Guardian Technologies Quietpact 40Lp 004701 0 Users Manual

004701-0 to the manual 60103ba3-ce65-46b3-a4d3-94664771f762

: Guardian-Technologies Guardian-Technologies-Quietpact-40Lp-004701-0-Users-Manual-563104 guardian-technologies-quietpact-40lp-004701-0-users-manual-563104 guardian-technologies pdf

Open the PDF directly: View PDF .
Page Count: 52

Owner’s Manual and

Installation Instructions

Air-cooled Recreational

Vehicle Generators

• Model: 004701-0

QUIETPACT 40LP

This manual should remain with the unit.

INTRODUCTION

Thank you for purchasing this model of the

QUIETPACT product line. This model is designed

and manufactured to supply electrical power for rec-

reational vehicles.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact

an Authorized Service Dealer for starting, operating

and servicing procedures.

Throughout this publication, and on tags and

decals affixed to the generator, DANGER, WARNING,

CAUTION and NOTE blocks are used to alert person-

nel to special instructions about a particular opera-

tion that may be hazardous if performed incorrectly

or carelessly. Observe them carefully. Their defini-

tions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in personal inju-

ry, including death, or severe property damage.

After this heading, read instructions that, if not

strictly complied with, may result in personal injury

or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to

equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

These safety warnings cannot eliminate the hazards

that they indicate. Common sense and strict compli-

ance with the special instructions while performing

the service are essential to preventing accidents.

Four commonly used safety symbols accompany the

DANGER, WARNING and CAUTION blocks. The type

of information each indicates follows:

 This symbol points out important safety informa-

tion that, if not followed, could endanger personal

safety and/or property of others.

 This symbol points out potential explosion hazard.

 This symbol points out potential fire hazard.

 This symbol points out potential electrical shock

hazard.



The operator (driver) is responsible for proper and

safe use of the vehicle and its equipment, and the

safety of all vehicle occupants. We strongly recom-

mend that the operator read this manual and thor-

oughly understand all instructions before using this

equipment. We also strongly recommend instructing

other occupants in the vehicle to properly start and

operate the generator. This prepares them if they need

to operate the equipment in an emergency.

CONTENTS

This manual contains pertinent owner’s information,

including warranty, electrical diagrams, exploded

views and lists of repair parts for generator model

numbers 004701-0. In addition, the latter portion of

this manual contains information necessary for the

proper installation of these generators.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety

checks, to make sure that all maintenance for safe

operation is performed promptly, and to have the

equipment checked periodically by an Authorized

Service Dealer. Normal maintenance service and

replacement of parts are the responsibility of the

owner/operator and, as such, are not considered

defects in materials or workmanship within the

terms of the warranty. Individual operating habits

and usage contribute to the need for maintenance

service.

Proper maintenance and care of the generator ensures

a minimum number of problems and keep operating

expenses at a minimum. See an Authorized Service

Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs,

simply contact an Authorized Service Dealer for

assistance. Service technicians are factory-trained

and are capable of handling all service needs.

When contacting an Authorized Service Dealer or the

factory about parts and service, always supply the

complete model number and serial number of the

unit as given on its data label, which is located on the

generator.

Model No. ____________ Serial No. ______________







AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest AUTHORIZED SERVICE

DEALER, please call this number:

1-800-333-1322

or access the web at

www.generac.com

Table of Contents

Recreational Vehicle Generator

1

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

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

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

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

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

1.3 Safety..... ....................................................................5

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

1.5 Specifications .............................................................5

Section 2 – Operation ......................................................6

2.1 Generator Control Panel ............................................6

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

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

2.4 Starting the Generator ...............................................7

2.5 Stopping the Generator ..............................................8

2.6 Applying Loads to Generator .....................................8

2.7 Do Not Overload the Generator ..................................8

2.8 Protection Systems.....................................................8

2.9 Additional Information ...............................................9

Section 3 – Maintenance .............................................. 10

3.1 Checking the Engine Oil Level ..................................10

3.2 Changing the Engine Oil and/or Oil Filter ................10

3.3 Maintaining the Engine Air Cleaner..........................11

3.4 Clean Air Intake .......................................................11

3.5 Checking the Engine Spark Plug ..............................12

3.6 Clean Spark Arrestor ...............................................12

3.7 Cleaning the Generator ............................................12

3.8 Battery Maintenance.................................................13

3.9 Major Service Manual ..............................................13

3.10 Exercising the Generator .........................................13

3.11 Out of Service Procedure .........................................13

3.12 Adjusting Valve Clearance ........................................14

3.13 RV Generator Service Interval ..................................14

Part II – Installation Instructions

Safety Rules ..................................................................... 16

Section 1 – General Information ................................ 18

1.1 Purpose and Scope of the Manual ............................18

1.2 Safety...... .................................................................18

1.3 Standards Booklets ..................................................18

1.4 Equipment Description ............................................18

1.5 Generator Engine Operating Speed ..........................18

1.6 Generator AC Connection System ............................18

Section 2 – Installation ................................................. 20

2.1 Location and Support ..............................................20

2.2 Generator Compartments ........................................21

2.3 Cooling and Ventilating Air ......................................23

2.4 LP Gasoline Fuel System .........................................24

2.5 Exhaust System........ ...............................................26

2.6 Electrical Connections .............................................27

2.7 Battery Installation... ................................................28

2.8 Optional Accessories ................................................30

Section 3 – Post-installation Start-up

Adjustments ............................................... 31

3.1 Post Installation Tests ..............................................31

3.2 Before Initial Start-up ..............................................31

3.3 Initial Start ...............................................................31

3.4 Testing Under Load .................................................31

3.5 Installation Checklist ...............................................32

Appendix 1 – Troubleshooting .................................... 33

Appendix 2 – Electrical Data ....................................... 34

Appendix 3 – Exploded Views and Parts Lists ........ 36

Appendix 4 – Warranty ................................................. 48

2

WARNING!

This product contains or emits chemicals

known to the state of California to cause

cancer, birth defects or other reproductive harm.

 

WARNING!

The engine exhaust from this product contains

chemicals known to the state of California to cause

cancer, birth defects or other reproductive harm.

 

Study these SAFETY RULES carefully before install-

ing, operating or servicing this equipment. Become

familiar with this manual and with the unit. The gen-

erator can operate safely, efficiently and reliably only

if it is properly installed, operated and maintained.

Many accidents are caused by failing to follow simple

and fundamental rules or precautions.

The manufacturer cannot anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals affixed

to the unit, are, therefore, not all inclusive. If using

a procedure, work method or operating technique

the manufacturer does not specifically recommend,

ensure that it is safe for others. Also make sure the

procedure, work method or operating technique uti-

lized does not render the generator unsafe.

DANGER

 Despite the safe design of this generator,

operating this equipment imprudently, neglecting

its maintenance or being careless can cause

possible injury or death. Permit only responsible

and capable persons to operate or maintain this

equipment.

 Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

 Parts of the generator are rotating and/or hot

during operation. Exercise care near running

generators.

 GENERAL HAZARDS 

• For safety reasons, the manufacturer recommends

that the installation, initial start-up and main-

tenance of this equipment is carried out by an

Authorized Service Dealer.

• The generator engine releases DEADLY carbon

monoxide gas through its exhaust system. This

dangerous gas, if breathed in sufficient concentra-

tions, can cause unconsciousness or even death.

Never operate the generator set with the vehicle

inside any garage or other enclosed area. DO NOT

OPERATE THE GENERATOR IF THE EXHAUST

SYSTEM IS LEAKING OR HAS BEEN DAMAGED.

SYMPTOMS OF CARBON MONOXIDE POISONING

ARE (a) inability to think coherently, (b) nausea,

(c) vomiting, (d) twitching muscles, (e) throbbing

temples, (f) dizziness, (g) headaches, (h) weak-

ness, and (i) sleepiness. IF EXPERIENCING ANY

OF THESE SYMPTOMS, MOVE INTO FRESH AIR

IMMEDIATELY. IF SYMPTOMS PERSIST, GET

MEDICAL HELP. Shut down the generator and

do not operate it until it has been inspected and

repaired.

• Never sleep in the vehicle while the genset is run-

ning unless the vehicle has a working carbon

monoxide detector. The exhaust system must be

installed in accordance with the genset installation

manual. Make sure there is ample fresh air when

operating the genset in a confined area.

• The engine exhaust fumes contain carbon monox-

ide, which can be DEADLY. This dangerous gas, if

breathed in sufficient concentrations, can cause

unconsciousness or even death. This exhaust

system must be installed properly, in strict com-

pliance with applicable codes and standards.

Following installation, do nothing that might ren-

der the system unsafe or in noncompliance with

such codes and standards. The generator com-

partment must be completely vapor sealed from

the vehicle interior. There must be no possibility of

exhaust fumes entering the vehicle interior. Never

operate this equipment with a leaking or defective

exhaust system.

• Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never

remove any drive belt or fan guard while the unit

is operating.

• Adequate, unobstructed flow of cooling and ven-

tilating air is critical to correct generator opera-

tion and is required to expel toxic fumes and fuel

vapors from the generator compartment. Without

sufficient cooling airflow, the engine/generator

quickly overheats, which causes serious damage

to the generator. Do not alter the installation or

permit even partial blockage of ventilation provi-

sions, as this can seriously affect safe operation of

the generator.

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. 



3

• When working on this equipment, remain alert

at all times. Never work on the equipment when

physically or mentally fatigued.

• Inspect the generator regularly, and contact the

nearest Authorized Service Dealer immediately for

parts needing repair or replacement.

• Before performing any maintenance on the gen-

erator, disconnect its battery cables to prevent

accidental start up. Disconnect the cable from the

battery post indicated by a NEGATIVE, NEG or (–)

first. Reconnect that cable last.

• Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break

parts, and may result in dangerous operating con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

 ELECTRICAL HAZARDS 

• The generator covered by this manual produces

dangerous electrical voltages and can cause fatal

electrical shock. Avoid contact with bare wires, ter-

minals, connections, etc., while the unit is running.

Ensure all appropriate covers, guards and barriers

are in place before operating the generator. If work

must be done around an operating unit, stand on

an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

• During installation onto the vehicle, have the

generator properly grounded (bonded) either by

solid mounting to the vehicle frame or chassis,

or by means of an approved bonding conductor.

DO NOT disconnect the bonding conductor, if so

equipped. DO NOT reconnect the bonding conduc-

tor to any generator part that might be removed or

disassembled during routine maintenance. If the

grounding conductor must be replaced, use only a

flexible conductor that is of No. 8 American Wire

Gauge (AWG) copper wire minimum.

• In case of accident caused by electric shock, imme-

diately shut down the source of electrical power.

If this is not possible, attempt to free the victim

from the live conductor. AVOID DIRECT CONTACT

WITH THE VICTIM. Use a nonconducting imple-

ment, such as a rope or board, to free the victim

from the live conductor. If the victim is uncon-

scious, apply first aid and get immediate medical

help.

• Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

 FIRE HAZARDS 

• For fire safety, the generator must be installed

and maintained properly. Installation always must

comply with applicable codes, standards, laws

and regulations. Adhere strictly to local, state and

national electrical and building codes. Comply

with regulations the Occupational Safety and

Health Administration (OSHA) has established.

Also, ensure that the generator is installed in

accordance with the manufacturer’s instructions

and recommendations. Following proper installa-

tion, do nothing that might alter a safe installation

and render the unit in noncompliance with the

aforementioned codes, standards, laws and regula-

tions.

• Keep a fire extinguisher in the vehicle at all times.

Extinguishers rated “ABC” by the National Fire

Protection Association are appropriate for use on

the recreational vehicle generator electrical sys-

tem. Keep the extinguisher properly charged and

be familiar with its use. If there are any questions

pertaining to fire extinguishers, consult the local fire

department.

 EXPLOSION HAZARDS 

• Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no com-

bustible materials are left in the generator com-

partment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surround-

ing the generator clean and free from debris.

• Gasoline is extremely FLAMMABLE and its vapors

are EXPLOSIVE. Do not permit smoking, open

flame, sparks or any source of heat in the vicinity

while handling gasoline. Comply with all laws gov-

erning the storage and handling of gasoline.

Safety Rules

Recreational Vehicle Generator

4

1. Generator Air Intake

2. Engine Start/Stop Switch

3. Fuse

4. Optional Remote Panel Receptacle (Side View)

5. Generator AC Output Leads (Side View)

6. Fuel Primer Switch

7. Circuit Breaker

8. Starter Contactor

9. Fuel Inlet

10. Battery Hookup

11. LP Regulator/Solenoid

12. Oil Filter

13. Oil Drain Cap

14. Oil Dipstick

15. Air Filter (Behind Access Panel)

16. Oil Fill

17. Spark Plug

Section 1 – General Information

Recreational Vehicle Generator

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 __________________

*

S E R V IC E A C C E S S P A N E L

OIL LEVEL: CHECK DAILY

AIR FILTER: CLEAN PREFILTER

EVERY 100 HOURS.

REPLACE ELEMENT

EVERY 250 HOURS.

OIL & OIL FILTER:

CHANGE EVERY 100

(IF NECESSARY)

EVERY 500 HOURS.

HOURS. REPLACE PLUGS

PLUGS EVERY 100

INSPECT & CLEANSPARK PLUGS:

REPLACEMENT INFORMATION

*

PERFORM MORE OFTEN IN DUSTY CONDITIONS

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE

AIR FILTER P/N: 0D3262

070185OIL FILTER P/N:

SPARK PLUG P/N: 072347

OIL CAPACITY WITH FILTER:

0.8L/0.84QT

TEMPERATURE SAE VISCOSITY

32°F AND HIGHER

10°F TO 100°F

0°F TO 80°F

-20°F TO 50°F 5W-30

10W-30

15W-40

30

WHEN SERVICE OR PARTS ARE NEEDED IN

THE USA OR CANADA, CONTACT THE GENERAC

SERVICE LOCATOR AT 1-800-333-1322.

HOURS. (OR ANNUALLY)

PREFILTER P/N: 0D4511

FUEL FILTER P/N: 087769

FUEL FILTER: CHANGE EVERY 400

HOURS. (OR ANNUALLY)

*

*

P R IM E

F U E L

S T O P

S T A R T 3 0 A

C .B .

15 A

F U S E

CONTROL CENTER

NEG.

BATTERY

FUEL

INLET

BATTERY

POS.

REMOTE

1

2

34

5

67

8

9

15

11

1213

14/16

17 10

1.1 GENERATOR IDENTIFICATION

Model: 004701-0

5

Section 1 – General Information

Recreational Vehicle Generator

1.2 GENERATOR APPLICABILITY

These generators have been designed and manufac-

tured for supplying electrical power for recreational

vehicles. Do not modify the generator or use it for

any application other than for what it was designed.

If there are any questions pertaining to its applica-

tion, write or call the factory. Do not use the unit until

advised by a competent authority.

