effectively than a single
material. For example, a sheet of lead or visco-elastic
material, along with a layer of other acoustical material, is more effective than when a single material is
used.

2.2.4 ACOUSTICS
For additional noise abatement, the installer may
wish to consider the following:
• Using special sound insulating materials.
• Construction of a special noise abatement compartment.
NOTE:
Any method used to reduce noise must not
adversely affect the flow of cooling and ventilating
air into or out of the compartment.

• After the compartment has been metal lined and
vapor sealed, line the compartment interior walls
and ceiling with an approved, nonflammable sound
insulating material. See Section 2.2.3.

DANGER
not install any flammable material directly
 Do
above or around the compartment. Heat, transferred through the compartment structure, may
be sufficient to ignite, char or discolor seat cushions, fiberboard and other flammable materials.
Use approved nonflammable insulating materials in high temperature areas.

2.2.3 SOUND INSULATING MATERIALS
Once installers have determined that a compartment
is properly constructed and metal lined, they can add
acoustical material. This may include additional sealant or insulating material, to reflect noise away from
the vehicle interior.
Sound insulating materials should be of a nonflam24

In addition to the effective use of sound insulating
materials, construction of a special noise abatement
compartment might be considered to reduce noise
levels. Such a compartment might be constructed as
follows (Figure 2.7):
• Use 5/8-inch thick or 3/4-inch thick plywood in the
compartment.
• Construct the compartment floor of a double thickness of 5/8-inch or 3/4-inch plywood.
• Line the compartment interior walls and floor, as
well as the underside of the floor, with 26-gauge
galvanized steel.
• Vapor seal all compartment seams and joints.
• Over the galvanized steel lining, install a combination of acoustical materials as mentioned in
Section 2.2.3.

DANGER
prevent fire or explosion, do not install any
 To
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.

Section 2 – Installation
Recreational Vehicle Generator

• Line the compartment door interior (except for air
openings) with suitable, fireproof sound insulation
(such as 1-inch (25 mm) thick fiberglass with a 2pound density).

2.2.5 COMPARTMENT FLOOR CUTOUTS
Provide openings in the generator compartment for
the following items (Figure 1.2):
• Engine exhaust and cooling air outlets
• Generator cooling air inlet
• Four holes for passage of generator mounting
bolts. See Section 2.1.4.

Figure 2.7 – Typical Noise Abatement

DANGER
lines and exhaust piping must not pen Fuel
etrate into the vehicle living area.

Figure 2.8 – Compartment Floor Cutout (Drawing 0D8716-G)

VIEW FROM TOP
423.2
[ 16 11/16"]

TYP.
6.7
[ 1/4"]

717.7
[ 28 1/4"]
5/16"-18 WELDNUTS
(6 PLACES)

343.4
[ 13 1/2"]

82.5
[ 3 1/4"]

50.8
[2"]

476.4
[ 18 3/4"]

60
[ 2 3/8"]
210
[ 8 1/4"]

HOT AIR
EXHAUST

118
[ 4 5/8"]

170
[ 6 11/16"]

416
[ 16 3/8"]

429.5
[ 16 15/16"]

NOTE: ALL AIR
KEPT CLEA
IS REQUIRE

414.5
[ 16 5/16"]

AIR
INTAKE
TAIL PIPE
EXIT

376.5
[ 14 13/16"]

79
[ 3 1/8"]

101
[ 4"]

360.5
[ 14 3/16"]
83.5
[ 3 5/16"]

223.5
[ 8 13/16"]
176.6
[ 6 15/16"]

36.5 [ 1 7/16"]
55.5
[ 2 3/16"]

48.1
[ 1 7/8"]
29
[ 1 1/8"]

63.5
[ 2 1/2"]

222.7
[ 8 3/4"]
300.7
[ 11 13/16"]

OIL DRAIN
369.7
[ 14 9/16"]
688.3
[ 27 1/8"]
736.4
[ 29"]

REF.

All measurements are in millimeters, 25.4 mm = 1”.
25

Section 2 – Installation
Recreational Vehicle Generator

2.3

COOLING AND VENTILATING AIR

It is absolutely essential that an adequate flow of
air for cooling, ventilating and engine combustion
be supplied to the generator set. Without sufficient
airflow, the engine/generator quickly overheats. Such
overheating can cause serious operating difficulties
and also may cause fire and personal injury. The
installer must make sure that sufficient air is available to the generator for cooling, 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.

DANGER
use discharged cooling air for heating or
 Never
permit such air to enter the vehicle interior. This
air contains deadly carbon monoxide gas and
other poisonous, flammable or explosive gases.

2.3.2 TESTING THE INSTALLATION
The manufacturer recommends testing the installation to be sure adequate cooling airflow is available to
the unit before placing the unit into service. If the unit
shows signs of overheating, enlarge the air openings.
Never place a unit into service until absolutely certain
that cooling and ventilation is adequate.
NOTE:
Test the installation, especially if bringing in air
from below the generator set.

2.4

GASOLINE FUEL SYSTEM

The installation of a gasoline fuel system (Figure
2.10) for a recreational vehicle generator set must
comply with applicable codes, standards and regulations. The entire fuel system must be completely free
of leaks. There must be no possibility of gasoline
vapors entering the vehicle interior.

