Generac 005753-0, 005856-0, 005411-0, 005415-0, 005855-0 User Manual

...
Models: 005411-0, 005413-0, 005415-0, 005751-0, 005752-0, 005753-0, 005855-0, 005856-0, 005857-0

Owner's Manual

www.generac.com or 1-888-GENERAC
Air-cooled Recreational
Vehicle Generators
RV 45, 55 and 65

Table of Contents

Introduction .............................................................. 1
Read This Manual Thoroughly ........................................... 1
Contents ............................................................................. 1
Operation and Maintenance .............................................. 1
How to Obtain Service ....................................................... 1
Authorized Service Dealer Locator Number ..........................1
Safety Rules .............................................................2
Section 1 – General Information .............................4
1.1 Generator Identification .............................................. 4
1.2 Generator Applicability ............................................... 5
1.3 Installation ...................................................................5
1.4 Safety .......................................................................... 5
1.5 Generator AC Connection System .............................5
1.6 Specifications .............................................................. 6
1.7 Exhaust Emissions Information (Gasoline) ................ 7
1.8 Evaporative Emissions Information ............................8
Section 2 – Operation .............................................. 8
2.1 Generator Control Panel ............................................. 8
2.2 Optional Remote Start/Stop Panel ............................. 9
2.3 Automatic Choke ........................................................ 9
2.4 Before Starting the Engine ......................................... 9
2.5 Starting the Generator .............................................. 10
2.6 Stopping the Generator ............................................10
2.7 Applying Loads to Generator ................................... 10
2.8 Protection Systems ................................................... 11
Section 3 – Maintenance........................................ 12
3.1 Checking the Engine Oil Level ................................. 12
3.2 Changing the Engine Oil and/or Oil Filter ................ 12
3.3 Maintaining the Engine Air Cleaner .......................... 13
3.4 Checking the Engine Spark Plug ............................. 13
3.5 Fuel Filter (Gasoline Only) ........................................ 13
3.6 Clean Spark Arrestor ................................................14
3.7 Cleaning the Generator ............................................ 14
3.8 Battery Maintenance ................................................. 14
3.9 Adjusting Valve Clearance ........................................ 15
3.10 Major Service Manual ............................................... 16
3.11 Drive Belt ................................................................... 16
3.12 Exercising the Generator ..........................................16
3.13 Out of Service Procedure ......................................... 16
3.14 RV Generator Service Interval .................................. 16
Part II — Installation Instructions
Safety Rules ...........................................................18
Notice to Installer ............................................................. 18
Section 1 — General Information .......................... 20
1.1 Purpose and Scope of the Installation
Instructions ................................................................ 20
1.2 Safety ........................................................................ 20
1.3 Standards Booklets .................................................. 20
1.4 Equipment Description .............................................20
1.5 Generator Engine Operating Speed ........................20
1.6 Generator AC Connection System ...........................20
Section 2 — Installation ......................................... 21
Major Features and Dimensions ..............................21
2.1 Location and Support ...............................................22
2.2 Generator Compartments ......................................... 23
2.3 Cooling and Ventilating Air .......................................25
2.4 Gasoline Fuel System ............................................... 27
2.5 Exhaust System ........................................................ 28
2.6 Electrical Connections .............................................. 29
2.7 Battery Installation .................................................... 30
2.8 Optional Accessories ................................................ 32
Section 3 — Post Installation ................................33
3.1 Post Installation Tests ............................................... 33
3.2 Before Initial Start-up ................................................ 33
3.3 Initial Start ................................................................. 33
3.4 Testing Under Load ................................................... 33
3.5 Installation Checklist ................................................. 34
Section 4 – Troubleshooting .................................. 35
4.1 Troubleshooting Guide ............................................. 35
Section 5 – Electrical Data .....................................36
Section 6 – Exploded Views and Parts Lists ........40
Section 7 – Warranty .............................................. 52

Introduction

INTRODUCTION

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the near­est Authorized Service Dealer for starting, operating and servicing procedures.
Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or care­lessly. Observe them carefully. Their definitions are as follows:
After this heading, read instructions that, if not
strictly complied with, will result in personal injury, including death, and 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 compliance 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:
The operator (driver) is responsible for proper and safe use of the vehicle and its equipment, and the safety of all vehicle occupants. We strongly recommend that the operator read this manual and thoroughly understand all instructions before using this equipment. We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator. This prepares them if they need to operate the equipment in an emergency.