DANGER

 For fire safety, the generator must have been

properly installed in compliance with ANSI

119.2-1975/NFPA 501C-1974, “Standard for

Recreational Vehicles, Part III – Installation of

Electrical Systems.” The generator also must

have been installed in strict compliance with the

manufacturer’s detailed installation instructions.

After installation, do nothing that might ren-

der 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 elec-

trical loads. These loads can require up to 3,400

watts (3.4 kW) of power, but cannot exceed 28.3 AC

amperes of current at 120 volts.

 Do not overload the generator. Some installa-

tions may require that electrical loads be alter-

nated to avoid overloading. Applying excessive-

ly high electrical loads may damage the genera-

tor and may shorten its life. Add up the rated

watts of all electrical lighting, appliance, tool

and motor loads the generator will power at

one time. This total should not be greater than

the wattage capacity of the generator. If an

electrical device nameplate gives only volts and

amps, multiply volts times amps to obtain watts

(volts x amps = watts). Some electric motors

require more watts of power (or amps of cur-

rent) for starting than for continuous operation.

1.3 SAFETY

Before attempting to use the generator set, care-

fully read the “Safety Rules” section of this manual.

Comply strictly with these rules to prevent accidents

and damage to equipment and/or property. We sug-

gest copying and posting the “Safety Rules” in poten-

tial hazard areas of the vehicle. Stress safety to all

operators and potential operators of this equipment.

1.4 GENERATOR AC

CONNECTION SYSTEM

This generator set is equipped with dual stator AC

power windings. These two-stator windings sup-

ply electrical power to customer electrical loads by

means of a two-wire connection system. Note, how-

ever, that the neutral is bonded to the frame of the

engine-generator.

The generator may have been installed so that it pow-

ers 120-volt AC loads (Figure 1.1).

Figure 1.1 – Connections for 120 Volts Only

28.3 AMP

1.5 SPECIFICATIONS

1.5.1 FUEL REQUIREMENTS

These generators are equipped with a liquefied petro-

leum (LP) gas fuel system. LP gas is usually aupplied

as a liquid in pressure tanks.

These generators require a “vapor withdrawal” type

fuel system. This type of gaseous fuel system uses the

vapors forming above the liquid fuel in the storage

tank. Air temperature around the storage tank must

be high enough to sustain adequate fuel vaporization.

In colder climates, use of an independent heat source

may be needed to be sure the fuel sufficiently vapor-

izes in the storage tank.

LP gas may consist of propane, butane, or a mixture

of the two gases. Propane vaporizes at tempertures as

low as -20°F (-29°C), but butane returns to its liquid

state when the temperature drops below about 32°F

(0°C). For that reason, a higher ratio of propane is

desired in the gas mixure when temperatures drop

below freezing.

1.5.2 FUEL CONSUMPTION

Fuel consumption is in gal/hr.





Model 1/2 Load Full Load

004701-0 0.55 0.73

6

Section 1 – General Information

Recreational Vehicle Generator

1.5.3 ENGINE OIL REQUIREMENTS

Use only high quality detergent oil rated with American

Petroleum Institute (API) Service Classification SF,

SG or SH. The recommended oil weights include the

following:

• During summer months: SAE 30. An acceptable

substitute is SAE 10W-30.

• During winter months: SAE 5W-30. DO NOT USE

SAE 10-W40.

Crankcase and oil filter capacity is approximately

800 mL or .84 U.S. quarts. Do NOT use special addi-

tives. See Sections 3.1 and 3.2 (Page 12) 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 ...........................Part No. 0E7585

Spark Plug Gap .........................................0.030 inch (76 mm)

Recommended Minimum Battery .............. 400 Cold-cranking

Amperes

1.5.5 GENERATOR

Rated Maximum Continuous

AC Output (Gasoline) ...........................3,400 Watts (3.4 kW)

Rated Voltage .......................................................120 Volts AC

Rated Maximum Continuous

AC Current (Gasoline) .................................... 28.3 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.)

1.5.6 EMISSIONS COMPLIANCE PERIOD

For non-handheld engines the Emissions Compliance

Period referred to on the Emissions Compliance

Label indicates the number of operating hours for

which the engine has been shown to meet Federal

emission requirements.









• For engines less than 225 cc displacement, Category

C=125 hours, B=250 hours, and A=500 hours.

• For engines of 225 cc or more, Category C=250

hours, B=500 hours, and A=1000 hours.

2.1 GENERATOR CONTROL PANEL

The following features are mounted on the generator

control panel (Figure 2.1):

Figure 2.1 – Generator Control Panel

P R I M E

F U E L

S T O P

S T A R T 3 0 A

C . B .

F U S E

CONTROL CENTER

7. 5 A

2.1.1 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.

2.1.2 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.

2.1.3 MAIN BREAKER

The main breaker protects the generator’s AC out-

put circuit against overload and provides a method

of turning OFF the generator’s 120-volt AC output

to the vehicle circuits. The generator has a 30-amp

breaker.







7

Section 2 – Operation

Recreational Vehicle Generator

2.2 OPTIONAL REMOTE

START/STOP PANEL

A remote mounted Start/Stop Panel is available that

permits starting and stopping the generator engine

conveniently from inside the vehicle.

Contact an Authorized Service Dealer to order, 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 BEFORE STARTING THE ENGINE

NOTE:

Instructions and information in this manual

assume the generator has been properly installed,

connected, serviced, tested and adjusted by a

qualified installation technician or installation

contractor.

2.3.1 INSTALLATION

Generator installation must have been properly com-

pleted so it complies with all applicable codes, stan-

dards and regulations and with the manufacturer's

recommendations.

2.3.2 ENGINE LUBRICATION

Have the engine crankcase properly serviced with the

recommended oil before starting. Refer to Section

1.5.4 and Sections 3.1 and 3.2 for oil servicing pro-

cedures and recommendations.

 Any attempt to crank or start the engine before

it has been properly serviced with the recom-

mended oil may result in an engine failure.

2.3.3 FUEL SUPPLY

The engine must have an adequate supply of proper

fuel to operate. Before starting it, check that suffi-

cient fuel is available.

2.3.4 COOLING AND VENTILATING AIR

Air inlet and outlet openings in the generator com-

partment must be open and unobstructed for con-

tinued proper operation. Without sufficient cooling

and ventilating airflow, the engine/generator quickly

overheats, which causes it to shut down and may

damage the generator.









2.3.5 ENGINE EXHAUST GAS

Before starting the generator engine, be sure there is

no way for exhaust gases to enter the vehicle interior

and endanger people or animals. Close windows,

doors and other openings in the vehicle that, if open,

might permit exhaust gases to enter the vehicle.

DANGER

 The generator engine releases DEADLY carbon

monoxide gas through its exhaust system. This

dangerous gas, if breathed in sufficient con-

centrations, can cause unconsciousness or even

death. Never operate the generator set with

the vehicle inside any garage or other enclosed

area. DO NOT OPERATE THE GENERATOR IF THE

EXHAUST SYSTEM IS LEAKING OR HAS BEEN

DAMAGED. SYMPTOMS OF CARBON MONOXIDE

POISONING ARE (a) inability to think coher-

ently, (b) nausea, (c) vomiting, (d) twitching

muscles, (e) throbbing temples, (f) dizziness,

(g) headaches, (h) weakness, and (i) sleepiness.

IF EXPERIENCING ANY OF THESE SYMPTOMS,

MOVE INTO FRESH AIR IMMEDIATELY. IF

SYMPTOMS PERSIST, GET MEDICAL HELP. Shut

down the generator and do not operate it until

it has been inspected and repaired.

DANGER

 Never sleep in the vehicle while the genset is

running unless the vehicle has a working carbon

monoxide detector. The exhaust system must be

installed in accordance with the genset installa-

tion manual. Make sure there is ample fresh air

throughout the RV when operating the genset

at all times.

2.4 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 con-

trol panel or from the optional remote panel, proceed

as follows:

1. Turn OFF electrical loads using the means pro-

vided in the vehicle (such as a main line circuit

breaker or transfer switch).



8

Section 2 – Operation

Recreational Vehicle Generator

NOTE:

If starting from the generator control panel, turn

OFF loads by setting the generator’s main circuit

breaker to the OFF (or open) position. If starting

from a remote panel, turn OFF loads using the

means provided in the vehicle (such as a main

circuit breaker). Electrical load circuits will be

turned ON after the generator has started, stabi-

lized and warmed up.

2. If the engine has not been started in more than

two weeks, press the Fuel Pump Primer switch

and hold it for about 10 to 15 seconds to prime

the fuel system. However, if the engine is warm,

skip Step 2.

3. Hold the engine Start/Stop switch in the START

position to crank the engine. Release the switch

when the engine starts.

 If the engine does not start after it has been

cranking for 15 seconds, release the Start/Stop

switch, wait one minute and try again. Holding

the switch for longer than 15 seconds can dam-

age the starter motor.

4. 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).

2.5 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.

2.6 APPLYING LOADS TO GENERATOR

When applying electrical loads to the generator,

observe these guidelines:

• Before applying electrical loads, let the generator

stabilize and warm up for a minute or two.

• DO NOT overload the generator.

2.6.1 LETTING THE ENGINE STABILIZE

The generator supplies correct rated voltage only at

the proper governed speed. Some electrical appli-

ances may be extremely sensitive to voltage. Incorrect

voltages can damage such appliances.



If electrical loads are applied at reduced operating

speeds, such loads imposed on the engine when suf-

ficient power is not available may shorten engine life.

Never turn ON electrical loads until after the genera-

tor engine has started and stabilized at no-load.

2.7 DO NOT OVERLOAD THE

GENERATOR

Read the rated wattage/amperage capacity of the gen-

erator 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 automati-

cally shut down.

To avoid overloading, add up the wattage of all con-

nected electrical lighting, appliance, tool and motor

loads. This total should not be greater than the

generator’s rated wattage capacity.

• Most lighting, appliance, tool and motor loads

indicate their required watts on their nameplate or

data plate. For light bulbs, simply note the wattage

rating of the bulb.

• If a load does not show its rated wattage, multiply

that load’s rated VOLTS times AMPS to obtain

WATTS.

• Induction type motors (such as those that run the

vehicle’s furnace fan, refrigerator, air conditioner,

etc.) need about 2-1/2 time more watts of power for

starting than for running (for a few seconds during

motor starting). Be sure to allow for this when con-

necting electrical loads to the generator. First, fig-

ure the watts needed to start electric motors in the

system. To that figure, add the running wattages of

other items that will be operated by the generator.

• Do not apply heavy electrical loads for the first two

or three hours of operation.

2.8 PROTECTION SYSTEMS

2.8.1 LOW OIL PRESSURE SWITCH

This switch (Figure 2.2) has normally closed (N.C.)

contacts that are held open by engine oil pressure dur-

ing cranking and operating. Should oil pressure drop

below a preset level, switch contacts close, and the

engine automatically shuts down. The unit should not

be restarted until oil is added.

2.8.2 HIGH TEMPERATURE SWITCH

This switch (Figure 2.2), which has normally open

(N.O.) contacts, is mounted near the oil filter. The

contacts close if the temperature should exceed

approximately 284º F (140º C), initiating an engine

shutdown.





9

Section 2 – Operation

Recreational Vehicle Generator

Figure 2.2 – Low Oil Pressure and

High Temperature Switches

High Temperature Switch

Low Oil Pressure

Switch

2.8.3 FIELD BOOST

The Controller Circuit Board houses a field boost

diode and resistor that are not part of the automatic

choke circuit. These two components are part of

a “field boost” circuit (Figure 2.3). 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

2.8.4 OVERVOLTAGE PROTECTION

A solid-state voltage regulator (Figure 2.4) controls

the generator’s AC output voltage. This regulator sup-

plies an excitation current to the rotor. By regulating

the rotor’s excitation current, the strength of its mag-

netic field is regulated and, in turn, the voltage deliv-

ered to connected electrical loads is controlled. When

the AC frequency is 60 Hertz, voltage is regulated at

120 volts (voltage-to-frequency ratio is 2-to-1).





Figure 2.4 – Solid State Voltage Regulator

The voltage regulator also incorporates a “voltage

surge protection circuit.” This circuit prevents trou-

blesome surges in the generator AC output voltage.

Voltage surge is a common cause of damage to elec-

tronic equipment.

2.9 ADDITIONAL INFORMATION

2.9.1 25-HOUR BREAK-IN PERIOD

The first 25 hours of operation is the break-in period

for the generator. Properly breaking in the genera-

tor is essential to minimize fuel consumption and

provide maximum engine performance. During this

25-hour break-in period, follow this procedure:

• Run the unit at varying electrical loads to help seat

the engine piston rings properly.

• Check the engine oil level frequently. Add oil if

needed. It is normal for the generator engine to

consume more oil than is normal until the piston

rings have properly seated.

• For the 75-hour operation following the break-in

period, avoid light electrical loads. Load the gen-

erator at 50 percent (or more) of its rated watt-

age capacity. Repeated light loads during these 75

hours can cause improper seating of engine piston

rings, resulting in blowby and high oil consump-

tion.

• After operating the unit for 25 hours, complete the

tasks recommended under Section 2.10.2.

2.9.2 25-HOUR CHECK-UP

After the 25-hour break-in period, contact an

Authorized Service Dealer for the following main-

tenance. The vehicle owner is responsible for any

charges:

• Change the engine crankcase oil and oil filter.

• Check the oil level.

• Inspect the cooling and ventilation openings.

• Check the engine carburetor adjustments.

• Check the engine ignition system.

• Inspect the entire electrical system.

• Inspect the engine exhaust system.





10

Section 3 – Maintenance

Recreational Vehicle Generator

10

2.9.3 ATTENTION REQUIRED AFTER

SUBMERSION

If the recreational vehicle generator has been sub-

merged in water, it MUST NOT be started and oper-

ated. Following any submersion in water, have an

Authorized Service Dealer thoroughly clean and dry

the generator.

2.9.4 OPERATION IN HIGH GRASS ORBRUSH

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.

2.9.5 EFFECTS OF MOISTURE AND DIRT

Keep the generator set as clean and dry as possible.

Protect the unit against excessive dust, dirt, cor-

rosive vapors, road splash, etc. Permitting dirt and

moisture to accumulate on generator windings will

have an adverse effect on the insulation resistance of

those windings.

When moisture is allowed to remain in contact with

windings, some of the moisture will be retained in

voids and cracks in the insulation. This causes a

reduced insulation resistance and will eventually

cause problems. Dirt will make the problem worse,

since dirt tends to hold moisture in contact with

windings. Salt (as from sea air) also will worsen the

problem since it tends to absorb moisture from the

air. Salt and moisture, when combined, form a good

electrical conductor.