2.3.1 GENERATOR AIRFLOW

Figure 2.10 – Generator Fuel System

CONTROL CENTER
C .B .
3 0 A

F U E L

S T A R T

S T O P

P R IM E

FUS E
7.5 A

S E R V IC E

A C C E S S

MAINTENANCE SCHEDULE
CHECK DAILY

AIR FILTER:

CLEAN PREFILTER
EVERY 100 HOURS. *
REPLACE ELEMENT
EVERY 250 HOURS. *

OIL & OIL FILTER:

CHANGE EVERY 100
HOURS. (OR ANNUALLY) *

SPARK PLUGS:

INSPECT & CLEAN
PLUGS EVERY 100
HOURS. REPLACE PLUGS
EVERY 500 HOURS.
(IF NECESSARY)

FUEL FILTER:

CHANGE EVERY 400
HOURS. (OR ANNUALLY)

GENERAC
OHVI POWERED

GEN
ER A
C

, W
ter
P owe
ew a
r S y s t e m s , I n c . - W h it

To Re

PERFORM MORE OFTEN IN DUSTY CONDITIONS

REPLACEMENT INFORMATION
PREFILTER P/N:
AIR FILTER P/N:
OIL FILTER P/N:
SPARK PLUG P/N:
FUEL FILTER P/N:
OIL CAPACITY WITH FILTER:

TEMPERATURE

Figure 2.9 – Airflow Through Engine/Generator

P A N E L

AIR FILTER LOCATED BEHIND PANEL.

OIL LEVEL:

ve
mo

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 2.9).
This airflow cools the engine/generator and electronic
components. The second part of the cooling system, a
suction fan, draws air that is heated from a hot engine
into a collector 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.

32˚F AND HIGHER
10˚F TO 100˚F
0˚F TO 80˚F
-20˚F TO 50˚F

GENERAC OHVI INDUSTRIAL ENGINE

0D4511
0D3262
070185
072347
0D7515
0.8L/0.84QT

SAE VISCOSITY
30
15W-40
10W-30
5W-30

QUIETPACT 40G
RV SERVICE LOCATOR:

WHEN SERVICE OR PARTS ARE NEEDED IN
THE USA OR CANADA, CONTACT THE GENERAC
SERVICE LOCATOR AT 1-800-333-1322.

1.800.333.1322

Fuel Pump & Fuel Filter
(Behind Access Panel & Air Filter)

DANGER
is highly flammable, and its vapors are
 Gasoline
explosive. Comply with all codes, standards and
regulations pertaining to gasoline fuel systems
used in recreational vehicle generators. Properly
install and maintain the fuel system and keep it
entirely free of leaks. Gasoline vapors must not
enter the vehicle interior.
Factory installed generator fuel system components
include (a) fuel filter, (b) 12-volt DC electric pump,
(c) engine carburetor, and (d) interconnecting lines
and fittings. Connect a fuel supply line to the fuel
filter inlet. Use a flexible length of approved fuel hose
between the fuel filter inlet connection and rigid fuel
lines.

Section 2 – Installation
Recreational Vehicle Generator

2.4.1 FUEL TANK

2.4.2.2 Flexible Fuel Line

Either the generator must share the vehicle engine's
fuel tank, or install a separate fuel tank for the
generator set. All fuel tanks installed on the vehicle
must be constructed, installed and restrained so they
comply with applicable codes, standards and regulations.

Use an approved flexible length of fuel hose between
the generator fuel inlet connection and rigid fuel
lines. This prevents breaking of the line caused by
vibration, shifting, settling or movement. The following rules apply:

If the generator is to share the vehicle engine's tank,
separate fuel pickup tubes are required for the engine
and the generator. The manufacturer recommends
that the fuel pickup tube be 2 to 3 inches (51 to 76
mm) shorter than the vehicle engine's pickup tube.
This prevents the generator from depleting the entire
fuel supply during prolonged generator operating
periods.

NOT tee the generator fuel supply line
 Do
into the vehicle engine fuel supply line. If this
is done, the generator will be starved of fuel
when both engines are operating at the same
time. Also, while the vehicle engine is not running, generator operation may drain the vehicle
engine supply line, making it difficult to start
the vehicle engine.

2.4.2 GENERATOR FUEL SUPPLY LINE
2.4.2.1 Rigid Fuel Lines
Those lines used to supply fuel from a tank to the
generator must comply with applicable codes, standards and regulations. The following general rules
apply to rigid fuel lines:
• Rigid lines should be of annealed, seamless, drawn
aluminum or steel.
• Lines and fittings must comply with SAE J512F,
“Standard Automotive Fittings,” or with ANSI
B126.26 (latest edition).
• Route the fuel line so that at least 2 inches (51 mm)
of clearance is maintained between the line and
any exhaust system parts.
• Do not attach electrical wiring to fuel lines. Route
the wiring so it cannot come into contact with any
fuel line.
• Route fuel lines so if they leak, fuel does not drip
onto any electrical or exhaust system parts.
• Use nonferrous metal straps without sharp edges
to secure fuel lines.

• The flexible hose must comply with SAE J30B,
“Standard for Fuel and Oil Hose.” It must be
approved for use with gasoline.
• The hose should be at least 6 inches (152 mm)
longer than is needed to prevent the hose from
rupturing if the generator shifts or settles.

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.

DANGER
generator engine gives off DEADLY carbon
 The
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even
death. Never operate the generator set with
the vehicle inside any garage or other enclosed
area. DO NOT OPERATE THE GENERATOR IF THE
EXHAUST SYSTEM IS LEAKING OR HAS BEEN
DAMAGED. SYMPTOMS OF CARBON MONOXIDE
POISONING ARE (a) inability to think coherently; (b) vomiting; (c) twitching muscles; (d)
throbbing temples; (e) dizziness; (f) headaches;
(g) weakness; and (h) sleepiness. IF FEELING
ANY OF THESE SYMPTOMS, MOVE INTO FRESH
AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP. Do not operate the generator
until its exhaust system has been inspected and
properly repaired.

tee the generator engine exhaust pipe
 Never
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.