CONTENTS

This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views and lists of repair parts. 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 about parts and service, always supply the complete model number and serial number of the unit as given on its data decal, which is located on the generator.
This symbol points out important safety
n
information 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.
Model No. _________________ Serial No. ______________
Authorized SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED SERVICE
DEALER, please call this number:
1-800-333-1322
ONLY DEALER LOCATION INFORMATION
CAN BE OBTAINED AT THIS NUMBER.
1

Safety Rules

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be
n
copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of this equipment.
Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this manual and with the unit. The generator can operate safely, efficiently and reli­ably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.
The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit, are, therefore, not all-inclusive. If using a procedure, work method or operating technique the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique that chosen does not render the generator unsafe.
Despite the safe design of this generator,
n
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
n
during operation. Exercise care near running generators.
CALIFORNIA PROPOSITION 65 WARNING
Engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects
and other reproductive harm.
CALIFORNIA PROPOSITION 65 WARNING
This product contains or emits chemicals known to the
State of California to cause cancer, birth defects and
other reproductive harm.
For safety reasons, the manufacturer recommends that the
installation, initial start-up and maintenance of this equipment is carried out by an Authorized Service Dealer.
The generator engine releases DEADLY carbon monoxide gas
through its exhaust system. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. Shut down the generator and do not operate it until it has been inspected and repaired.
DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM
IS LEAKING OR HAS BEEN DAMAGED.
SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a)
inability to think coherently, (b) nausea, (c) vomiting, (d) twitching muscles, (e) throbbing temples, (f) dizzi­ness, (g) headaches, (h) weakness, and (i) sleepiness. IF EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET MEDICAL HELP.
Never sleep in the vehicle while the genset is running unless
the vehicle has a working carbon monoxide detector. The exhaust system must be installed in accordance with the genset installation manual. Make sure there is ample fresh air when operating the genset in a confined area.
Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.
Adequate, unobstructed flow of cooling and ventilating air is
critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment. Without sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to the generator. Do not alter the installation or permit even partial blockage of ven­tilation provisions, as this can seriously affect safe operation of the generator.
When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally fatigued.
Inspect the generator regularly, and contact the nearest
Authorized Service Dealer immediately for parts needing repair or replacement.
Before performing any maintenance on the generator, discon-
nect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.
Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in dan­gerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

GENERAL HAZARDS

2
Safety Rules

ELECTRICAL HAZARDS

The generator covered by this manual produces dangerous
electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and bar­riers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.
Do not handle any kind of electrical device while stand-
ing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.
During installation onto the vehicle, have the generator prop-
erly grounded (bonded) either by solid mounting to the vehicle frame or chassis, or by means of an approved bonding conduc­tor. DO NOT disconnect the bonding conductor, if so equipped. DO NOT reconnect the bonding conductor to any generator part that might be removed or disassembled during routine mainte­nance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 American Wire Gauge (AWG) copper wire minimum.
In case of accident caused by electric shock, immediately
shut down the source of electrical power. If this is not pos­sible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim from the live conductor. If the victim is unconscious, apply first aid and get immediate medical help.
Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

FIRE HAZARDS

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

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any fuel or oil
spills immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
Gasoline is extremely FLAMMABLE and its vapors are
EXPLOSIVE. Do not permit smoking, open flame, sparks or any source of heat in the vicinity while handling gasoline. Comply with all laws governing the storage and handling of gasoline.
This generator may use liquid propane (LP) gas as a fuel. LP
gas is highly EXPLOSIVE. The gas is heavier than air and tends to settle in low areas where even the slightest spark can ignite the gas and cause an explosion.
3

General Information

1.1 GENERATOR IDENTIFICATION

Please record the following information from the generator DATA DECAL or information decal.
1. Model Number ____________________ 2. Serial Number _________________
3. kW Rating _________________________ 4. Rated Voltage _________________
5. Phase _____________________________ 6. Hertz __________________________
18
815
2
13
345
1
12 1110, 17
1614
1. Generator Air Intake
2. Data Plate
3. Engine Start/Stop Switch
4. 7.5 amp Fuse
5. Circuit Breaker
6. Optional Remote Panel Receptacle
7. Generator AC Output Leads
8. Starter Contactor
9. Fuel Inlet
4
7
9, 17
REFERENCE NUMBER IDENTIFICATION
10. Fuel Pump
11. Oil Filter
12. Oil Drain Plug
13. Oil Dipstick and Filler Tube
14. Air Filter (Behind access panel.)
15. Spark Plugs
16. Exhaust Outlet
17. Fuel Filter
18. Evaporative Port
6
10
General Information