3.1 CHECKING THE ENGINE OIL

LEVEL

For oil capacities and requirements, see “Engine

Oil Requirements,” Section 1.5.4. Check the engine

crankcase oil level at least every eight hours of opera-

tion, or before using it. To check the engine oil level,

proceed as follows (see Figure 3.1):

1. Be sure the generator is as level as possible.

2. Remove the dipstick and wipe it dry with a clean,

lint-free cloth.

3. Install and tighten the dipstick cap; then, remove

it again. The oil level should be at the dipstick

“Full” mark.

4. If necessary, remove the oil fill cap on the rocker

cover and slowly add oil until it reaches the dip-

stick “Full” mark. DO NOT FILL ABOVE THE

“FULL” MARK.

 Never operate the engine with the oil level

below the “Add” mark on the dipstick. Doing

this could damage the engine.

5. Install and tighten the oil fill cap and the dipstick

before operating the engine.

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 peri-

od, 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.

GENERAC OHVI INDUSTRIAL ENGINE

I

t

r

e

,

e

h

i

t

w

a

n

c

.

-

s

m

,

I

e

W

POWERED

W

y

s

S

r

o

P

w

e

A

C

N

R

E

G

E

OHVI

t

GENERAC

TM

RV SERVICE LOCATOR:

1.800.333.1322

QUIETPACT 40G

*

S E R V I C E A C C E S S P A N E L

OIL LEVEL: CHECK DAILY

AIR FILTER: CLEAN PREFILTER

EVERY 100 HOURS.

REPLACE ELEMENT

EVERY 250 HOURS.

OIL & OIL FILTER:

CHANGE EVERY 100

(IF NECESSARY)

EVERY 500 HOURS.

HOURS. REPLACE PLUGS

PLUGS EVERY 100

INSPECT & CLEANSPARK PLUGS:

REPLACEMENT INFORMATION

*

PERFORM MORE OFTEN IN DUSTY CONDITIONS

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE

AIR FILTER P/N: 0D3262

070185OIL FILTER P/N:

SPARK PLUG P/N: 072347

OIL CAPACITY WITH FILTER:

0.8L/0.84QT

TEMPERATURE SAE VISCOSITY

32˚F AND HIGHER

10˚F TO 100˚F

0˚F TO 80˚F

-20˚F TO 50˚F 5W-30

10W-30

15W-40

30

WHEN SERVICE OR PARTS ARE NEEDED IN

THE USA OR CANADA, CONTACT THE GENERAC

SERVICE LOCATOR AT 1-800-333-1322.

HOURS. (OR ANNUALLY)

PREFILTER P/N: 0D4511

FUEL FILTER P/N: 0D7515

FUEL FILTER: CHANGE EVERY 400

HOURS. (OR ANNUALLY)

*

*

P R I M E

F U E L

S T O P

S T A R T 3 0 A

C . B .

A

F U S E

CONTROL CENTER

7.5

T

o

R

e

m

o

v

e

Oil Dipstick/Oil Fill Oil Drain Oil Filter

Figure 3.1 – Oil Maintenance Features

11

Section 3 – Maintenance

Recreational Vehicle Generator

• Change the engine oil filter after the first 25 hours

of operation, and every 100 operating hours there-

after.

To change the oil and/or oil filter, proceed as

follows (see Figure 3.1):

1. Run the engine until it is thoroughly warmed up

(at least five minutes) then shut OFF the engine.

2. Immediately after the engine shuts OFF, pull the

oil drain cover free of the base. Remove the plug

from the tube with a 5/16” allen wrench and drain

the oil into a suitable container. Loosening the oil

fill cap will allow the crankcase to drain faster.

3. After the oil has drained, replace the plug onto

the end of the oil drain tube. Retain the cover in

the base.

4. With the oil drained, remove the old oil filter by

turning it counterclockwise. Place a towel under-

neath to catch excess oil.

5. Apply a light coating of clean engine oil to the gas-

ket of the new filter. Fill the filter until saturated

with clean oil.

6. Screw the new filter on by hand until its gasket

lightly contacts the oil filter adapter. Then, tighten

the filter an additional 3/4 to one turn.

7. Remove the dipstick and wipe it dry with a clean,

lint-free cloth. This will be used later to check the

oil level.

8. Remove the oil fill cap on the oil fill tube and

slowly add the proper type and amount of recom-

mended oil (see 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 fre-

quently 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.

4. Wash the foam precleaner in liquid detergent and

water.

5. Wrap the foam precleaner in a clean cloth and

gently squeeze it dry.

6. Saturate the foam precleaner in clean engine

oil. Gently squeeze it in a clean cloth to remove

excess oil and to distribute oil (DO NOT TWIST).

7. Install the foam precleaner into the cover, fol-

lowed by the paper filter.

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.

3.4 CLEAN AIR INTAKE

Clean all foreign material from the air intake (Figure

3.3) at least once every 100 hours of operation. Clean

more often if necessary.

Inspect the area around the generator exhaust muf-

fler periodically and remove all grass, leaves, dirt,

etc., from this area.



12

Section 3 – Maintenance

Recreational Vehicle Generator

Figure 3.3 – Cleaning Air Intake

USTC

3.5 CHECKING THE ENGINE SPARK

PLUG

Clean the spark plug and reset the spark plug gap

every 100 hours of operation.

1. Clean the area around the base of the spark plug

to keep dirt and debris out of the engine. Remove

the spark plug and check the condition. Replace

the spark plug if worn or if reuse is question-

able.

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

 Sparking can occur if the wire terminal does

not fit firmly on the spark plug terminal end. If

necessary, re-form the wire terminal to obtain

a tight fit.

3.6 CLEAN SPARK ARRESTOR

The engine exhaust muffler has a spark arrestor

screen. Inspect and clean the screen every 50 hours

of operation or once each year, whichever comes first

(Figure 3.5).

NOTE:

If using the generator on any forest-covered,

brush-covered or grass-covered unimproved land,

it must equipped with a spark arrestor. The spark

arrestor must be maintained in good condition by

the owner/operator.

Clean and inspect the spark arrestor as follows:

• Remove the screen retaining bracket by removing

the screw.

• Slide the spark arrestor screen out from the tail

pipe.

• Inspect screen and replace if torn, perforated or

otherwise damaged. DO NOT USE a defective

screen. If screen is not damaged, clean it with com-

mercial solvent.

• Replace the screen and the retaining bracket.

Figure 3.5 - Spark Arrestor

RETAINING

SCREW P/N 056892

SPARK ARRRESTOR

SCREEN P/N 089680

TAILPIPE

P/N 0E0683

3.7 CLEANING THE GENERATOR

Keep the generator set as clean and dry as possible.

Protect the unit against excessive dust, dirt, corrosive

vapors, road splash, etc. Permitting dirt and mois-

ture to accumulate on generator windings will have

an adverse effect on the insulation resistance of those

windings.

When moisture is allowed to remain in contact with

windings, some of the moisture will be retained in

voids and cracks in the insulation. This causes a

reduced insulation resistance and will eventually

cause problems. Dirt will make the problem worse,

since dirt tends to hold moisture in contact with

windings. Salt (as from sea air) also will worsen the

problem since it tends to absorb moisture from the

air. Salt and moisture, when combined, form a good

electrical conductor which can be damaging to the

generator windings.

Section 3 – Maintenance

Recreational Vehicle Generator

 Do NOT use a forceful spray of water to clean

the generator. Water will enter the generator

interior and cause problems, and may also con-

taminate the generator fuel system.

3.8 BATTERY MAINTENANCE

All lead-acid batteries will discharge when not in

use. The generator battery should be inspected as

follows:

3.8.1 WEEKLY

• Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

• Check the battery fluid level of unsealed batteries

and, if necessary, fill with Distilled Water Only. Do

not use tap water in batteries.

3.8.2 EVERY SIX MONTHS

• Have the state of charge and condition checked.

This should be done with an automotive-type bat-

tery hydrometer.

NOTE:

Servicing of the battery is to be performed or

supervised by personnel knowledgeable of batter-

ies and the required precautions. Keep unauthor-

ized personnel away from batteries.

Damage will result if the battery connections are

made in reverse.

DANGER

 Do not dispose of the battery in a fire. The

battery is capable of exploding. Storage bat-

teries give off explosive hydrogen gas. This gas

can form an explosive mixture around the bat-

tery for several hours after charging. The slight-

est spark can ignite the gas and cause an explo-

sion. Such an explosion can shatter the battery

and cause blindness or other injury. Any area

that houses a storage battery must be properly

ventilated. Do not allow smoking, open flame,

sparks, or any spark producing tools or equip-

ment near the battery. Discharge static electric-

ity from body before touching the battery by

first touching a grounded metal surface.

 A battery presents a risk of electrical shock

and high short circuit current. The following

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.

 Do not open or mutilate the battery. Released

electrolyte has been known to be harmful to

the skin and eyes, and to be toxic.

 The electrolyte is a dilute sulfuric acid that is

harmful to the skin and eyes. It is electrically

conductive and corrosive. The following

procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

• Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and seek

medical attention; and

• Spilled electrolyte is to be washed down with an

acid neutralizing agent. A common practice is to

use a solution of 1 pound (500 grams) bicarbonate

of soda to 1 gallon (4 liters) or water. The bicar-

bonate of soda solution is to be added until the

evidence of reaction (foaming) has ceased. The

resulting liquid is to be flushed with water and the

area dried.

3.9 MAJOR SERVICE MANUAL

To obtain a service manual for the generator, contact

the nearest Authorized Service Dealer or. Make sure

to identify the MODEL NUMBER and SERIES.

3.10 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.

3.11 OUT OF SERVICE PROCEDURE

3.11.1 REMOVAL FROM SERVICE

If the generator cannot be exercised every seven days,

and it is to be out of service longer than 30 days, pre-

pare the generator for storage as follows:

1. Start the engine and let it warm up.

2. Close the fuel shutoff valve in the fuel supply line

and allow the unit to shut down.

NOTE:

Using a fuel additive such as STA-BIL fuel stabi-

lizer, or an equivalent, will prevent gum deposits

from forming in the engine’s fuel system.



13

14

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.

3.11.2 RETURN TO SERVICE

To return the unit to service after storage, proceed

as follows:

1. Check the tag on the engine for oil viscosity and

classification. Verify that the correct recommend-

ed oil is used in the engine (see Section 1.5.4,

Page 6). If necessary, drain and refill with the

proper oil.

2. Check the state of the battery. Fill all cells of

unsealed batteries to the proper level with dis-

tilled water. DO NOT USE TAP WATER IN THE

BATTERY. Recharge the battery to 100 percent

state of charge, or, if defective, replace the battery.

3. Clean and wipe the entire generator.

4. Reconnect the battery. Observe battery polarity.

Damage may occur if the battery is connected

incorrectly.

5. Turn OFF all electrical loads. Add fuel if neces-

sary and then start the engine.

6. Allow the unit to 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.

3.12 ADJUSTING VALVE CLEARANCE

After the first 50 hours of operation, adjust the valve

clearance in the engine.

When adjusting valve clearance, the engine should be

at room temperature and the piston should be at Top

Dead Center (TDC) of its compression stroke (both

valves closed). Correct clearance is 0.001-0.003 inch

(0.03-0.07mm). Adjust valve clearance as follows:

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 3.6).



Figure 3.6 — Adjusting Valve Clearance

2. When valve clearance is correct, hold the pivot

ball stud with the allen wrench and tighten the

rocker arm jam nut with a crows foot. Tighten

the jam nut to 65-85 inch-pounds torque. After

tightening the jam nut, recheck valve clearance to

make sure it did not change (Figure 3.7).

Figure 3.7 — Tightening Jam Nut

3.13 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

500 Hours ................................Replace Spark Plugs

1st 50 Hours-then

every 500 Hrs. .......................... Adjust Valve Lash

Section 3 – Maintenance

Recreational Vehicle Generator

PART II –

INSTALLATION

INSTRUCTIONS

DANGER

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

16

NOTICE TO INSTALLER

These Installation Instructions have been published

by the manufacturer to aid in the installation of the

products described in this manual. The manufac-

turer assumes that installation personnel are familiar

with the procedures for installing such products, or

similar products. The manufacturer also assumes

that personnel have been trained in the recommend-

ed 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 anticipate every possible

circumstance that might involve a hazard. The warn-

ings in this manual, and on tags and decals affixed

to the unit, are, therefore, not all inclusive. If using

a procedure, work method or operating technique

the manufacturer does not specifically recommend,

ensure that it is safe for others. Also make sure the

procedure, work method or operating technique uti-

lized does not render the generator unsafe.

Information, illustrations, specifications, etc., con-

tained in these Installation Instructions are based on

the latest information available at the time of publica-

tion. Every effort has been expended to be sure that

such data is both accurate and current. However, the

manufacturer reserves the right to change, alter or

otherwise improve this product at any time without

prior notice.

DANGER

 Despite the safe design of this generator,

operating this equipment imprudently, neglecting

its maintenance or being careless can cause

possible injury or death. Permit only responsible

and capable persons to operate or maintain this

equipment.

 Potentially lethal voltages are generated by

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

 Parts of the generator are rotating and/or hot

during operation. Exercise care near running

generators.

 GENERAL HAZARDS 

• For safety reasons, the manufacturer recommends

that the installation, initial start-up and main-

tenance of this equipment is carried out by an

Authorized Service Dealer.

• The engine exhaust fumes contain carbon monox-

ide, which can be DEADLY. This dangerous gas, if

breathed in sufficient concentrations, can cause

unconsciousness or even death. This exhaust

system must be installed properly, in strict com-

pliance with applicable codes and standards.

Following installation, do nothing that might ren-

der the system unsafe or in noncompliance with

such codes and standards. The generator com-

partment must be completely vapor sealed from

the vehicle interior. There must be no possibility of

exhaust fumes entering the vehicle interior. Never

operate this equipment with a leaking or defective

exhaust system.

• Keep hands, feet, clothing, etc., away from drive

belts, fans, and other moving or hot parts. Never

remove any drive belt or fan guard while the unit

is operating.

• Adequate, unobstructed flow of cooling and ven-

tilating air is critical to correct generator opera-

tion and is required to expel toxic fumes and fuel

vapors from the generator compartment. Without

sufficient cooling airflow, the engine/generator

quickly overheats, which causes serious damage

to the generator. Do not alter the installation or

permit even partial blockage of ventilation provi-

sions, as this can seriously affect safe operation of

the generator.

• When working on this equipment, remain alert

at all times. Never work on the equipment when

physically or mentally fatigued.

• Before performing any maintenance on the gen-

erator, disconnect its battery cables to prevent

accidental start up. Disconnect the cable from the

battery post indicated by a NEGATIVE, NEG or (–)

first. Reconnect that cable last.

• Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break

parts, and may result in dangerous operating con-

ditions from leaking exhaust gases, fuel leakage,

oil leakage, etc.

• Never insert any tool or other object through open-

ings in the generator interior, even if the unit is not

running. Serious injury or damage to the equip-

ment may occur.

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.