Section 2 – Installation
Recreational Vehicle Generator

2.5.1 SPARK ARRESTOR

2.5.2 EXHAUST SYSTEM SAFETY

This spark arrestor assembly meets code and standard requirements of the U.S. Forest Service. Use
only mufflers and parts approved by the manufacturer. Any person(s) installing an unapproved muffler, or
an unapproved exhaust system part, or modifying an
exhaust system in any way that might cause a hazard,
is liable for any damage, injury or warranty expense
that might be caused by such unapproved installation
or modification.

• Maintain a clearance of at least 3 inches (76 mm)
between exhaust system parts and any combustible material (such as wood, felt, cotton, organic
fibers or other like material). If the 3-inch (76 mm)
clearance cannont 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
temperature.
• Extend the exhaust system at least 1 inch (25 mm)
past the outer edge of the vehicle. Do not terminate
the exhaust system under the vehicle.
• Terminate the exhaust tailpipe such that exhaust
gases will not be drawn back into the generator
compartment and recirculated.
• If there is any possibility of the tailpipe or muffler
being damaged, protect these damage-prone areas
by means of a protective device (such as a skid
bar).
• Install the generator exhaust system according to
safe automotive practices.
• Use enough exhaust system hangers to prevent any
part of the system from being dislocated.
• Use exhaust system parts recommended by the
manufacturer. Using unapproved exhaust mufflers
and exhaust system parts is the responsibility of
the person(s) installing such unauthorized parts.
• Do not terminate the exhaust system under any
opening, window or vent that can be 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 regulations.

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 vehicle owner or operator must maintain this device in
good condition. In the state of California, the preceding is required by law (Section 4442 of the California
Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.
When installing/replacing the tailpipe or spark arrestor components, verify that the tailpipe has a hole
to securely fasten the spark arrestor components
(see Figures 2.11 and 2.12). Use only manufacturer
supplied hardware. Substitution of parts may cause
damage to the screen or a loose fit to the tailpipe.

Figure 2.11 - Spark Arrestor

TAILPIPE
P/N 0E0683

SPARK ARRRESTOR
SCREEN P/N 089680
RETAINING
SCREW P/N 056892

Figure 2.12 — Spark Arrestor Installation

2.6

ELECTRICAL CONNECTIONS

Be sure to read Section 1.6.
The following general rules apply to electrical connections in a recreational vehicle:

27.4 [1.08"] I.D.

40 [1.58"]

5.5 [7/32"] DRILL
BOTTOM SIDE ONLY

• Qualified electricians who are familiar with applicable codes, standards and regulations should
install electrical wiring.
• The wiring should comply with codes, standards
and regulations. The National Electrical Code
(NFPA 70), and state and local codes apply.
• Switches and circuit breakers should be of a type
approved for use in recreational vehicles and must
be mounted and installed to prevent damage from
road shock.

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 compartment (if used) must be vapor-sealed to prevent
entry of flammable, explosive or poisonous gases
into the vehicle.

Figure 2.13 – Generator AC Output Leads
483.1

REMOTE PANEL
CONNECTOR

2.6.1 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.

GEN
ER A
C

, W
ter
P owe
ew a
r S y s t e m s , I n c . - W h it

AC OUTPUT
HARNESS

FUEL FILTER

BATTERY
CONNECTIONS

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 electrical junction box on the compartment wall.
If flexible metal conduit is used between the generator and the compartment junction box, the conduit end that terminates the compartment junction
box must be vapor-sealed. Flexible metal conduit
is NOT vapor tight along its entire length.
• From the junction box, route power supply wires
through approved conduit to either (a) double-pole,
double-throw transfer switch, or (b) approved isolation receptacle. Connecting to a transfer switch
or isolation receptacle must prevent vehicle electrical circuits from being connected to two different
power supplies at the same time (such as generator and dockside power).
• Conductors must be rated 221° F (105° C) or must
be of a larger conductor size.

2.6.3 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 overload by a 30-amp circuit breaker (CB1). Use this
line-to-neutral connection separately to operate 120volt, single-phase, 60 Hertz, AC loads requiring up to
3,600 watts (3.6 kW) of power.

NOT connect electrical loads in excess of any
 Do
circuit breaker rating or problems will develop
with circuit breaker tripping, which causes a loss
of AC output. Also, do NOT exceed the generator's rated wattage capacity. Add the watts
or amperes of all lighting, appliance, tool and
motor loads the generator will operate at one
time. This total should be less than the unit's
rated wattage/amperage capacity.

2.6.4 CONDUIT
Route the connections between the generator and the
junction box through approved, flexible conduit. The
following general rules apply:
• Cut wiring to the required length and allow extra
wire for junction box connections.
• Carefully prepare conduit ends to prevent sharp
edges from cutting through wiring insulation.
• Route conduit so it does not interfere with generator 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.

Section 2 – Installation
Recreational Vehicle Generator

2.6.5 ISOLATING DIFFERENT POWER
SOURCES
Connections from the junction box must terminate in
a double-pole, double-throw transfer switch (Figure
2.14). An alternate method for isolating different
power sources is by using an isolating receptacle
(Figure 2.15). Whichever method is used, be certain
that both power sources are NOT connected at the
same time.

2.6.6 POWER SUPPLY CORD
The power supply cord must comply with all applicable codes, standards and regulations. It must be
large enough to handle the full amperage to which it
will be subjected.