1.2 GENERATOR APPLICABILITY

These generators have been designed and manufactured for sup­plying electrical power for recreational vehicles. DO NOT modify the generator or use it for any application other than for what it was designed. If there are any questions pertaining to its applica­tion, write or call the factory. Do not use the unit until advised by competent authority.
For fire safety, the generator must have been
properly installed in compliance with ANSI
119.2-1975/NFPA 501C-1974, “Standard for Recreational Vehicles, Part III – Installation of Electrical Systems.” The generator also must have been installed in strict compliance with the manufacturer’s detailed installation instructions. After installation, do nothing that might render the unit in noncompliance with such codes, standards and instructions.
Use the generator set to supply electrical power for operating one of the following electrical loads:
RV 45 G: 120 and/or 240 volts, single phase, 60 Hz electrical
loads. These loads can require up to 4500 watts (4.5 kW) of total power, but cannot exceed 37.5 AC amperes of current at 120 volts (breaker is limited to 30 Amps).
RV 55 G: 120 and/or 240 volts, single phase, 60 Hz electrical
loads. These loads can require up to 5500 watts (5.5 kW) of total power, but cannot exceed 45.8 AC amperes of current at 120 volts or exceed 22.9 AC amperes at 240 volts.
RV 65 G: 120 and/or 240 volts, single phase, 60 Hz electrical
loads. These loads can require up to 6500 watts (6.5 kW) of total power, but cannot exceed 54.1 AC amperes of current at 120 volts or exceed 27 AC amperes at 240 volts.
Do not overload the generator. Some instal­lations may require that electrical loads be
n
alternated to avoid overloading. Applying excessively high electrical loads may dam­age the generator and may shorten its life. Add up the rated watts of all electrical lighting, appliance, tool and motor loads the generator will power at one time. This total should not be greater than the watt­age capacity of the generator. If an electri­cal device nameplate gives only volts and amps, multiply volts times amps to obtain watts (volts x amps = watts). Some elec­tric motors require more watts of power (or amps of current) for starting than for con­tinuous operation.

1.3 INSTALLATION

This Owner’s Manual has been prepared under the assumption that a competent, qualified technician installed the generator into a recreational vehicle. We also assume the installer complied with all applicable codes, standards and regulations pertaining to installation.
An INSTALLATION MANUAL was shipped with the generator. That Manual contains manufacturer’s instructions and recommenda­tions for installing the unit into an industrial vehicle. After installa­tion, installers should forward the Installation Manual to Owners/ Operators for their information.
Owners/Operators have the responsibility to make sure that noth­ing is done that might render the installation unsafe or in non­compliance with applicable codes, standards and instructions.

1.4 SAFETY

Before using the generator set, carefully read GENERAL SAFETY RULES inside the cover. Comply with these RULES to prevent accidents and damage to equipment and/or property. The manu­facturer suggests copying and posting the GENERAL SAFETY RULES to potential operators of this equipment.
1.5 GENERATOR AC CONNECTION
SYSTEM
These air-cooled generator sets are equipped with dual stator AC power windings. These two stator windings supply electrical power to customer electrical loads by means of a dual 2-wire connection system.
Generators may be installed to provide the following outputs:
1. 120 VAC loads only — two loads, each with a maximum
total wattage requirement equal to half of the generator’s rated power output (in watts), and 120V across the generator output terminals. Figure 1.1 shows the generator lead wire connections for 120VAC ONLY.
Figure 1.1 – Connection for 120 Volts Only
5
SA E 30
Sy nt he ti c 5W -3 0
10 W- 30
General Information
2. 120/240 VAC loads — one load with a maximum total watt­age requirement equal to the generator’s rated power output, and 240V across the generator output terminals; or two sepa­rate loads, each with a maximum total wattage requirement equal to half of the generator’s rated power output (in watts), and 120V across the generator output terminals. Figure 1.2, shows the generator lead wire connections for 120/240 VAC loads. Also refer to the "Line Breakers" section for circuit breaker ratings.
This procedure should be done by an Authorized Service Dealer or other qualified installer.
Figure 1.2 - Connection for 120/240 Volts
T1
CB1
RED
T2
WHITE
NOTE
Some installations using a “shared” fuel tank may have a gen­erator fuel pickup tube that is shorter than the vehicle engine’s pickup tube. Such an arrangement causes the generator engine to “run out of gas” while adequate fuel for the vehicle remains in the tank.
To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator. Leaded REGULAR grade gasoline is an acceptable substitute.
NOTE:
Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits.
The manufacturer does not recommend
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using any gasoline containing alcohol (such as “gasohol”). If using any gasoline contain­ing alcohol, it must not contain more than 10 percent ethanol (Do not use E85), and it must be removed from the generator during storage. Do NOT use any gasoline contain­ing methanol. If using gasoline with alcohol, inspect more frequently for fuel leaks and other abnormalities.
STATOR POWER WINDINGS
CB2
GROUNDED NEUTRAL
T3
BLACK