17

 ELECTRICAL HAZARDS 

• The generator covered by this manual produces

dangerous electrical voltages and can cause fatal

electrical shock. Avoid contact with bare wires, ter-

minals, connections, etc., while the unit is running.

Ensure all appropriate covers, guards and barriers

are in place before operating the generator. If work

must be done around an operating unit, stand on

an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while

standing in water, while barefoot, or while hands or

feet are wet. DANGEROUS ELECTRICAL SHOCK

MAY RESULT.

• During installation onto the vehicle, properly

ground (bond) the generator either by solid mount-

ing to the vehicle frame or chassis, or by means of

an approved bonding conductor. DO NOT connect

the bonding conductor to any generator part that

might be removed or disassembled during routine

maintenance. If the grounding conductor must be

replaced, use only a flexible conductor that is of

No. 8 American Wire Gauge (AWG) copper wire

minimum.

• If the vehicle electrical circuits can be powered by

any other source of electricity (such as a “dockside”

power receptacle), there must be no possibility of

connecting the different power sources to the vehi-

cle circuits at the same time. The dockside (utility)

power source must be positively isolated from the

vehicle circuits whenever the generator is operat-

ing. Failure to isolate the vehicle circuits from

the dockside power supply when the generator is

running may result in damage to the generator or

serious injury or death to dockside (utility) power

workers due to backfeed of electrical energy.

• In case of accident caused by electric shock, imme-

diately shut down the source of electrical power.

If this is not possible, attempt to free the victim

from the live conductor. AVOID DIRECT CONTACT

WITH THE VICTIM. Use a nonconducting imple-

ment, such as a rope or board, to free the victim

from the live conductor. If the victim is uncon-

scious, apply first aid and get immediate medical

help.

• Never wear jewelry when working on this equip-

ment. Jewelry can conduct electricity resulting in

electric shock, or may get caught in moving com-

ponents causing injury.

 FIRE HAZARDS 

• For fire safety, the generator must be installed

and maintained properly. Installation always must

comply with applicable codes, standards, laws

and regulations. Adhere strictly to local, state and

national electrical and building codes. Comply

with regulations the Occupational Safety and

Health Administration (OSHA) has established.

Also, ensure that the generator is installed in

accordance with the manufacturer’s instructions

and recommendations. Following proper installa-

tion, do nothing that might alter a safe installation

and render the unit in noncompliance with the

aforementioned codes, standards, laws and regula-

tions.

• Keep a fire extinguisher in the vehicle at all times.

Extinguishers rated “ABC” by the National Fire

Protection Association are appropriate for use on

the recreational vehicle generator electrical system.

Keep the extinguisher properly charged and be

familiar with its use. If there are any question per-

taining to fire extinguishers, consult the local fire

department.

 EXPLOSION HAZARDS 

• Do not smoke around the generator. Wipe up any

fuel or oil spills immediately. Ensure that no com-

bustible materials are left in the generator com-

partment, or on or near the generator, as FIRE or

EXPLOSION may result. Keep the area surround-

ing the generator clean and free from debris.

• Gasoline is extremely FLAMMABLE and its vapors

are EXPLOSIVE. Do not permit smoking, open

flame, sparks or any source of heat in the vicinity

while handling gasoline. Comply with all laws gov-

erning the storage and handling of gasoline.

• Fuel lines must be properly installed and

fastened, and free of leaks. There must be

no possibility of gasoline vapors entering the

vehicle interior.

• You are required to install an approved, flexible,

nonconductive fuel line between the generator fuel

connection point and rigid fuel lines.

Safety Rules

Recreational Vehicle Generator

18

1.1 PURPOSE AND SCOPE

OF THE MANUAL

These Installation Instructions have been prepared

especially for the purpose of familiarizing installers

and owners of the applicable equipment with the

product's installation requirements. Give serious

consideration to all information and instructions in

the manual, both for safety and for continued reliable

operation of the equipment.

Because of the different recreational vehicle mod-

els and the variations between the models, it would

be extremely difficult, if not impractical, to provide

detailed instructions for every possible installation.

For that reason, instructions and illustrations in this

manual are general in nature. Illustrations are not

intended to serve as detailed installation blueprints.

The installation should comply strictly with all appli-

cable codes, standards and regulations pertaining

to the installation and use of this product. If any

portion of this manual appears to be in conflict with

such codes, standards or regulations, the applicable

codes, standards or regulations must take prece-

dence over the manual.

1.2 SAFETY

Before handling, installing, operating or servicing this

equipment, carefully read the “Notice to Installer”

and “Safety Rules” on Pages 18 and 19. Comply with

all safety rules to prevent death, personal injury or

damage to equipment and/or property. Stress safety

to all installers, operators and service technicians

who work on this equipment.

1.3 STANDARDS BOOKLETS

Installation, use and servicing of this equipment

should comply strictly with published standards, as

well as the manufacturer's recommendations. The

following standards booklets (latest revision) are

available from the sources indicated:

1. 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, avail-

able from the State of California, Documents

Section, P.O. Box 1015, North Highlands,

CA 95660.

6. CSA Electrical Bulletin 946, available from the

Canadian Standards Association, Housing and

Constructions Materials Section, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada, M9W 1R3.

1.4 EQUIPMENT DESCRIPTION

Instructions and information in this section pertain

to air-cooled generators. This generator is designed

specifically for installing in recreational vehicles. This

generator operates 120-volts, single-phase, 60-Hertz,

AC electrical loads that require 28.3 amps.

1.5 GENERATOR ENGINE

OPERATING SPEED

The generator’s revolving field (rotor) is driven by a

single-cylinder, four-cycle engine. The generator sup-

plies 120 volts AC at 60 Hertz when the rotor is oper-

ating at 3,600 rpm.

1.6 GENERATOR AC

CONNECTION SYSTEM

The generator is equipped with dual stator power

windings as shown in Figure 1.1.

Figure 1.1 – 120-volt Single Voltage Connection

28.3 AMP

• The AC connection system on all air-cooled genera-

tors uses a GROUNDED neutral.

• A separate green ground wire is connected to the

recreational vehicle’s junction box.

NOTE:

Do NOT connect loads in excess of circuit

breaker ratings.

Section 1 – General Information

Recreational Vehicle Generator

19

Figure 1.2 – Major Features and Dimensions (Drawing No. 0F4610)

Section 1 – General Information

Recreational Vehicle Generator

3

42.

2

[13 1/2"]

77

8

.

9

[

30 11/16"

]

REF.

FR

O

NT D

OO

R A

CC

E

SS

F

OR

ALL RE

Q

UIRED MAINTENANC

E

REM

O

TE PANE

L

CO

NNE

C

T

OR

500

.

2

[

19 11/16"

]

REF.

A

C

OU

TP

UT

HARNE

SS

H

O

T AI

R

EXHA

UST

TAIL PIPE

EXIT

O

IL DRAI

N

AIR

INTAKE

4

8

.

1

[

1 7/8"

]

222.7

[

8 3/4"

]

300

.

7

[

11 13/16"

]

369

.

7

[

14 9/16"

]

688

.

3

[

27 1/8"

]

2

9

[

1 1/8"

]

55

.

5

[

2 3/16"

]

3

7

6

.

5

[14 13/16"]

5/

1

6

"-1

8

WELDN

U

T

S

(

6 PLACES

)

8

2.

5

[

3 1/4"

]

3

4

3

.

4

[

13 1/2"

]

42

3

.

2

[

16 11/16"

]

717.7

[

28 1/4"

]

50

.

8

[

2"

]

11

8

[

4 5/8"

]

22

3

.

5

[8 13/16"]

60

[

2 3/8"

]

21

0

[8 1/4"]

17

6

.

6

[6 15/16"]

83

.

5

[

3 5/16"

]

42

9

.

5

[16 15/16"]

414.

5

[16 5/16"]

360

.

5

[14 3/16"]

63

.

5

[

2 1/2"

]

41

6

[16 3/8"]

17

0

[6 11/16"]

7

9

[

3 1/8"

]

1

01

[4"]

TYP.

6

.

7

[

1/4"

]

7

36

.

4

[

29"

]

47

6

.

4

[18 3/4"]

36

.

5

[1 7/16"]

[1 7/16

[1 7/16

39

.

6

[

1 9/16"

]

69

.

6

[

2 3/4"

]

3

4.

3

[

1 3/8"

]

71.2

[

2 13/16"

]

211.

3

[8 5/16"]

NE

G

. BAT

.

CO

NNE

C

TI

ON

P

OS

. BAT

.

CO

NNE

C

TI

ON

LP F

U

EL INLE

T

VIEW FR

O

M T

OP

N

O

TE: ALL AIR INTAKE

S

AND EXHA

US

T

OU

TLET

S

M

US

T B

E

KEPT

C

LEAR

O

F ANY

O

B

S

TR

UC

TI

O

N

S

. ALL

O

PEN ARE

A

IS RE

Q

UIRED FOR COOLING

.

CO

NNE

C

TI

O

N

S

IN

BA

C

K

O

F

G

ENERAT

OR

20

2.1 LOCATION AND SUPPORT

2.1.1 GENERATOR LOCATION

The most desirable location for the generator set is

between the vehicle's main frame members. However,

this is seldom possible. Most units must be installed

on the side of the vehicle and are difficult to rein-

force.

Many recreational vehicles have been factory equipped

with an area for the generator set. Some vehicles may

even have a generator compartment provided by the

vehicle manufacturer.

Plan the generator location based on the following:

• The generator set must be installed on a frame-

work that is part of the recreational vehicle, as

outlined in 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 under-

neath the supporting framework).

• The location must provide easy access to frequent-

ly serviced components, such as filters, oil drains,

spark plugs and other common maintenance

parts.

• The location must provide sufficient room to allow

minimum clearances as outlined in 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 compart-

ment, the base of the generator must rest flat on

the floor without any gaps.

• When using a suspended mounting system, ensure

the base of the generator is flush with the sur-

rounding bodywork. If the unit is mounted higher

in the structure, heated air may recirculate into the

generator causing it to overheat.

2.1.2 GENERATOR SUPPORT

The generator must be securely attached to a metal

framework that has been made part of the vehicle

frame structure by bolting or welding. The metal

framework on which the generator will rest and

which will restrain the generator set should consist

of at least two horizontal beams. These beams should

consist of (a) 1-1/2-inch square, 11-gauge steel tub-

ing OR (b) 1-1/2-inch, 11-gauge angle iron. A typical

supporting frame with horizontal support tubing, is

shown in Figure 2.1.

The generator can be installed so that it sits on top

of the horizontal support tubing if the vehicle design

permits. Another method is to suspend the genera-





tor below the horizontal support tubing by means of

suitable, structurally sound metal framework. The

following general rules apply:

• Vehicle construction MUST be capable of support-

ing the weight of the generator.

• Whether the generator is mounted above the hori-

zontal support tubing or suspended below the tub-

ing, the supporting frame used must be structur-

ally sound.

• If the generator cannot be bolted directly to

the supporting frame or support tubing, con-

sider using additional tubing, angle brackets

or other supports to give the supporting frame suf-

ficient strength.

Figure 2.1 – Typical Horizontal Support Frame

2.1.4 GENERATOR RESTRAINT

Use four 5/16"-18 hardened steel bolts (Grade 5) to

fasten the generator to the supporting frame or the

support tubing. These bolts must pass through (a)

the generator mounting base, (b) the compartment

floor (if a compartment is used) and (c) the support-

ing framework (Figure 2.2). All bolts must be long

enough so that when tight, at least three threads are

visible past the retaining lock nuts. Refer to Section

2.2 for the location of the generator mounting holes.

Figure 2.2 – Typical Generator Restraint



Section 2 – Installation

Recreational Vehicle Generator

21

2.2 GENERATOR COMPARTMENTS

Whether the generator set is being installed inside a

compartment specifically manufactured to house a

generator or inside a compartment that the installer

constructs, the compartment must meet certain spec-

ifications as outlined in the following sections:

2.2.1 COMPARTMENT SIZE

Plan the compartment size carefully. Provide a mini-

mum clearance of 1/2 inch (13 mm) on the front and

top, 1/2 inch (25 mm) on the left side, two (2) inches

on the right side, and 2-1/2 inch (63.5 mm) from the

back for air circulation AFTER the compartment has

been lined with metal and sound insulation (Figure

2.3).

Figure 2.3 – Clearances

2-1/2" Clearance

in Back

1/2" Clearance on Top

2" Right Side

1/2"

in Front

Insulation

Plywood

Compartment

18" Clearance Recommended

Below (Minimum 12")

1/2" Left Side

NOTE:

Refer to “Figure 1.2 – Major Features and

Dimensions”.

2.2.2 COMPARTMENT CONSTRUCTION

• The generator compartment should be either con-

structed of, or lined with, 26-gauge galvanized

steel.

NOTE:

Aluminum is NOT an acceptable alternative

to galvanized steel due to aluminum’s low

melting point.

• If the compartment is lined with galvanized steel,

it may be constructed of any material. The manu-

facturer recommends that the compartment be

constructed of 1/2-inch thick plywood (not strand-

board), with the floor made of a double thickness

of 1/2-inch plywood with the grain of the wood at

cross section for added strength (Figure 2.4).

• If constructing a compartment, line the exterior

(underside) of the compartment floor with 26-

gauge galvanized steel.





Figure 2.4 – Typical Compartment Construction

• All seams, splices and joints of the compart-

ment walls (unless vapor tight by design) should

be caulked to prevent poisonous, flammable or

explosive vapors from entering the vehicle inte-

rior.

NOTE:

Caulking must be done so that the caulking mate-

rial will stay in place permanently. Pressing such

materials as putty tape onto joints and seams is

NOT acceptable. A high quality silicone rubber base

sealant is recommended.

• Holes and openings made in the compartment

walls to allow for the passage of electrical conduit,

conductors, hoses, cables, etc., into the vehicle liv-

ing area must be sealed vapor tight with silicone

rubber base sealant.

• If flexible metal conduit is used, it must be sealed

internally at the end where it terminates inside the

compartment’s electrical junction box.

NOTE:

Flexible metal conduit, due to its unique construc-

tion, is NOT vapor tight along its entire length.

• Seams and joints of the galvanized steel (whether

used as a liner or for the compartment itself) must

be lapped and mechanically secured. Such seams

may be manufactured, welded, bolted, riveted or

screwed. Manufactured lock seams are shown in

Figure 2.5. Installer constructed compartments

typically utilize a standard lap joint.

• After the compartment has been metal lined and

vapor sealed, line the compartment interior walls

and ceiling with an approved, nonflammable sound

insulating material. See Section 2.2.3.

Section 2 – Installation

Recreational Vehicle Generator

22

Figure 2.5 – Types of Lock Seams

DANGER

 Do not install any flammable material directly

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 insulat-

ing 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 seal-

ant or insulating material, to reflect noise away from

the vehicle interior.