Figure 2.14 – Transfer Switch Isolation Method

GE
G

OH ERA
VI POW C

N
E
R
A

Po
w
er

ERE

Sy
ste
ms
, Inc
I
- Whitewater, W

GENE

RAC
OH

IET

VI IND

PACUSTRIAL ENGIN
T4 E
0G

SER
VICE

LOC

ATO

1.80

0.33
3.13
22

Figure 2.15 – Installation With Isolation Receptacle

GE
N
OH ERA
VI
C

E
R
A
C

POWE

Po
w
er

RED

Sy
ste
ms
, Inc
I
- Whitewater, W

GENE

RAC

IET OHVI INDUSTR
PAC IAL ENGIN
T4 E
0G
RV

SER
VICE

LOC

ATO

1.8

00.

333

.13

Section 2 – Installation
Recreational Vehicle Generator

2.6.7 GROUND FAULT CIRCUIT
INTERRUPTERS
The National Electrical Code (NFPA 70, 551-7)
requires that ground fault circuit interrupters (GFCIs)
be installed on all external and some internal electrical receptacles. Contact the dealer for recommendations.

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
POS

2.7

BATTERY INSTALLATION

2.7.1

FUEL

RECOMMENDED BATTERY

Install a battery that meets the following requirements:
• The battery must be a 12-volt, automotive type
storage battery.
• For prevailing ambient temperatures above 32°
F (0° C), use a battery rated 70 amp-hours and
capable of delivering 400 cold-cranking amperes.
• For prevailing ambient temperatures below 32°
F (0° C), use a battery rated 95 amp-hours and
capable of delivering 400 cold-cranking amperes.
NOTE:
If the battery is to be used to power other vehicle
accessories, as well as start the generator, a battery with a larger capacity may be needed.

2.7.2

BATTERY CABLES

Using battery cables that are too long or too small in
diameter may cause a drop in voltage, which causes
starting problems. For the best cold weather starting,
the voltage drop between battery terminals and the
generator connection point should not exceed 0.12
volts per 100 amperes of cranking current.
These generators are rated at about 100 DC amperes
of cranking current.

NEG

2.7.4

BATTERY COMPARTMENT

Install the generator battery in its own, vented compartment. Place the battery compartment away from
any source of heat, sparks or flame.
Provide ventilation openings in the battery compartment. The minimum size of openings should be 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.

Figure 2.17 – Remote Panel Plug-in Receptacle

Select battery cables based on (a) cable length and
(b) prevailing ambient temperatures. Generally, the
longer the cable and the colder the weather, the larger
the cable size must be, as shown in the chart.
CABLE LENGTH
in Feet (Meters)
0 to 10 (0 to 3)
11 to 15 (3.4 to 4.5)
16 to 20 (4.5 to 6)

CABLE SIZE
2*
0
000

14A

5
4

3
2

* For warm weather, use No. 2 cable up to 20 feet.
12.00"

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.

WIRE
No.

WIRE
COLOR

0
14
15
17
18
14A

WHITE
RED
ORANGE
YELLOW
BROWN
BLUE

LENGTH (mm)
12.0 (305)
12.0 (305)
12.0 (305)
12.0 (305)
12.0 (305)
12.0 (305)

FUNCTION
GROUND
ENGINE RUN SIGNAL

12 VDC
START
STOP
PRIME

P/N: 0D9099-B

Section 3 – Post-Installation Start-up Adjustments
Recreational Vehicle Generator

2.8.1 REMOTE START/STOP PANEL

3.3

A remote mounted Start/Stop panel (Figure 2.18) is
available that allows the user to start and stop the
generator engine conveniently from inside the vehicle.
The remote panel includes a Start/Stop switch, hourmeter, 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.

When absolutely certain that the unit has been properly installed and prepared for use, start the engine
as follows:

Figure 2.18 – Optional Remote Panel

FUEL

RUN

PRIME

3.1

STOP

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.

not make any unnecessary adjustments.
 Do
Factory settings are correct for most applications. When making adjustments, however, be
careful to avoid overspeeding the engine.

3.2

BEFORE INITIAL START-UP

Before starting, complete the following:
1. Check the engine crankcase oil level and, if necessary, fill to the dipstick “FULL” mark (crosshatched 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 accordance with applicable fuel codes. All fuel shutoff
valves in the fuel supply lines must be open.

DANGER



If a liquid propane (LP) gas fuel system has been
installed, it must be properly tested for leaks
before operating the system in compliance with
ANSI A119.2/NFPA 501C. No leakage is permitted. Be sure that no gasoline fuel vapors enter
the vehicle interior.

INITIAL START

1. Turn off all electrical loads. Do this by setting the
generator’s main circuit breakers to their “OFF”
(or open) position.
2. Refer to Part I, Section 2.5, “Starting the
Generator”, for cranking and starting 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 Section 3.4.
Run the unit at least 30 minutes with loads
applied.
6. Turn off all electrical loads by setting the generator’s main circuit breakers to their “OFF” (or
open) position.
7. Let the unit run at no-load for a few minutes to
stabilize internal engine/generator temperatures.
Then, shut down the engine.
NOTE:
The generator set was thoroughly tested and
adjusted at the factory before shipping. No additional adjustment should be necessary. Only qualified service technicians who have been trained
should perform adjustments outlined in this
manual.

3.4

TESTING UNDER LOAD

Apply electrical loads equal to about 75 to 100 percent of the unit's rated wattage/amperage capacity.
Let the unit run at least 30 minutes with load applied.
During this part of the test, check that the unit is not
running excessively hot and that adequate cooling
airflow is available. Do not allow the unit to overheat
during prolonged operation.
NOTE:
The generator engine is equipped with a high temperature switch. The switch has normally closed
(N.C.) contacts. When the engine temperature is
too high, switch contacts close, and the engine
shuts down automatically.
THE MANUFACTURER RECOMMENDS THAT THE
GENERATOR BE TESTED FOR ADEQUATE COOLING.