1.6 SPECIFICATIONS

1.6.1 FUEL REQUIREMENTS (GASOLINE)
This generator is equipped with a gasoline fuel system as standard equipment. Specific installations may provide either a separate fuel tank for the generator, or the generator may “share” the vehicle engine’s fuel tank.
1.6.1.1 Fuel Consumption (gph)
Model 10% Load 50% Load 100% Load
RV45G .33 .45 .73
RV55G .35 .55 .89
RV65G .37 .65 .97
1.6.2 ENGINE OIL REQUIREMENTS
All oil should meet minimum American Petroleum Institute (API) Service Class SJ, SL or better. Use no special additives. Select the oil's viscosity grade according to the expected operating tempera­ture (also see chart).
SAE 30 Î Above 32° F 10W-30 Î Between 40° F and -10° F Synthetic 5W-30 Î 10° F and below
SAE 30
10W-30
Synthetic 5W-30
Crankcase and oil filter capacity is approximately 1.4 L or 1.5 U.S. quarts. DO NOT use special additives. See sections "Checking the Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter" for oil level check and filling procedures.
6
General Information
1.6.3 GENERATOR SPECIFICATIONS
SERIES RV45G RV55G RV65G
Rotor RPM 3600 3600 3600
Rotor Poles 2 2 2
Engine RPM 2571 2571 2571
Rated Max. Continuous AC Output Watts* 4500 5500 6500
Voltage* 120 120 120
Rated Max. Continuous Current Amps (240V) 37.5 (18.7) 45.8 (22.9) 54.1 (27)
Phase 1 1 1
Frequency 60 Hertz 60 Hertz 60 Hertz
Weight 278 lbs. 285 lbs. 293 lbs.
Length 33.7 in. 33.7 in. 33.7 in.
Width 21.5 in. 21.5 in. 21.5 in.
Height 16.8 in. 16.8 in. 16.8 in.
* All units are re-connectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output ** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambient temperature, altitude, engine condition, etc.. Maximum power
decreases about 3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16° C (60° F) ambient temperature.
1.6.4 ENGINE SPECIFICATIONS
Type of Engine ........................................................................GT-530
Cooling Method ................................................................ Air-cooled
Rated Horsepower ...................................................18 at 3600 rpm
Displacement ........................................................................... 530cc
Compression Ratio ................................................................8.5 to 1
Cylinder Block .................................. Aluminum w/Cast Iron Sleeve
Type of Governor ....................................... Electronic, Fixed Speed
Engine Governor Speed ................................................... 2571 rpm
Air Cleaner ................................................................. Paper Element
Starter .................................................................. 12-volt DC Electric
Ignition System ............................ Solid-state w/Flywheel Magneto
Recommended Spark Plug
NGK ....................................................................................BPR6HS
Spark Plug Gap ............................................. 0.030 inch (0.76 mm)
Recommended Min. Battery .................. 400 Cold Cranking Amps
Class II Emission Certified
1.7 EXHAUST EMISSIONS
INFORMATION (GASOLINE)
The Environmental Protection Agency (EPA) and the California Air Resource Board (CARB) require that this generator comply with exhaust emission standards. The generator is certified to meet all applicable exhaust emission levels. This generator is certified for use as a mobile engine. It is important that you follow the mainte­nance specifications listed in this manual to ensure that the engine complies with emission standards for the duration of its life. This engine is certified to operate on gasoline. The emission control system on the generator consists of the following:
Fuel Metering System• ~ Carburetor assembly ~ Fuel pump and lines
Air Induction System• ~ Intake pipe / manifold ~ Air cleaner
Ignition System• ~ Spark plug ~ Ignition module
Catalytic Converter (if equipped)
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 and California emission requirements. See the table below to determine the com­pliance period for this generator. The displacement of the engine is listed on the Emissions Compliance Label.
Displacement Category Compliance Period
A 500 Hours
> 66 cc - < 225 cc
B 250 Hours
C 125 HOurs
A 1000 Hours
225 cc
B 500 Hours
C 250 Hours
7