Sound insulating materials should be of a nonflam-

mable type. One excellent insulating material is a 1-

inch (25 mm) thick fiberglass having a 2-pound den-

sity. When fiberglass is used, its coated side should

face toward the compartment interior.

DANGER

 Do not install sound insulation or any absorbent

material on the compartment floor interior. Such

materials will become soaked with combustible

or explosive vapors and liquids and will become

a fire hazard.

Using a combination of sound insulating materials

can often reduce noise more effectively than a single

material. For example, a sheet of lead or visco-elastic

material, along with a layer of other acoustical mate-

rial, is more effective than when a single material is

used.



2.2.4 ACOUSTICS

For additional noise abatement, the installer may

wish to consider the following:

• Using special sound insulating materials.

• Construction of a special noise abatement

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.

In addition to the effective use of sound insulating

materials, construction of a special noise abatement

compartment might be considered to reduce noise

levels. Such a compartment might be constructed as

follows (Figure 2.6):

• Use 5/8-inch thick or 3/4-inch thick plywood in the

compartment.

• Construct the compartment floor of a double thick-

ness of 5/8-inch or 3/4-inch plywood.

• Line the compartment interior walls and floor, as

well as the underside of the floor, with 26-gauge

galvanized steel.

• Vapor seal all compartment seams and joints.

• Over the galvanized steel lining, install a combi-

nation of acoustical materials as mentioned in

Section 2.2.3.

DANGER

 To prevent fire or explosion, do not install any

insulation or other absorbent materials on the

interior or underside of the compartment floor.

• Seal all compartment door edges to prevent noise

leakage around the door perimeter.

• Line the compartment door interior (except for air

openings) with suitable, fireproof sound insulation

(such as 1-inch (25 mm) thick fiberglass with a 2-

pound density).

Figure 2.6 – Typical Noise Abatement



Section 2 – Installation

Recreational Vehicle Generator

23

2.2.5 COMPARTMENT FLOOR CUTOUTS

Provide openings in the generator compartment for

the following items (Figure 2.7):

• Engine exhaust and cooling air outlets

• Generator cooling air inlet

• Four holes for passage of generator mounting

bolts. See Section 2.1.4.

DANGER

 Fuel lines and exhaust piping must not pen-

etrate into the vehicle living area.

2.3 COOLING AND VENTILATING AIR

It is absolutely essential that an adequate flow of

air for cooling, ventilating and engine combustion

be supplied to the generator set. Without sufficient

airflow, the engine/generator quickly overheats. Such

overheating can cause serious operating difficulties

and also may cause fire and personal injury. The

installer must make sure that sufficient air is avail-

able to the generator for cooling, ventilating and

combustion. The installer also must provide for a

path for exhausting the cooling air to the exterior of a

compartment, if so equipped.



DANGER

 Never use discharged cooling air for heating or

permit such air to enter the vehicle interior. This

air contains deadly carbon monoxide gas and

other poisonous, flammable or explosive gases.

2.3.1 GENERATOR AIRFLOW

Engine operation drives cooling fans for the two-stage

cooling air system. A pressure fan draws cooling air

into the bottom right side of the generator (Figure

2.8). This airflow cools the engine/generator and elec-

tronic components. The second part of the cooling

system, a suction fan, draws air that is heated from

a hot engine into a collector compartment at the left

side of the unit. This heated air (although cooler than

exhaust muffler) is then deflected out the bottom

toward the ground.



Section 2 – Installation

Recreational Vehicle Generator

Figure 2.7 – Compartment Floor Cutout (Drawing 0F4610)

3

42.

2

[13 1/2"]

77

8

.

9

[

30 11/16"

]

REF.

FR

O

NT D

OO

R A

CC

E

SS

F

OR

ALL RE

Q

UIRED MAINTENANC

E

REM

O

TE PANE

L

CO

NNE

C

T

OR

500

.

2

[

19 11/16"

]

REF.

A

C

OU

TP

UT

HARNE

SS

H

O

T AI

R

EXHA

UST

TAIL PIPE

EXIT

O

IL DRAI

N

AIR

INTAKE

4

8

.

1

[

1 7/8"

]

222.7

[

8 3/4"

]

300

.

7

[

11 13/16"

]

369

.

7

[

14 9/16"

]

688

.

3

[

27 1/8"

]

2

9

[

1 1/8"

]

55

.

5

[

2 3/16"

]

3

7

6

.

5

[14 13/16"]

5/

1

6

"-1

8

WELDN

U

T

S

(

6 PLACES

)

8

2.

5

[

3 1/4"

]

3

4

3

.

4

[

13 1/2"

]

42

3

.

2

[

16 11/16"

]

717.7

[

28 1/4"

]

50

.

8

[

2"

]

11

8

[

4 5/8"

]

22

3

.

5

[8 13/16"]

60

[

2 3/8"

]

21

0

[8 1/4"]

17

6

.

6

[6 15/16"]

83

.

5

[

3 5/16"

]

42

9

.

5

[16 15/16"]

414.

5

[16 5/16"]

360

.

5

[14 3/16"]

63

.

5

[

2 1/2"

]

41

6

[16 3/8"]

17

0

[6 11/16"]

7

9

[

3 1/8"

]

1

01

[4"]

TYP.

6

.

7

[

1/4"

]

7

36

.

4

[

29"

]

47

6

.

4

[18 3/4"]

36

.

5

[1 7/16"]

[1 7/16

[1 7/16

39

.

6

[

1 9/16"

]

69

.

6

[

2 3/4"

]

3

4.

3

[

1 3/8"

]

71.2

[

2 13/16"

]

211.

3

[8 5/16"]

NE

G

. BAT

.

CO

NNE

C

TI

ON

P

OS

. BAT

.

CO

NNE

C

TI

ON

LP F

U

EL INLE

T

VIEW FR

O

M T

OP

N

O

TE: ALL AIR INTAKE

S

AND EXHA

US

T

OU

TLET

S

M

US

T B

E

KEPT

C

LEAR

O

F ANY

O

B

S

TR

UC

TI

O

N

S

. ALL

O

PEN ARE

A

IS RE

Q

UIRED FOR COOLING

.

CO

NNE

C

TI

O

N

S

IN

BA

C

K

O

F

G

ENERAT

OR

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

24

Figure 2.8 – Airflow Through Engine/Generator

2.3.2 TESTING THE INSTALLATION

The manufacturer recommends testing the installa-

tion to be sure adequate cooling airflow is available to

the unit before 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 LP GAS FUEL SYSTEM

DANGER

 LP gas is highly EXPLOSIVE. The gas is heavier

than air and tends to settle in low areas. Even

the slightest spark can ignite it and cause and

explosion. Only competent, qualified people

should be allowed to install, test, adjust or ser-

vice an LP gas fuel system. Install the optional

fuel system in compliance with applicable codes,

standards and regulations. After the installa-

tion, do not do anything that might render the

system in noncompliance with applicable codes

and standards.

The LP powered range of generators are fitted with a

nonadjustable, factory set system. These systems are

tamper-proof to meet 1997 California Air Resources

Board requirements for engine emission.

2.4.1 PARTS NOT INCLUDED IN FUEL

SYSTEM

The propane fuel system does NOT include such

items as (a) gas tank, (b) gas piping, (c) fittings, (d)

valves, and (e) primary regulator, used to store the

gaseous fuel and deliver it to the gaseous fuel sole-

noid (Figure 2.9).





DANGER

 Use only approved components in the fuel sup-

ply system. All components must be properly

installed in accordance with applicable codes.

Improper installation or use of unauthorized

components may result in fire or an explosion.

Follow approved methods to test the system

for leaks. No leakage is permitted. Do not allow

fuel vapors to enter the vehicle interior.

Figure 2.9 – Typical Propane Gas Fuel System

2.4.2 SOME IMPORTANT CONSIDERATIONS

When installing an LP gas system, consider seriously

the following items:

• All fittings, lines, hoses and clamps must be

tight and free of leaks. Apply a pipe sealant to

threads when assembling threaded connections.

This reduces the possibility of leakage.

• Test the entire fuel system for leaks using approved

test methods.

• Optimum gas pressure at the inlet to the gaseous

fuel solenoid valve and secondary regulator is 11

inches water column.

• The installer’s fuel supply connection point is at

the gaseous fuel solenoid valve. This is a 3/4-inch

(female) connection. Provide a suitable 3/4-inch

NPT (male) connector to attach to the fuel supply

line.



Section 2 – Installation

Recreational Vehicle Generator

25

• Use a length of approved flexible fuel hose between

the gaseous fuel solenoid valve and rigid gas pip-

ing. The flexible line should be at least 6 inches

longer than necessary.

2.4.3 VAPOR WITHDRAWAL

LP gas is stored in pressure tanks as a liquid. The

gas systems used with these generators were designed

only for vapor withdrawal type systems. Vapor with-

drawal systems use the gas vapors that form above

the liquid fuel in the tank. Do NOT attempt to use the

generator with any liquid withdrawal type system.

2.4.4 PRIMARY REGULATOR

Gas pressure delivered to the solenoid valve must be

properly regulated by means of a primary gas regu-

lator. Mount the primary regulator at the gas tank

outlet or in the supply line from the gas tank. The

following rules apply:

• For best results, the primary regulator supplies

gaseous fuel to the secondary regulator at 11 inch-

es water column. Do NOT exceed 14 inches water

column.

• The installer must be sure the primary regulator is

rated at sufficient gas flow to operate the generator

plus all other gas appliances in the circuit.

NOTE:

Recommended MINIMUM gas flow rate for all air-

cooled generators is 40 cubic feet per hour.

If an existing primary gas regulator does not have

a sufficient flow capacity for the generator and

other gas appliances in the circuit, (a) install a

primary regulator with adequate flow rate, or (b)

install a separate regulator only and rated at least

40 cubic feet per hour. The inlet side of any pri-

mary regulator that supplies the generator must

connect directly to a gas pressure tank. Do NOT

tee the generator line into a gas circuit feeding

other areas.

2.4.5 GASEOUS CARBURETION

LP gas vapors should be supplied to the secondary

regulator inlet at about 11 inches water column (posi-

tive pressure). The engine pistons draw air in dur-

ing the intake stroke (Figure 2.10). This air passes

through a carburetor venturi, which creates a low

pressure that is proportional to the quantity of air

being pumped. The low pressure from the carburetor

venturi acts on the regulator diaphragm to pull the

diaphragm toward the source of low pressure. A lever

attached to the diaphragm opens a valve to permit

gas glow through the carburetor.







Figure 2.10 – LP Gas Carburetion Diagram

The greater the airflow through the carburetor ven-

turi, the lower the pressure at the venturi throat. The

lower the pressure at the venturi throat, the greater

the diaphragm movement, and the greater the move-

ment of the regulator valve. The more the regulator

valve opens, the greater the gas flow that is propor-

tional to airflow through the generator.

The following facts about the secondary regulator

must be emphasized:

• The regulator must be sensitive to venturi throat

pressure changes throughout the operating range.

• The regulator must be properly adjusted so it will

stop the flow of gas when the engine is not running

(no air flow through the carburetor).

• The slightest airflow (and vacuum in the venturi

throat) should move the regulator valve off its seat

and permit gas to flow.

2.4.6 FUEL SUPPLY LINES

• LP gas lines must be accessible, but protected

against possible damage.

• Do NOT connect electrical wiring to any LP gas fuel

line or run wiring alongside the lines.

• Route gas lines away from hot engine exhausts.

• Retain gas lines with metal clamps that do not have

sharp edges.

• Install an approved length of flexible hose between

the gaseous fuel solenoid valve and rigid fuel

supply lines. The flexible line must be nonmetal-

lic, nonorganic and nonconductive. It must be

approved for use with LP gas.

2.4.7 EXCESS FLOW VALVE

LP gas tanks should have an excess flow valve,

according to NFPA 501C, Paragraph 3-4.4. This

valve and the gas lines must be carefully sized so the

valve will close when a fuel line is severed or broken.

Consult the Natural-LP Gas Association for informa-

tion and limitations of excess flow valves.

Manual shutoff valves on the supply tank and else-

where in the system must be fully open when oper-

ating the generator. The excess flow valve functions

properly only if all valves are fully open.





Section 2 – Installation

Recreational Vehicle Generator

26

2.4.8 LEAKAGE TESTS

Do not place the generator into service until the gas

system has been properly tested for leaks. To test the

system, a separate source of 12 volts DC is needed to

open the gaseous fuel solenoid valve.

The leak test must comply fully with NFPA, Paragraph

318. All connections, hoses, valve regulators, fittings,

and other fuel system parts must be tested under

gas or air pressure of not less than 90 psi (620 kPa),

while using soap and water or an equivalent solution

to check for leaks. Other approved methods of testing

for leaks may be used, if appropriate. DO NOT USE

ANY FLAME TO TEST FOR LEAKS.

DANGER

 Gaseous fuel lines between the tank and the

secondary regulator are under a positive pres-

sure (about 11 inches water column). Gas pres-

sure at the outlet side of the secondary regula-

tor, however, is a negative pressure and can

draw flame inside a line or fitting and cause an

explosion.

2.5 EXHAUST SYSTEM

The generator exhaust system must be safely and

properly installed. Only approved mufflers and other

exhaust system parts must be used. A properly

installed exhaust system must be vapor tight, quiet

and completely safe.

DANGER

 The generator engine gives off DEADLY carbon

monoxide gas through its exhaust system. This

dangerous gas, if breathed in sufficient con-

centrations, can cause unconsciousness or even

death. Never operate the generator set with

the vehicle inside any garage or other enclosed

area. DO NOT OPERATE THE GENERATOR IF THE

EXHAUST SYSTEM IS LEAKING OR HAS BEEN

DAMAGED. SYMPTOMS OF CARBON MONOXIDE

POISONING ARE (a) inability to think coher-

ently; (b) vomiting; (c) twitching muscles; (d)

throbbing temples; (e) dizziness; (f) headaches;

(g) weakness; and (h) sleepiness. IF FEELING

ANY OF THESE SYMPTOMS, MOVE INTO FRESH

AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET

MEDICAL HELP. Do not operate the generator

until its exhaust system has been inspected and

properly repaired.



 Never tee the generator engine exhaust pipe

into the vehicle engine exhaust piping. This

causes excessive back pressure on the generator

engine. Also, water from one engine can dam-

age the other engine.

2.5.1 SPARK ARRESTOR

This spark arrestor assembly meets code and stan-

dard requirements of the U.S. Forest Service. Use

only mufflers and parts approved by the manufactur-

er. Any person(s) installing an unapproved muffler, or

an unapproved exhaust system part, or modifying an

exhaust system in any way that might cause a hazard,

is liable for any damage, injury or warranty expense

that might be caused by such unapproved installation

or modification.