Section 3 – Post-installation Start-up Adjustments
Recreational Vehicle Generator

3.5

INSTALLATION CHECKLIST

EXHAUST SYSTEM

LOCATION AND SUPPORT

❑ Exhaust system complies with all applicable
codes.

❑ Generator is properly located.

❑ Exhaust system is properly and safely installed.

❑ Generator is properly supported.
❑ Generator is properly restrained.

ELECTRICAL CONNECTIONS

GENERATOR COMPARTMENT

❑ Connections comply with local code requirements
and all National Electrical Codes.

❑ Compartment construction is proper.

❑ Junction box is properly installed.

❑ Holes/Openings are vapor-sealed.

❑ Wiring meets all standards.

❑ Compartment size is correct.

❑ All connections are correct.

❑ Compartment is vapor-sealed.

❑ Conduit is properly installed and sealed.

❑ Sound insulation is correct.

❑ Generator is properly bonded to the vehicle.

❑ Floor cutouts are properly completed.

BATTERY INSTALLATION

COOLING AND VENTILATING AIR

❑ Recommended battery is installed.

❑ Airflow is adequate.

❑ Recommended cables are installed.

❑ Air inlet opening is correct.

❑ Cables are clean and tight.

❑ Compensate for restrictions.

❑ Cables are connected properly.

❑ Check that installation has been tested.

❑ Proper ventilation is provided.

GASOLINE FUEL SYSTEM

❑ Terminals are coated with anti-corrosion grease,
and terminal covers are positioned.

❑ Fuel tank complies with all applicable codes.
❑ Fuel system is properly installed and checked
for leaks.

OPTIONAL LP GAS FUEL SYSTEM
❑ Fuel system is properly installed and checked
for leaks.
❑ Pressure at regulator inlet is correct.
❑ Rated flow of primary regulator is correct.
❑ All parts are properly installed.
❑ Fuel system is properly tested/adjusted.

OPTIONAL ACCESSORIES
❑ Check that remote start/stop panels (if used) are
installed properly.
❑ Check that hourmeter kit (if used) is installed
properly.
❑ Check that any other options and accessories (if
used) are installed properly.

POST INSTALLATION TESTS
❑ Check that all tests are completed properly.

DATE OF INSTALLATION ____________________________________________________
NAME OF INSTALLER _______________________________________________________
SIGNATURE OF INSTALLER _________________________________________________
33

Appendix 1 – Notes
Recreational Vehicle Generator

Appendix 2 – Troubleshooting
Recreational Vehicle Generator

TROUBLESHOOTING GUIDE
Problem

Cause

Correction

The engine will not crank.

1. Fuse blown
2. Loose, corroded or defective
battery cables
3. Defective engine Start/Stop
switch
4. Defective starter contactor
5. Defective starter motor
6. Low or defective battery

1. Replace fuse.
2. Tighten, clean or replace
as necessary.
3. Replace Start/Stop switch.

The engine cranks but
will not start.

1. Out of fuel
2. Defective fuel pump
3. Open #14 wire from
engine control board
4. Flooded engine
5. Defective spark plug(s)
6. Fuel line shut-off closed
7. Plugged fuel filter

1. Replenish fuel.
2. Replace fuel pump.
3. Check connections and.
insulation of #14 wires.
4. Wait 5-10 minutes before trying.
5. Clean, re-gap or replace plug(s).
6. Open fuel line shut-off.
7. Clean or replace fuel filter.

The engine starts hard
and runs rough.

1. Air cleaner
plugged or damaged
2. Defective spark plug(s)

1. Check, clean or replace air cleaner.

1. Engine oil level low
2. Defective low oil
pressure switch
3. Defective high temperature
switch
4. Defective engine control board
5. Overheated engine

1. Check oil and add oil as needed.
2. Replace pressure switch.

1. Defective Start/Stop switch
2. Open/Disconnected #18 wire
between Start/Stop switch
and engine control board
3. Open/Disconnected #0 wire
between Start/Stop switch
and engine control board
4. Defective engine control board

1. Replace switch.
2. Reconnect or close wire.

1. Main line circuit breaker open

1. Reset circuit breaker
to ON (or closed).
2. Reset and replace if necessary.

The engine starts, but shuts
down when the Start/Stop
switch is released.

The Start/Stop switch is
set to Stop, but the engine
continues to run.

There is no AC output from
the generator.

2. Fault with vehicle circuit
breaker and/or fuses
3. Transfer switch set to NORMAL
4. Start switch not held long
enough to flash the field
5. Generator internal failure

4. Replace contactor.
5. Replace starter motor.
6. Charge or replace battery.

2. Clean, re-gap or replace plug(s).

3. Replace temperature switch.
4. Replace control board.
5. Check that the airflow
openings are adequate.

3. Reconnect or close wire.
4. Replace control board.

3. Set switch to GENERATOR.
4. Stop, then restart the engine
(Hold Start switch for at least
2 seconds).
5. Contact aN Authorized Service
Dealer.
35

Appendix 3 — Electrical Data
Recreational Vehicle Generator
Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D

BATTERY
RED

BLK
SC

RED

F1
15
14A

14
CH

SW2

16
PCB

J1-1

J1-2

J1-3
14

J1-4

18A

J1-5
J1-6

J1-7

(START)

SW1
(STOP)

J1-8

J1-13

LOP
0

REMOTE
PANEL
CONNECTOR

J1-14

J1-15

4
17

14
BCR
66
15

1
2
3
4

15
14 A

5
6
7
8

14 A 1 5 18 14 17 0

0I
17
14
18

WHITE

J1-12

RED

YELLOW

J1-11

HTO
0

BROWN

J1-10

BLUE

ORANGE

J1-9

BATTERY CHARGE WINDING
STOP

55
R1

START

0N
4
L1
POWER WINDING
HM

33
0N

22S

11S

FUEL
PRIME

11P

22P
ELECTRONIC
VOLTAGE

REMOTE PANEL
(OPTIONAL)

CB1

LEGEND

REGULATOR

0K
2A

4
CB3
0N

4
2

6
DPE WINDING

4
FIELD

WHITE
GREEN

T2
120V 30A
NEUTRAL CONNECTION
BY CUSTOMER

BLACK

BCR - BATTERY CHARGE RECTIFIER
CB1 - CIRCUIT BREAKER, 30A
CB3 - CIRCUIT BREAKER, 2.5A
CH - CHOKE HEATER (GASOLINE ONLY)
CS - CHOKE SOLENOID
F1 - FUSE, 7.5A
FP - FUEL PUMP-OR-LPG SHUT OFF VALVE
FS - FUEL SOLENOID (GASOLINE ONLY)
GT - TERMINAL, GROUND 4-TAB
HM - METER, HOUR (OPTIONAL)
HTO - SWITCH, HIGH TEMP. OIL (CLOSES ON HIGH TEMP.)
IM - IGNITION MAGNETO
L1 - LIGHT, RUN (OPTIONAL)
LOP - SWITCH, LOW OIL PRESSURE (CLOSES ON LOW PRESSURE)
PCB - ENGINE CONTROLLER
R1 - RESISTOR, 1 OHM 25W
SC - STARTER CONTACTOR
SM - STARTER MOTOR
SW1 - SWITCH, START/STOP
SW2 - SWITCH FUEL PRIMER
SP - SPARK PLUG
TC - TERMINAL, CONN. 4-TAB

Appendix 3 — Electrical Data
Recreational Vehicle Generator
Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D

SUPPLIED BY
CUSTOMER
SUPPLIED BY
CUSTOMER
12V
BATTERY

4 0K

11S

6 2A

ELECTRONIC
VOLTAGE
REGULATOR

22S

STATOR

0
0

15
14

J1-1
J1-2
J1-3
J1-4
J1-5
J1-6
PCB J1-7
J1-8
J1-9
J1-10
J1-11
J1-12
J1-13
J1-14
J1-15

22S

18A

11S

17
17

4
66

33 11P
22P
44
55

0
16

CLOSEST TO BEARING

RED

FIELD
0F

CB3

77
2

11P

BCR

22P

R1
0F

2
66

15
0

0N
18

18A
85

CONN. 1
PIN#

0F
0

14
14

SW1

SW2

RED

0
90

14A

11P

14A

REMOTE
PANEL
CONNECTOR

11P

6
5

CONN. 2
PIN#

15
FS

14A

3 7

14
1

1
2 8

WHITE

BLACK

18
14

CB1

14A

18A
85

14A
15

85
LOP

HTO

FILTER MTG
SCREW
T2
T1

GREEN

18A

CUSTOMER
AC CONNECTION
0
90

SP1

IM1

BLACK

WHITE

GREEN

NEUTRAL CONNECTION
BY CUSTOMER

36
58

21
27

TO CARB

1
21
53

21 57

21 41

22
23

21
26

Appendix 4 — Exploded Views and Parts Lists

Recreational Vehicle Generator
Enclosure – Drawing No. 0D8352-G

Appendix 4 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Enclosure – Drawing No. 0D8352-G

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
32

PART NO. QTY.

DESCRIPTION

0D6822
0D6942
0D6939
0D6943
0D6941
0D6940
0D6945
0D6944
0D8254
0C5644
0D7513
087769
0D7613
0D7614
048031C
047411
022473
023484S
022097
086729
0D3700
022129
022259
075763A
0D7293
064113
0C7561
0A4456
049813
022237
022131

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
PUMP, FUEL
FILTER, FUEL
FUEL LINE, FILTER TO PUMP
FUEL LINE, PUMP TO CARB
CLAMP HOSE BAND ¼”
SCREW HHC M6-1.0 X 16
WASHER FLAT ¼”
BUSHING, 1.09” SNAP
WASHER LOCK M6-1/4”
CONTACTOR, STARTER
NUT FLANGE M6-1.0 NYLOK
WASHER LOCK M8-5/16”
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”
3/8” SPECIAL L/WASHER
NUT HEX M6 X 1.0
WASHER LOCK 3/8”
WASHER FLAT 3/8-M10”

1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
2
2
1
2
1
24
2
2
2
1
1
1
1
2
1
2

ITEM

PART NO. QTY.