Failure to provide and maintain a spark arrestor may

be in violation of the law. If this generator is used on

any forest covered, brush covered or grass covered

unimproved land, provide a spark arrestor. The vehi-

cle owner or operator must maintain this device in

good condition. In the state of California, the preced-

ing is required by law (Section 4442 of the California

Public Resources Code). Other states may have simi-

lar laws. Federal laws apply on federal lands.

When installing/replacing the tailpipe or spark arres-

tor components, verify that the tailpipe has a hole

to 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

RETAINING

SCREW P/N 056892

SPARK ARRRESTOR

SCREEN P/N 089680

TAILPIPE

P/N 0E0683



Section 2 – Installation

Recreational Vehicle Generator

27

Figure 2.12 — Spark Arrestor Installation

40

[

1.58"

]

5.5

[

7/32"

]

DRIL

L

B

O

TT

O

M

S

IDE

O

NL

Y

27.4

[

1.08"

]

I.D

.

2.5.2 EXHAUST SYSTEM SAFETY

• Maintain a clearance of at least 3 inches (76 mm)

between exhaust system parts and any combus-

tible material (such as wood, felt, cotton, organic

fibers or other like material). If the 3-inch (76 mm)

clearance cannot be maintained, locate, insulate or

shield the exhaust part(s) so that the temperature

of any combustible material is not raised more

than 117° F (65° C) above the ambient air tempera-

ture.

• Extend the exhaust system at least 1 inch (25 mm)

past the outer edge of the vehicle. Do not terminate

the exhaust system under the vehicle.

• Terminate the exhaust tailpipe such that exhaust

gases will not be drawn back into the generator

compartment and recirculated.

• 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 regula-

tions.



2.6 ELECTRICAL CONNECTIONS

Be sure to read Section 1.6.

The following general rules apply to electrical connec-

tions in a recreational vehicle:

• Qualified electricians who are familiar with appli-

cable codes, standards and regulations should

install electrical wiring.

• The wiring should comply with codes, standards

and regulations. The National Electrical Code

(NFPA 70), and state and local codes apply.

• Switches and circuit breakers should be of a type

approved for use in recreational vehicles and must

be mounted and installed to prevent damage from

road shock.

• Wiring must be of adequate size, have approved

insulative qualities and be properly supported.

• Conduit and wire openings into the generator com-

partment (if used) must be vapor-sealed to prevent

entry of flammable, explosive or poisonous gases

into the vehicle.

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 planed for installation of the generator (NOT

on the generator). Route the generator's AC output

leads into this junction box through approved flex-

ible conduit. This is the point of first termination for

generator AC output leads.

2.6.2 WIRING

• Wiring should be of stranded copper to reduce the

chance that vibration may cause breakage.

• Wire gauge size should be large enough to handle at

least 115 percent of the installed generator's rated

maximum current.

• Neutral conductors must be the same size as other

leg wires.

• Route power supply conductors from generator AC

output leads (white), (black) and the green ground

wire through approved flexible conduit to the elec-

trical junction box on the compartment wall.

If flexible metal conduit is used between the gen-

erator and the compartment junction box, the con-

duit end that terminates the compartment junction

box must be vapor-sealed. Flexible metal conduit

is NOT vapor tight along its entire length.

• From the junction box, route power supply wires

through approved conduit to either (a) double-pole,

double-throw transfer switch, or (b) approved iso-

lation receptacle. Connecting to a transfer switch

or isolation receptacle must prevent vehicle electri-

cal circuits from being connected to two different

power supplies at the same time (such as genera-

tor and dockside power).





Section 2 – Installation

Recreational Vehicle Generator

28

• 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.

Figure 2.13 – Generator AC Output Leads

3

42.

2

[13 1/2"]

77

8

.

9

[

30 11/16"

]

REF.

FR

O

NT D

OO

R A

CC

E

SS

F

OR

ALL RE

Q

UIRED MAINTENANC

E

REM

O

TE PANE

L

CO

NNE

C

T

OR

500

.

2

[

19 11/16"

]

REF.

A

C

OU

TP

UT

HARNE

SS

H

O

T AI

R

EXHA

UST

TAIL PIPE

EXIT

O

IL DRAI

N

AIR

INTAKE

4

8

.

1

[

1 7/8"

]

222.7

[

8 3/4"

]

300

.

7

[

11 13/16"

]

369

.

7

[

14 9/16"

]

688

.

3

[

27 1/8"

]

2

9

[

1 1/8"

]

55

.

5

[

2 3/16"

]

3

7

6

.

5

[14 13/16"]

5/

1

6

"-1

8

WELDN

U

T

S

(

6 PLACES

)

8

2.

5

[

3 1/4"

]

3

4

3

.

4

[

13 1/2"

]

42

3

.

2

[

16 11/16"

]

717.7

[

28 1/4"

]

50

.

8

[

2"

]

11

8

[

4 5/8"

]

22

3

.

5

[8 13/16"]

60

[

2 3/8"

]

21

0

[8 1/4"]

17

6

.

6

[6 15/16"]

83

.

5

[

3 5/16"

]

42

9

.

5

[16 15/16"]

414.

5

[16 5/16"]

360

.

5

[14 3/16"]

63

.

5

[

2 1/2"

]

41

6

[16 3/8"]

17

0

[6 11/16"]

7

9

[

3 1/8"

]

1

01

[4"]

TYP.

6

.

7

[

1/4"

]

7

36

.

4

[

29"

]

47

6

.

4

[18 3/4"]

36

.

5

[1 7/16"]

[1 7/16

[1 7/16

39

.

6

[

1 9/16"

]

69

.

6

[

2 3/4"

]

3

4.

3

[

1 3/8"

]

71.2

[

2 13/16"

]

211.

3

[8 5/16"]

NE

G

. BAT

.

CO

NNE

C

TI

ON

P

OS

. BAT

.

CO

NNE

C

TI

ON

LP F

U

EL INLE

T

VIEW FR

O

M T

OP

N

O

TE: ALL AIR INTAKE

S

AND EXHA

US

T

OU

TLET

S

M

US

T B

E

KEPT

C

LEAR

O

F ANY

O

B

S

TR

UC

TI

O

N

S

. ALL

O

PEN ARE

A

IS RE

Q

UIRED FOR COOLING

.

CO

NNE

C

TI

O

N

S

IN

BA

C

K

O

F

G

ENERAT

OR

Leads BLACK to WHITE are protected against over-

load by a 30-amp circuit breaker (CB1). Use this

line-to-neutral connection separately to operate 120-

volt, single-phase, 60 Hertz, AC loads requiring up to

3,400 watts (3.4 kW) of power.

 Do NOT connect electrical loads in excess of any

circuit breaker rating or probems will develop

with circuit breaker tripping, which causes a loss

of AC output. Also, do NOT exceed the gener-

ator's rated wattage capacity. Add the watts

or amperes of all lighting, appliance, tool and

motor loads the generator will operate at one

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 genera-

tor movement.





• If using metallic conduit, vapor seal the end of the

conduit where it enters the junction box. Do this

because flexible metallic conduit is not vaporproof

along its entire length.

2.6.5 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 appli-

cable codes, standards and regulations. It must be

large enough to handle the full amperage to which it

will be subjected.

2.6.7 GROUND FAULT CIRCUIT

INTERRUPTERS

The National Electrical Code (NFPA 70, 551-7)

requires that ground fault circuit interrupters (GFCIs)

be installed on all external and some internal electri-

cal receptacles. Contact the dealer for recommenda-

tions.

2.7 BATTERY INSTALLATION

2.7.1 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 bat-

tery 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.











Section 2 – Installation

Recreational Vehicle Generator

29

These generators are rated at about 100 DC amperes

of cranking current.

Select battery cables based on (a) cable length and

(b) prevailing ambient temperatures. Generally, the

longer the cable and the colder the weather, the larger

the cable size must be, as shown in the following

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

Section 2 – Installation

Recreational Vehicle Generator

Figure 2.14 – Transfer Switch Isolation Method

Figure 2.15 – Installation With Isolation Receptacle

CABLE LENGTH

in Feet (Meters) CABLE SIZE

0 to 10 (0 to 3) 2*

11 to 15 (3.4 to 4.5) 0

16 to 20 (4.5 to 6) 000

30

2.7.3 BATTERY CABLE CONNECTIONS

1. Connect the battery cable from the battery post or

terminal indicated by a POSITIVE, POS or (+) to

the lug on the starter contactor (Figure 2.16).

NOTE:

Check to be sure the battery cable boot for the

starter cable has been installed.

2. Connect the battery cable from the battery post

indicated by a NEGATIVE, NEG or (-) to the

frame ground connection (Figure 2.16).

3. Connect cables so the connectors are clean

and tight.

Figure 2.16 – Connecting Battery Cables

3

42.

2

[13 1/2"]

77

8

.

9

[

30 11/16"

]

REF.

FR

O

NT D

OO

R A

CC

E

SS

F

OR

ALL RE

Q

UIRED MAINTENANC

E

REM

O

TE PANE

L

CO

NNE

C

T

OR

500

.

2

[

19 11/16"

]

REF.

A

C

OU

TP

UT

HARNE

SS

H

O

T AI

R

EXHA

UST

TAIL PIPE

EXIT

O

IL DRAI

N

AIR

INTAKE

4

8

.

1

[

1 7/8"

]

222.7

[

8 3/4"

]

300

.

7

[

11 13/16"

]

369

.

7

[

14 9/16"

]

688

.

3

[

27 1/8"

]

2

9

[

1 1/8"

]

55

.

5

[

2 3/16"

]

3

7

6

.

5

[14 13/16"]

5/

1

6

"-1

8

WELDN

U

T

S

(

6 PLACES

)

8

2.

5

[

3 1/4"

]

3

4

3

.

4

[

13 1/2"

]

42

3

.

2

[

16 11/16"

]

717.7

[

28 1/4"

]

50

.

8

[

2"

]

11

8

[

4 5/8"

]

22

3

.

5

[8 13/16"]

60

[

2 3/8"

]

21

0

[8 1/4"]

17

6

.

6

[6 15/16"]

83

.

5

[

3 5/16"

]

42

9

.

5

[16 15/16"]

414.

5

[16 5/16"]

360

.

5

[14 3/16"]

63

.

5

[

2 1/2"

]

41

6

[16 3/8"]

17

0

[6 11/16"]

7

9

[

3 1/8"

]

1

01

[4"]

TYP.

6

.

7

[

1/4"

]

7

36

.

4

[

29"

]

47

6

.

4

[18 3/4"]

36

.

5

[1 7/16"]

[1 7/16

[1 7/16

39

.

6

[

1 9/16"

]

69

.

6

[

2 3/4"

]

3

4.

3

[

1 3/8"

]

71.2

[

2 13/16"

]

211.

3

[8 5/16"]

NE

G

. BAT

.

CO

NNE

C

TI

ON

P

OS

. BAT

.

CO

NNE

C

TI

ON

LP F

U

EL INLE

T

VIEW FR

O

M T

OP

N

O

TE: ALL AIR INTAKE

S

AND EXHA

US

T

OU

TLET

S

M

US

T B

E

KEPT

C

LEAR

O

F ANY

O

B

S

TR

UC

TI

O

N

S

. ALL

O

PEN ARE

A

IS RE

Q

UIRED FOR COOLING

.

CO

NNE

C

TI

O

N

S

IN

BA

C

K

O

F

G

ENERAT

OR

2.7.4 BATTERY COMPARTMENT

Install the generator battery in its own, vented com-

partment. Place the battery compartment away from

any source of heat, sparks or flame.

Provide ventilation openings in the battery compart-

ment. The minimum size of openings should be 2

square inches at the top of the compartment. Mount

the battery on a strong, rigid supporting structure,

where leaks and spills of battery fluid will not cause

damage.

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

12.00"

14

0

17

1

5

1

8

14A

1

3

2

5

4

6

0

14

17

1

8

14A

1

5

1

5

17

14A

1

8

14

0

N

o.

WIRE

WIRE

CO

L

OR

RED

YELL

OW

O

RAN

GE

WHITE

BL

UE

BR

O

W

N

12.0

(

305

)

LENGTH

(

mm

)

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:

0

D

9099

-

B

2.8.1 REMOTE START/STOP PANEL

A remote mounted Start/Stop panel (Figure 2.18) is

available that allows the user to start and stop the

generator engine conveniently from inside the vehicle.

The remote panel includes a Start/Stop switch, hour-

meter, generator run lamp, a fuel prime switch, and

a wire harness. The hourmeter should be used in

conjunction with the maintenance operations found

in Part I of this manual.

Figure 2.18 – Optional Remote Panel

PRIME

F

U

E

L

S

T

OP

R

UN



Section 2 – Installation

Recreational Vehicle Generator

31

Section 3 – Post-installation Start-up Adjustments

Recreational Vehicle Generator

3.1 POST INSTALLATION TESTS

The air-cooled generator set was factory tested and

adjusted. It should not be necessary to adjust the unit

any further except under special circumstances.

 Do not make any unnecessary adjustments.

Factory settings are correct for most applica-

tions. When making adjustments, however, be

careful to avoid overspeeding the engine.

3.2 BEFORE INITIAL START-UP

Before starting, complete the following:

1. Check the engine crankcase oil level and, if nec-

essary, fill to the dipstick “FULL” mark (cross-

hatched area) with the recommended oil. Do not

fill above the FULL mark.

2. Check the fuel supply. Gas fuel lines must have

been properly purged and leak tested in accor-

dance with applicable fuel codes. All fuel shutoff

valves in the fuel supply lines must be open.

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 permit-

ted. Be sure no gasoline fuel vapors enter the

vehicle interior.

3.3 INITIAL START

When absolutely certain that the unit has been prop-

erly installed and prepared for use, start the engine

as follows:

1. Turn off all electrical loads. Do this by setting the

generator’s main circuit breakers to their “OFF”

(or open) position.

2. Refer to Part I, Section 2.5, “Starting the

Generator”, for cranking and starting instruc-

tions. The engine may require more cranking

for initial starting since the fuel lines have to be

primed (use of the primer switch will shorten this

time).

3. 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 gener-

ator’s main circuit breakers to their “OFF” (or

open) position.

7. Let the unit run at no-load for a few minutes to

stabilize internal engine/generator temperatures.

Then, shut down the engine.

NOTE:

The generator set was thoroughly tested and

adjusted at the factory before shipping. No addi-

tional adjustment should be necessary. Only quali-

fied service technicians who have been trained

should perform adjustments outlined in this

manual.

3.4 TESTING UNDER LOAD

Apply electrical loads equal to about 75 to 100 per-

cent of the unit's rated wattage/amperage capacity.

Let the unit run at least 30 minutes with load applied.

During this part of the test, check that the unit is not

running excessively hot and that adequate cooling

airflow is available. Do not allow the unit to overheat

during prolonged operation.

NOTE:

The generator engine is equipped with a high tem-

perature switch. The switch has normally closed

(N.C.) contacts. When the engine temperature is

too high, switch contacts close, and the engine

shuts down automatically.

THE MANUFACTURER RECOMMENDS TESTING

THE GENERATOR FOR ADEQUATE COOLING.

32

3.5 INSTALLATION CHECKLIST

LOCATION AND SUPPORT

❑ Generator is properly located.

❑ Generator is properly supported.

❑ Generator is properly restrained.

GENERATOR COMPARTMENT

❑ Compartment construction is proper.

❑ Holes/Openings are vapor-sealed.

❑ Compartment size is correct.

❑ Compartment is vapor-sealed.

❑ Sound insulation is correct.

❑ Floor cutouts are properly completed.

COOLING AND VENTILATING AIR

❑ Airflow is adequate.

❑ Air inlet opening is correct.

❑ Compensate for restrictions.

❑ Check that installation has been tested.

LP GAS FUEL SYSTEM

❑ Fuel system is properly installed and checked

for leaks.

❑ Pressure at regulator inlet is correct.

❑ Rated flow of primary regulator is correct.

❑ All parts are properly installed.

❑ Fuel system is properly tested/adjusted.

EXHAUST SYSTEM

❑ Exhaust system complies with all applicable

codes.

❑ Exhaust system is properly and safely installed.











ELECTRICAL CONNECTIONS

❑ Connections comply with local code requirements

and all National Electrical Codes.

❑ Junction box is properly installed.

❑ Wiring meets all standards.

❑ All connections are correct.

❑ Conduit is properly installed and sealed.

❑ Generator is properly bonded to the vehicle.

BATTERY INSTALLATION

❑ Recommended battery is installed.

❑ Recommended cables are installed.

❑ Cables are clean and tight.

❑ Cables are connected properly.

❑ Proper ventilation is provided.

❑ Terminals are coated with anti-corrosion grease,

and terminal covers are positioned.

OPTIONAL ACCESSORIES

❑ Check that remote start/stop panels (if used) are

installed properly.

❑ Check that hourmeter kit (if used) is installed

properly.

❑ Check that any other options and accessories (if

used) are installed properly.

POST INSTALLATION TESTS

❑ Check that all tests are completed properly.









DATE OF INSTALLATION ____________________________________________________

NAME OF INSTALLER _______________________________________________________

SIGNATURE OF INSTALLER _________________________________________________

Section 3 – Post-Installation Start-up Adjustments

Recreational Vehicle Generator

33

Appendix 1 – Troubleshooting

Recreational Vehicle Generator

TROUBLESHOOTING GUIDE

Problem Cause Correction

The engine will not crank. 1. Fuse blown 1. Replace fuse.

2. Loose, corroded or defective 2. Tighten, clean or replace

battery cables as necessary.

3. Defective engine Start/Stop 3. Replace Start/Stop switch.

switch

4. Defective starter contactor 4. Replace contactor.

5. Defective starter motor 5. Replace starter motor.

6. Low or defective battery 6. Charge or replace battery.

The engine cranks but 1. Out of fuel 1. Replenish fuel.

will not start. 2. Defective fuel solenoid 2. Replace fuel solenoid.

3. Open #14 wire from 3. Check connections and.

engine control board insulation of #14 wires.

4. Flooded engine 4. Wait 5-10 minutes before trying.

5. Defective spark plug(s) 5. Clean, re-gap or replace plug(s).

6. Fuel line shut-off closed 6. Open fuel line shut-off.

The engine starts hard 1. Air cleaner 1. Check, clean or replace air cleaner.

and runs rough. plugged or damaged

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

The engine starts, but shuts 1. Engine oil level low 1. Check oil and add oil as needed.

down when the Start/Stop 2. Defective low oil 2. Replace pressure switch.

switch is released. pressure switch

3. Defective high temperature 3. Replace temperature switch.

switch

4. Defective engine control board 4. Replace control board.

5. Overheated engine 5. Check that the airflow

openings are adequate.

The Start/Stop switch is 1. Defective Start/Stop switch 1. Replace switch.

set to Stop, but the engine 2. Open/Disconnected #18 wire 2. Reconnect or close wire.

continues to run. between Start/Stop switch

and engine control board

3. Open/Disconnected #0 wire 3. Reconnect or close wire.

between Start/Stop switch

and engine control board

4. Defective engine control board 4. Replace control board.

There is no AC output from 1. Main line circuit breaker open 1. Reset circuit breaker

the generator. to ON (or closed).

2. Fault with vehicle circuit 2. Reset and replace if necessary.

breaker and/or fuses

3. Transfer switch set to NORMAL 3. Set switch to GENERATOR.

4. Start switch not held long 4. Stop, then restart the engine

enough to flash the field (Hold Start switch for at least

2 seconds).

5. Generator internal failure 5. Contact an Authorized Service

Dealer.

RED

BLUE

ORANGE

BROWN

77

YELLOW

WHITE

15

BATTERY CHARGE WINDING

NEUTRAL CONNECTION

GREEN

BY CUSTOMER

WHITE

T2

FIELD

120V 30A

44

0F

0N

0K

22P

DPE WINDING

2

CB3

6

ELECTRONIC

REGULATOR

VOLTAGE

2A

0N

0N

R1

POWER WINDING

22S 11S

77

55

BLACK

FUEL

PRIME

11P

4

4

T1

4

CB1

REMOTE PANEL

(OPTIONAL)

33

4

66

START

HM

L1

1

STOP

8

A41

8

514

18

0

17

BLK

14

4J1-9

J1-15

BCR

14

66

18

J1-11

J1-10

J1-13

J1-12

J1-14 18

0

85

66

J2

J3

15 14

SW2

15

J1-5

J1-4

J1-8

J1-7

J1-6 17

17

18A

J1-2

J1-1

J1-3

PCB

90

56

16

RED

RED

13

15

F1

16

14A

SC

BATTERY

HTO

CONNECTOR

4

17

14

4

1A

5

18

1

0I

17

66

85

85

33

6

5

4

6

5

4

1

2

1

2

PANEL

REMOTE

LOP

0

0

SP

0B

(START)

(STOP)

SW1

IM

SC

14

CH

CS 0

0

0

FS

FP

SM

HTO - SWITCH, HIGH TEMP. OIL (CLOSES ON HIGH TEMP.)

L1 - LIGHT, RUN (OPTIONAL)

LOP - SWITCH, LOW OIL PRESSURE

SW2 - SWITCH FUEL PRIMER

TC - TERMINAL, CONN. 4-TAB

SP - SPARK PLUG

SM - STARTER MOTOR

PCB - ENGINE CONTROLLER

IM - IGNITION MAGNETO

SW1 - SWITCH, START/STOP

SC - STARTER CONTACTOR

R1 - RESISTOR, 1 OHM 25W

(CLOSES ON LOW PRESSURE)

HM - METER, HOUR (OPTIONAL)

FP - FUEL PUMP-OR-LPG SHUT OFF VALVE

CB1 - CIRCUIT BREAKER, 30A

BCR - BATTERY CHARGE RECTIFIER

GT - TERMINAL, GROUND 4-TAB

CB3 - CIRCUIT BREAKER, 2.5A

FS - FUEL SOLENOID (GASOLINE ONLY)

CS - CHOKE SOLENOID

F1 - FUSE, 7.5A

CH - CHOKE HEATER (GASOLINE ONLY)

LEGEND

34

Appendix 2 — Electrical Data

Recreational Vehicle Generator

Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D

35

Appendix 2 — Electrical Data

Recreationl Vehicle Generator

Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D

0

CONN. 2

PIN#

0

90

14

14

CH

18A

90

85

LOP

CS

0

18

RED

18

85

17

18A

85

PCB

J1-7

J1-9

J1-12

J1-11

J1-10

J1-8

J1-15

J1-14

J1-13

J1-2

J1-5

J1-4

J1-3

J1-1

J2

J1-6

J3

18

1

FS

14

2

3

18

18A

18 CONN. 1

PIN#

0

0

FP

90

14

2

1

2A

2

17

18

4

16

CB3

66

0

56

14

15

90

0

90

16 56

IM1

18A

HTO

SP1

85

13 14A

15

18

15

66

77

14

15

14

15

0

0

2

14

14A

14

F1

66

BCR

15

14

2A

13

17

4

15

2A

17

0

15

SW1

SW2

TC

0K

0

0

0

0B

17

18

GT

0

0I

4

2

0

11S

13

0K

4

22S

4

2A

6 2A

REGULATOR

VOLTAGE

ELECTRONIC

14A

15

14A

14A

0F

44

14

0F

17

11P

22P

77

22S

11S

33

66

RED

22P

11P

44

55

6

2

R1

CONNECTOR

17

14

18

REMOTE

PANEL

3

4

7

5

6

0I

55

0N

1

28

14A

15

15

CLOSEST TO BEARING

4

FIELD

STATOR

SM

BATTERY

12V

SC

16

BLACK

NEUTRAL CONNECTION

BY CUSTOMER

BLACK

33

CB1

11P

GT

AC CONNECTION

CUSTOMER

WHITE

T1

GREEN

GREEN

WHITE

T2

11P

0SCREW

FILTER MTG

SUPPLIED BY

CUSTOMER

SUPPLIED BY

CUSTOMER

33

0F

0N

36

23

46

3

7

41

16

2

21

38

15

45

5

4

5

4

3

2

30

3

1

17

19

5

2

42

33

34

5

2

50

5

2

40

5

1

21

41

3

9

21

2

1

52

28

43

36

2

1

4

2

21

18

1

53

21

39

2

3

22

6

10

47

8

24

22

20

44

25

49

7

21

24

26

13

14

12

11

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

Enclosure – Drawing No. 0F4589

37

ITEM PART NO. QTY. DESCRIPTION

1 0F3916 1 TRAY, ENCLOSURE

2 0D6942 1 PANEL, ENCLOSURE SIDE

3 0D6939 1 PANEL, REAR DIVIDER

4 0F3920 1 PANEL, ENCLOSURE ROOF

5 0F3917 1 PANEL, ENCLOSURE BACK

6 0F3918 1 PANEL, FRONT DIVIDER

7 0F3919 1 COMPARTMENT, AIR INTAKE

8 0D6944 1 PANEL, ENCLOSURE DOOR

9 0D8254 1 SHIELD, MUFFLER

10 0C5644 2 SLIDE LATCH, FLUSH

11 0A1495 4 SCREW HHTT M4-0.7 X 10MM

12 0E1742A 1 LP REGULAT0R

13 047290 1 HOSE 3/8" I.D. SINGLE BRAID 33" LONG

14 048031E 1 HOSE CLAMP BAND 3/8"

15 0D8628B 1 FOAM, FRONT AIR OUT COMPARTMENT

16 047411 2 SCREW HHC M6-1.0 X 16

17 022473 2 WASHER FLAT ¼"

18 023484S 1 BUSHING, 1.09" SNAP

19 022097 2 WASHER LOCK M6-1/4"

20 086729 1 CONTACTOR, STARTER

21 0D3700 22 NUT FLANGE M6-1.0 NYLOK

22 022129 2 WASHER LOCK M8-5/16"

23 022259 2 NUT HEX 5/16"-18

24 075763A 2 BOOT BATTERY CABLE

25 0D7293 1 PANEL AIR BOX COVER

26 064113 1 SCREW, M6-1.00 X 20MM WING

27 0C7561 1 BOLT CARR 3/8"-16 X 1" BRASS

28 0A4456 1 3/8" SPECIAL L/WASHER

30 049813 2 NUT HEX M6 X 1.0

31 022237 1 WASHER LOCK 3/8"

32 022131 2 WASHER FLAT 3/8-M10"

33 0C5443 1 BLOCK, TERMINAL BATTERY POST

34 0C7423 1 STUD 3/8"-16 X 2"-1/4" BRASS

35 029451 2.1' TAPE FOAM 1/8" X ½"

36 074908 4 SCREW HHTT M5-0.8 X 10

37 0D8717 1 CUSTOMER CONNECTION HARNESS

38 0D9020 1 FOAM, AIR OUT COMPARTMENT SIDE

39 0742600144 1 CABLE, STARTER

40 0E0724 1 ASSEMBLY OIL DRAIN

41 0A7215 20 SCREW SW ¼"-20 X 5/8" WITH NYLON WASHER

42 0742600143 1 CABLE, BATTERY CONNECTION

43 029451A 8.75' FOAM TAPE 1/16" X ½"

44 0D8627 2 FOAM, AIR INTAKE COMPARTMENT

45 0D8628 1 FOAM, ROOF AIR OUT COMPARTMENT

46 0D8628A 1 FOAM, BACK COMPARTMENT

47 0D8691 1 FOAM, DOOR PANEL

48 0D7176 4 WASHER SELF LOCKING 1"

49 0A2115 1 WASHER NYLON .250"

50 0D9282 1 HARDWARE CLOTH COMPARTMENT AIR OUT

51 0E0393 1 ASSEMBLY, CAP & DIPSTICK

52 0C7968 4 NUT HEX JAM 3/8"-16 BRASS

53 0E0014 1 BOX, MUFFLER TAIL PIPE

54 0E0017 1 GASKET, MUFFLER TAIL PIPE BOX

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

Enclosure – Drawing No. 0F4589

38

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

Generator – Drawing No. 0F4590

22

2

2

5

3

24

25

18

4

1

7

8

9

24

2

21

2

3

7

18

23

2

21

15

18

21

2

18

2

8

38

10

35

28

27

26

11

2

18

23

36

13

2

39

12

2

18

17

43

18

16

14

29

0

1

34

30

3

2

42

3

1

29

33

39

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

Generator – Drawing No. 0F4590

ITEM PART NO. QTY. DESCRIPTION

1 050322 1 SCREW IHHC 5/16"-24 X 9-3/4"

2 022129 22 WASHER LOCK M8-5/16"

3 049451 1 WASHER FLAT .406" I.D. X 1.62" O.D.

4 0C8096A 1 FAN, 8" CURVE BLADE, 16.5MM I.D.

5 0D8120 4 SCREW IHHC M8-1.25 X 260MM

6 066849 2 SCREW HHTT M5-0.8 X 16

7 066386 1 ASSEMBLY, BRUSH HOLDER

8 0D4217 1 CARRIER, REAR BEARING

9 073159 1 BEARING

10 0D4484H 1 ROTOR

11 0D4430H 1 STATOR

12 0D4216 1 ADAPTOR, ENGINE

13 048614 4 SCREW HHC 5/16"-24 X 3/4"

14 0D2588A 1 GASKET, FRONT DIVIDER

15 022131 4 WASHER FLAT 3/8"-M10

16 027028 4 NUT LOCK HEX 5/16"-18 NYLON INSERT

17 0D6832 1 BRACKET, ENGINE MOUNTING

18 022145 18 WASHER FLAT 5/16"

19 030231 3 SCREW HHC 5/16"-18 X 1-1/2"

20 0C3168 1 5/16" SPECIAL LOCK WASHER

21 022259 10 NUT HEX 5/16"-18

22 0C8565 2 SCREW SHC M8-1.25 X 18MM

23 0D8048 4 VIBRATION MOUNT

24 083512 6 SCREW HHTT M8-1.2 X 16MM

25 0D6831 1 BRACKET, ALTERNATOR MOUNTING

26 029451 2.14' TAPE ELEC. UL FOAM 1/8" X 1/2"

27 0D6918 1 DUCT, ALTERNATOR AIR

28 0D2558 1 GASKET, ALTERNATOR DUCT

29 087680 2 NUT WING M6-1.0

30 0D7530 1 STUD, M6-1.0 OFFSET

31 0D9723 1 ELEMENT, AIR FILTER

32 0D4511 1 PRECLEANER, AIR

33 0D8451 1 WASHER FLAT .281" I.D. X 1.50" O.D.