DESCRIPTION

33
34
35
36
37
38
39
40
41

0C5443
0C7423
029451
074908
0D8717
0D9020
0742600144
0E0724
0A7215

1
1
2.1’
4
1
1
1
1
18

42
43
44
45
46
47
48
49
50

0742600143
0D8595
0D8627
0D8628
0D8628A
0D8691
0D7176
0A2115
0D9282

1
1
2
1
1
1
4
1
1

51
52
53
54
55
56
57
58
59

023484E
0F9176
0E0014
0E0017
0C7968
0E0393
0D8981
029451A
0D8628B

BLOCK, TERMINAL BATTERY POST
STUD 3/8”-16 X 2”-1/4” BRASS
TAPE FOAM 1/8” X ½”
SCREW HHTT M5-0.8 X 10
CUSTOMER CONNECTION HARNESS
FOAM, AIR OUT COMPARTMENT SIDE
CABLE, STARTER
ASSEMBLY OIL DRAIN
SCREW SW ¼”-20 X 5/8” WITH NYLON
WASHER
CABLE, BATTERY CONNECTION
MOUNT, FUEL FILTER SUPPORT
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
BUSHING, 0.50” SNAP
HOSE, 1/4” ID
BOX, MUFFLER TAIL PIPE
GASKET, MUFFLER TAIL PIPE BOX
NUT HEX JAM 3/8”-16 BRASS
ASSEMBLY, CAP & DIPSTICK
FILTER GASKET
FOAM TAPE 1/16” X ½”
FOAM, FRONT AIR OUT
COMPARTMENT

1
8.5”
1
1
4
1
1
8.75’
1

Appendix 4 — Exploded Views and Parts Lists

21
28
38

21
2
18

26
10

25
2
18
1

18
2

0
1

Recreational Vehicle Generator
Generator – Drawing No. 0D8353-H

Appendix 4 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Generator – Drawing No. 0D8353-H

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
41
42

PART NO.
050322
022129
049451
0C8096A
0D8120
066849
066386
0D4217
073159
0D4484H
0D4430H
0D4216
048614
0D2588A
022131
027028
0D6832
022145
030231
0C3168
022259
0C8565
0D8048
083512
0D6831
029451
0D6918
0D2558
087680
0D7530
0D9723
0D4511
0D8451
022097
0D7440
090388
0D7441
081105
089476
022531
0D8981

QTY.
1
22
1
1
4
2
1
1
1
1
1
1
4
1
4
4
1
18
3
1
10
2
4
6
1
2.14'
1
1
2
1
1
1
1
1
1
2
2
2
1
1
1

DESCRIPTION
SCREW IHHC 5/16"-24 X 9-3/4"
WASHER LOCK M8-5/16"
WASHER FLAT .406" I.D. X 1.62" O.D.
FAN, 8" CURVE BLADE, 16.5MM I.D.
SCREW IHHC M8-1.25 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"-M10
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 M8-1.25 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 M6-1/4"
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

Appendix 4 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Control Panel – Drawing No. 0D8354-E

21
20

24
23

12
1

11
31

39
38

4
18

17
5
6
5
4
5
3
14

36
29

Appendix 4 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Control Panel – Drawing No. 0D8354-E

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39

PART NO.
0830490
075210A
092234
065795
023484F
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
0D8794
025105
028739
0D8308
0D8418
023484S
043182
031879
0D6575D
0A9973

QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
5
1
2
2
4
1
5
4
4
2
1
2
2
1
2
2
1
1
1
2
2
1
1

DESCRIPTION
REGULATOR VOLTAGE
TERMINAL BLOCK
CONTROLLER P.C.B.
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 (50HZ)
SWITCH S.P.D.T.
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 M5-0.8 X 30MM
SCREW HHC M6-1.0 X 16MM
WASHER LOCK M5
NUT HEX M5-0.8
SCREW PPHM M4-0.7 X 16MM
WASHER LOCK #8-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 M5-0.8 X 16MM
SCREW HHC M6-1.0 X 30MM
NUT, HEX M3-0.5
PANEL CONTROL
SCREW RHM #6-32 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
DEUTSCH, MOUNTING CLIP
RIVET POP 0.125" LARGE FLANGE

Appendix 4 — Exploded Views and Parts Lists

35
53
52
43
41
42
44

59
60

45
9

39
9
38
44

26 27
22
21

23 24 25

34
20
40

17
16
15

Recreational Vehicle Generator
GN-220 H/SH Engine – Drawing No. 0D8355-S Part 1

Appendix 4 — Exploded Views and Parts Lists
Recreational Vehicle Generator
GN-220 H/SH Engine – Drawing No. 0D8355-S Part 1

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
52
53
54
55
56
57
58
59
60
61
62
63

PART NO.
0D8433
0C1069
090695F
081810
083312
0D8400
0C8917A
0C8798A
045756
082774
022129
081990
0D9004A
0E7585
022097
082981
081675
0D7666A
090051
080316
090948
078631
0D8332
091846
0D7558
078643
0D8372
0C2756
0D7458
0C3979
085953
0D8739
0D8398
091638A
083512
082025
092984
094820
089739
091848
0D8778
0D8803
0A8584
070185B
075281
043182
0C4739
0D9689
0A7095
077091
0D8397
077075
0C2824
0A7094
0D8590
0D8591

QTY.
1
10
1
1
1
1
1
1
9
1
2
2
1
1
2
2
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
2
1
1
1
2
2
1
1

DESCRIPTION
GUARD, FAN
SCREW, HHTT M6-1.0 X 8mm
BLOWER HOUSING
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 M8-1.25 X 40mm
ASSY, STARTER
SPARK PLUG, CHAMPION RC14YC
LOCKWASHER, ¼”- M6
TAPTITE, M6-1.0 x 30mm
ASSEMBLY, IGNITION COIL
BREATHER TUBE
GASKET, MANIFOLD/ HEAD
SCREW HHFC M6-1.0 X 30mm
INTAKE MANIFOLD
GASKET CARBURETOR/MANIFOLD
CARBURETOR
GASKET, CARB/ ADAPTOR
ADAPTOR, CARB
BOLT, CARB MOUNT M6-1.0 x 75mm
GASKET, CARB TO AIRBOX
ASSEMBLY, GOVERNOR LEVER
ROD, GOVERNOR
SPRING, ANTI LASH
WASHER, CARB WEAR
ASSEMBLY BRACKET GOVERNOR ADJUST
ROD, CHOKE LINKAGE
SPRING, GOVERNOR
SCREW HHTT M8-1.2 x 16mm
NUT, M5-0.8 LOCK
TOP WRAPPER
PLUG, EXPANSION
LOWER WRAPPER
GASKET, OIL PSI PAD
ADAPTER, OIL FILTER
SCREW SHC M6-1.0 X 22mm
SWITCH, OIL- 10 PSI
FILTER, OIL
SWITCH, THERMAL 284F
WASHER LOCK M3
SCREW PPHM M3-0.5 X 6mm
ELBOW 90D STREET 1/8NPT
RHMS #4-40 X 5/16” SEMS
COTTER PIN
ROD, CHOKE CONTROL
BOOT CHOKE SOLENOID PLASTIC
SCREW TAP-R #10-32 X 9/16”
RHMS #4-40 X 1/4” SEMS
ASSEMBLY, BI-METAL/HEATER
SOLENOID, CHOKE

Appendix 4 — Exploded Views and Parts Lists

13
11

29
18

36
46

25
48

23
22

24
46

Recreational Vehicle Generator
GN-220 H/SH Engine – Drawing No. 0D8355-S Part 2

Appendix 4 — Exploded Views and Parts Lists
Recreational Vehicle Generator
GN-220 H/SH Engine – Drawing No. 0D8355-S Part 2

ITEM

PART NO.

N/A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52

0E8804
078621
076389
088411
0A8897B
077168
088057
076390
0E8540A
078658
0F0967
089213E
0A7637
0E3811
0D1303
078645
0A7811
072683A
0A9878
089096
088156
0A8822
078691
0A5772
0A5776
074908
078606
076361
0D2414
099922
0C3733
0C4390
084186
083192
0E0057
078699B
021705B
0C3590
0C3591
0D9853A
083235
080336
0C8754
077161
077160
076307
088403
026073A
0D1411A
076329
0C3592
049340A
045761A

QTY.
1
1
1
1
1
5
1
2
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
4
1
6
1
2
2
2
1
1
4
1
1
1
2
2
1
1
2
2
2
1
1
1
1
4
1
1

DESCRIPTION
LONG BLOCK ASSEMBLY
CONNECTING ROD ASSEMBLY
PISTON PIN
PISTON RING SET
GEAR COVER ASSEMBLY
M8 x 56mm HEAD BOLT
PISTON
PIN RETAINER RING
TAPERED CRANKSHAFT ASSEMBLY
GOVERNOR “R” PIN
WASHER FLAT 1/4, .015 THK
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
OIL 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

Appendix 5 – Warranty
Recreational Vehicle Generator

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with
Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.*
New utility, and lawn and garden equipment engines must be designed, built and equipped to meet stringent anti-smog
standards for the state of California and the federal government. Generac will warrant the emission control system on your
engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improper
maintenance of your engine.
Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair
your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted. If, during such warranty period, any emission-related component or system on your engine is found to be defective in materials or
workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory
supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance
on your engine. However, Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure
the completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or
responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or the use of counterfeit and/or ‘grey market’ parts not made, supplied or approved by Generac.
You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem
occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.
To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the “Generac
Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you
by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in
terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where
the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe
important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner shall
be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the
inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or losses incurred
while the engine is being transported/shipped for inspection or warranty repairs.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:

ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part 1

Appendix 5 – Warranty
Recreational Vehicle Generator

EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:
(a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on
the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue
for 24 consecutive months thereafter.
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or
equipment, and to each subsequent purchaser/owner, that each of its engines is ...
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant
to their respective authority, and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a
warranted emissions-related part to fail to be identical in all material respects to the part as described in the engine
manufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the ECS
Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or replace
as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS Warranty
shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no
charge to the owner at a Generac Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible
for diagnostic costs if the repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused
by a failure under warranty of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient
to meet the expected demand for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS
Warranty maintenance or repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce
Generac’s ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or ‘grey market’ parts may not be used to modify or repair a Generac
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of
such an unapproved, add-on, modified, counterfeit and/or ‘grey market’ part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1) Fuel Metering System:
1.1) Gasoline carburetor assembly and its
internal components (if so equipped).
a) Fuel filter (if so equipped)
b) Carburetor gaskets
c) Fuel pump (if so equipped)
1.2) LPG carburetion assembly and its
internal components (if so equipped).
a) Fuel controller (if so equipped)
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)

2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
3) Ignition System including:
a) Spark plug
b) Ignition module
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
5) Crankcase Breather Assembly including:
a) Breather connection tube

*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

Appendix 5 – Warranty
Recreational Vehicle Generator

GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY
FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS
NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period
of 3 (three) years of operation from the date of original sale, Generac Power Systems, Inc. (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 Control Board (part numbers 0A6060 and 0A3369) and inverter, (if applicable with regard to the generator)
Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Valve, Valve Lifter(s), Intake and Exhaust Manifolds
Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators
manufactured after January 1, 1998, have a transferable warranty to the second owner ONLY for 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 exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent and/or insect infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty
period.
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.
• Rental equipment used while warranty repairs are being performed.
• Overnight freight costs for replacement part(s).
• Overtime labor.
• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO
OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL
GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT
RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages,
so the above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC® POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Revision 02.05

Part No. 0D8351

Revision R (02/22/06)

Printed in U.S.A.

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