34 022097 1 WASHER LOCK M6-1/4"

35 0D7440 1 MUFFLER

36 090388 2 SCREW HHTT M6-1.0 X 12MM

37 0D7441 2 BOLT CARR 5/16"-18 X 2"

38 081105 2 NUT FLANG 5/16"-18 LOCK

39 089476 1 GASKET, EXHAUST

41 022531 1 SCREW HHC 5/16"-18 X 1-3/4"

42 0D8981 1 FILTER GASKET RV

43 048031E 1 HOSE CLAMP 3/8"

40

31

1

3

1

1

37

36

30

12

1

0

25

1

9

2

8

22

35

14

23

2

3

8

2

9

9

1

6

1

2

6

1

7

1

5

17

3

21

27

6

5

4

17

1

8

24

25

2

0

2

24

2

3

7

2

5

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

Control Panel – Drawing No. 0F4591

41

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

Control Panel – Drawing No. 0F4591

ITEM PART NO. QTY. DESCRIPTION

1 0830490 1 REGULATOR VOLTAGE

2 075210A 1 TERMINAL BLOCK

3 092234 1 CONTROLLER P.C.B.

4 065795 1 BATTERY CHARGER RECTIFIER

5 023484F 2 BUSHING SNAP 1"

6 023484R 1 BUSHING SNAP 1-1/4"

7 075234 1 RESISTOR, 1 OHM 25W

8 057159 1 CIRCUIT BREAKER 2.0 AMP (60Hz)

054502 1 CIRCUIT BREAKER 3.0 AMP (50Hz)

9 087798 1 SWITCH S.P.D.T.

10 092113 1 SWITCH S.P.D.T. ON-MOM-ON

11 032300 1 HOLDER FUSE

12 0A9611 1 FUSE 7.5A

13 090145 1 CIRCUIT BREAKER, 30 X 1 (60Hz)

0E2314 1 CIRCUIT BREAKER, 15A 2 POLE (50Hz)

14 0A1658 2 LOCK WASHER SPECIAL

15 075235 2 SCREW HHC M5-0.8 X 30MM

16 047411 2 SCREW HHC M6-1.0 X 16MM

17 049226 5 WASHER LOCK M5

18 051716 1 NUT HEX M5-0.8

19 075476 2 SCREW PPHM M4-0.7 X 16MM

20 022264 2 WASHER LOCK #8-M4

21 051715 4 NUT HEX M4-0.7

22 0A2053 1 SCREW HHC M6-1.0 X 65MM

23 022473 5 WASHER FLAT 1/4"

24 022097 4 WASHER LOCK M6-1/4"

25 049813 4 NUT HEX M6-1.0

26 055440 2 SCREW HHC M5-0.8 X 25MM

27 049815 1 SCREW HHC M5-0.8 X 16MM

28 038750 2 SCREW HHC M6-1.0 X 30MM

29 051714 2 NUT, HEX M3-0.5

30 0D8794 1 PANEL CONTROL

31 025105 2 SCREW RHM #6-32 X 1/4" SIMS

32 028739 2 TIE WRAP UL 4" (NOT SHOWN)

33 0D8308 1 DECAL (NOT SHOWN)

34 0F5025 1 HARNESS (NOT SHOWN)

35 023484S 1 BUSHING, SNAP 1.09"

36 043182 2 WASHER LOCK M3

37 031879 2 WASHER FLAT M3

42

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

GN-220 H/SH Engine – Drawing No. 0F5791 Part 1

44

3

4

38

43

42

41

9

9

33

37

53

49

50

5

2

48

5

1

9

10

9

40

20

20

18

47

46

9

45

21

23

22

14

19

29

3

2

25

24

26

27

3

1

8

13

15

15

35

30

6

28

36

1

1

12

7

3

9

1

16

16

2

43

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

GN-220 H/SH Engine – Drawing No. 0F5791 Part 1

ITEM PART NO. QTY. DESCRIPTION

1 0D8433 1 GUARD, FAN

2 0C1069 10 SCREW, HHTT M6-1.0 X 8MM

3 090695F 1 BLOWER HOUSING

4 081810 1 NUT, HEX M16-1.5

5 083312 1 WASHER, M16 CONICAL

6 0D8400 1 ASSEMBLY, CHOKE SOLENOID BRACKET

7 0C8917D 1 FLYWHEEL, WITH RING GEAR

8 0C8798A 1 BACKPLATE, ELECTRIC START

9 045756 10 SCREW HHTT M6-1.0 X 10MM

10 082774 1 KEY, WOODRUFF 4 X 19D

11 022129 2 5/16"-M8 LOCK WASHER

12 081990 2 SCREW SHC M8-1.25 X 40MM

13 0D9004A 1 STARTER ASSEMBLY

14 072347 1 SPARKPLUG

15 022097 2 LOCKWASHER, ¼"- M6

16 082981 2 TAPTITE, M6-1.0 X 30MM

17 081675 1 ASSEMBLY, IGNITION COIL

18 0C1085 2 SCREW PPHM M3-0.5 X 8MM

19 0D7666A 1 BREATHER TUBE

20 090051 1 GASKET, MANIFOLD/ HEAD

21 080316 2 SCREW HHFC M6-1.0 X 30MM

22 090948 1 INTAKE MANIFOLD

23 078631 1 GASKET CARBURETOR/MANIFOLD

24 0F5759 1 CARBURETOR LP WITH CHOKE

25 091846 1 GASKET, CARB/ ADAPTOR

26 0D7558 1 ADAPTOR, CARB

27 078643 2 BOLT, CARB MOUNT M6-1.0 X 75MM

28 0D8372 1 GASKET, CARB TO AIRBOX

29 0C2756 1 ASSEMBLY, GOVERNOR LEVER

30 0D7458 1 ROD, GOVERNOR

31 0C3979 1 SPRING, ANTI LASH

32 085953 1 WASHER, CARB WEAR

33 0D8739A 1 ASSEMBLY BRACKET GOVERNOR ADJUST

34 036277 1 ELBOW 90D STREET 1/8NPT

35 0E7019 1 SPRING, GOVERNOR

36 083512 1 SCREW HHTT M8-1.2 X 16MM

37 082025 1 NUT HEX LOCK M5-0.8 NYLOCK

38 092984 1 TOP WRAPPER

39 094820 1 PLUG, EXPANSION

40 089739 1 LOWER WRAPPER

41 091848 1 GASKET, OIL PSI PAD

42 0D8778 1 ADAPTER, OIL FILTER

43 0D8803 2 SCREW SHC M6-1.0 X 22MM

44 0A8584 1 SWITCH, OIL- 10 PSI

45 070185B 1 FILTER, OIL

46 075281 1 SWITCH, THERMAL 284F

47 043182 2 WASHER LOCK M3

48 0D8397 1 ROD, CHOKE CONTROL

49 0D8591 1 SOLENOID, CHOKE

50 077091 1 PIN, COTTER

51 0A7095 2 SCREW PRHMS #4-40 X 1-1/8" LONG

52 077075 1 COVER, CHOKE COIL

53 0C2824 2 SCREW TAP-R #10-32 X 9/16"

44

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

GN-220 H/SH Engine – Drawing No. 0F5791 Part 2

20

36

50

43

42

45

44

46

25

26

48

24

22

23

31

30

3

2

17

28

13

4

29

38

37

40

39

21

5

1

15

35

16

5

41

49

34

19

18

1

8

1

5

2

7

2

6

47

11

13

7

3

10

12

9

10

45

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

GN-220 H/SH Engine – Drawing No. 0F5791 Part 2

ITEM PART NO. QTY. DESCRIPTION

N/A 0F5800 1 LONG BLOCK ASSEMBLY 220 RV LP

1 078621 1 CONNECTING ROD ASSEMBLY

2 076389 1 PISTON PIN

3 088411 1 PISTON RING SET

4 0A8897B 1 GEAR COVER ASSEMBLY

5 077168 5 M8 X 56MM HEAD BOLT

6 088057 1 PISTON

7 076390 2 PIN RETAINER RING

8 083337A 1 TAPERED CRANKSHAFT ASSEMBLY

9 078658 1 GOVERNOR "R" PIN

10 0F0967 2 WASHER FLAT 1/4, .015 THK

11 089213E 1 CRANKCASE ASSEMBLY

12 0A7637 1 GOVERNOR ARM

13 0E3811 2 OIL SEAL

14 0D1303 1 GOVERNOR GEAR ASSEMBLY

15 078645 1 GOVERNOR GEAR C-RING

16 0A7811 1 GOVERNOR SPOOL

17 072683A 1 1/8" NPT PIPE PLUG

18 0F0687 1 CAMSHAFT ASSEMBLY

19 089096 1 CRANKCASE GASKET

20 088156 1 VALVE STEM SEAL

21 0A8822 1 CYLINDER HEAD GASKET

22 078691 1 OIL PRESSURE RELIEF COVER

23 0A5772 1 OIL PRESSURE SPRING

24 0A5776 1 11/32" BALL

25 074908 1 M5 FORM SCREW

26 078606 4 M6-1.0 X 12MM SCREW

27 076361 1 GOVERNOR GEAR THRUST WASHER

28 0D2414 6 SCREW, HHFC M8-1.25 X 35MM

29 099922 1 SPRING WASHER

30 0C3733 2 VALVE RETAINER

31 0C4390 2 VALVE SPRING

32 084186 2 VALVE SPRING WEAR WASHER

33 083192 1 GEROTER SET

34 0E0057 1 "O" RING

35 078699B 4 SLEEVE, SEAM DWL

36 021705B 1 CYLINDER HEAD ASSEMBLY

37 0C3590 1 EXHAUST VALVE

38 0C3591 1 INTAKE VALVE

39 0D9853A 2 PUSH ROD

40 083235 2 TAPPET

41 080336 1 OIL PICK-UP ASSEMBLY

42 0C8754 1 ROCKER COVER GASKET

43 077161 2 PIVOT BALL STUD

44 077160 2 GN- 191/220 ROCKER ARM

45 076307 2 ROCKER ARM JAM NUT

46 088403 1 PUSH ROD GUIDE PLATE

47 026073A 1 1/4" NPT PIPE PLUG

48 088412A 1 ROCKER COVER ASSEMBLY

49 076329 1 PLASTIC OIL FILL PLUG

50 0C3592 4 VALVE SPRING KEEPER

51 049340 1 BARBED ELBOW 90 1/4" NPT X 3/8"

52 045761A 1 STUD M8-1.25 / 10MM X 30MM

46

9

14

12

11

1

8

1

6

1

3

1

5

17

1

9

2

3

21

2

0

22

2

5

24

2

6

8

1

0

4

6

5

3

2

1

7

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

Regulator – Drawing No. 0F5819

47

ITEM PART NO. QTY. DESCRIPTION

1 0D5694 1 CASTING, TWIN REGULATOR HOUSING

2 0F4795 4 SCREW PPHM SEMS M4-0.7 X 10

3 0F5022 1 SOLENOID COIL, 12VDC

4 0C6070 1 SPRING-SOLENOID PLUNGER

5 0C4680 1 PLUNGER LP REG. ASSY

6 0C4647 1 GASKET, SOLENOID

7 0C4643 1 INLET, TWIN REGULATOR NO HOLE

8 0D3973 1 PLUG, EXPANSION 16MM TWINREG

9 0D7020A 1 BARBED STR 1/2NPT X 3/8" W/VS

10 026073 2 PLUG STD PIPE 1/8 STEEL SQ HD

11 0D3308 2 WASHER FLAT 3.2MM ID X 10MM OD

12 070728 2 SCREW PFILHM M3-0.5 X 5

13 0C5764 1 SPRING, REGULATOR

14 0C4643A 1 INLET, TWIN REG 11.11 DIA.

15 0C5764 1 SEAL, INLET REGULATOR

16 0C5968 1 SUPPORT, INLET SEAL

17 0C5759 1 PIN, PIVOT ARM

18 0C5761 1 LEVER, REGULATOR

19 0C6069 1 GASKET, DIAPHRAGM

20 0C6731 1 RIVET .118 X .125 ALUMINUM

21 0C6067 1 SUPPORT, DIAPHRAGM

22 0C4706 1 DIAPHRAGM, TWIN REGULATOR

23 0C6068 1 CAP, DIAPHRAGM SUPPORT

24 0C5762 1 COVER,TWIN REGULATOR

25 045764 8 SCREW HHTT M4-0.7 X 8 BP

26 0C5760K 1 JET LP

Appendix 3 — Exploded Views and Parts Lists

Recreational Vehicle Generator

Regulator – Drawing No. 0F5819

48

CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with

Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.*

New utility, and lawn and garden equipment engines must be designed, built and equipped to meet stringent anti-smog

standards for the state of California and the federal government. Generac will warrant the emission control system on your

engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improper

maintenance of your engine.

Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair

your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted. If, dur-

ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or

workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:

As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory

supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance

on your engine. However, Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure

the completion of all scheduled maintenance.

As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or

responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unap-

proved modifications, or the use of counterfeit and/or ‘grey market’ parts not made, supplied or approved by Generac.

You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem

occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.

To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:

1-800-333-1322

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System

Warranty (ECS Warranty), which is provided to you by Generac pursuant to California and federal law. See also the “Generac

Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you

by Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in

terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where

the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe

important rights and obligations with respect to your new engine.

Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty ser-

vice, evidence must be presented showing the date of the sale to the original purchaser/owner. The purchaser/owner shall

be responsible for any expenses or other charges incurred for service calls and/or transportation of the product to/from the

inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or all damages or losses incurred

while the engine is being transported/shipped for inspection or warranty repairs.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the fol-

lowing address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 297

WHITEWATER, WI 53190

Part 1

Appendix 4 – Warranty

Recreational Vehicle Generator

49

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:

*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 4 – Warranty

Recreational Vehicle Generator

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

Part No. 0F4594 Revision 0 (06/29/05) Printed in U.S.A.

Appendix 4 – 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.

P.O. BOX 297 • WHITEWATER, WI 53190 Revision 02.05