Operation

1.8 EVAPORATIVE EMISSIONS INFORMATION

This generator is subject to evaporative emission standards which have been implemented by the California Air Resource Board (CARB) and the Environmental Protection Agency (EPA). If this generator is offered for sale in the state of California, it must be covered by a CARB evaporative Executive Order. If this generator is offered for sale to the final consumer in any other state, certified low-permeation fuel line must be used to supply fuel to the genera­tor as required by EPA.
Anyone who installs or configures a fuel system to supply this generator with gasoline is required to comply with all applicable evaporative emission regulations. If this generator is configured such that it shares the primary fuel system of a vehicle in which it is installed, reduced certification requirements may apply. See the CARB guidance document MAC 05-05, located at http://www.arb. ca.gov/msprog/macs/mac0505/mac0505.pdf for further details. If this generator is installed such that it uses a dedicated fuel system, detailed evaporative emission requirements apply; contact a repu­table fuel system manufacturer to purchase a complete fuel sys­tem certified for use with this generator, or consult the California Code of Regulations if you wish to obtain certification on your own. See the installation instructions in this manual for connecting fuel system vapor lines to the engine.
This generator is not legal for sale in the state of California unless all CARB evaporative emission requirements are adhered to, and is not legal for sale in any other state unless certified low-per­meation fuel line is used to supply the generator with gasoline. Contact the California Air Resource Board or the Environmental protection agency for further information. CARB regulations can be found in 13 CCR §§2750 – 2773; EPA regulations can be found in 40 CFR Part 90.
Figure 2.1 – Typical Control Panel
The switch center position is the RUN position.
To stop a running engine, press momentarily the bottom half of the switch to kill the ignition.
2.1.2 7.5 AMP 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 7.5 amp replacement fuse.
2.1.3 LINE BREAKERS
Protects generator’s AC output circuit against overload, i.e., pre­vents unit from exceeding wattage/amperage capacity. The circuit breaker ratings are as follows:

2.1 GENERATOR CONTROL PANEL

The following features are mounted on the generator control panel (Figure 2.1):
2.1.1 START/STOP SWITCH
This generator is started with a "One Touch" starting sequence. Push up on the top half of the momentary switch. Hold for one (1) second and release. Note flashing indicator light on the switch. Fuel pump engages automatically for a three (3) to five (5) second delay before starter motor cranks the engine for 16 seconds or until the engine starts. If the engine does not start, the starter will cool for seven (7) seconds and crank the engine again for 16 seconds. If the engine does not start, the starter will cool for seven (7) seconds before cranking for seven (7) seconds to a maximum cycle total of 90 seconds. Once started, the light on the switch stays on continuously. If the generator does not start at the end of the start sequence, a fault code will flash on the switch (see Diagnostics).
The switch center position is the RUN position.
To stop a running engine, press momentarily the bottom half of the switch to kill the ignition.
8
Model Cir. Breaker 1 Cir. Breaker 2 240 Volt
RV45 30A N/A N/A
RV55 20A 30A 25A 2P
RV65 30A 30A 30A 2P
NOTE:
If this generator has been reconnected for dual voltage AC out­put (120/240 volts), install line breakers having an amperage rating equal to that stated in the preceding chart. The replace­ment line breakers consist of two separate breakers with a connecting piece between the breaker handles (so that both breakers will operate at the same time). If the unit is recon­nected for dual voltage, it is no longer RVIA listed.
Operation
2.1.4 DIAGNOSTICS
If the generator shuts down due to a fault, the indicator will flash a code to identify the problem.
2 Flashes = Low Battery (Voltage falls below 11.0 VDC for one
minute)
NOTE:
Alarm will clear automatically if voltage rises over 11.0 VDC. Battery voltage is not monitored during crank cycle.
3 Flashes = Overcrank (Unit does not start through entire start
cycle)
4 Flashes = Overspeed (Alternator spins at 4200 rpm/72 Hz
or greater)
5 Flashes = Low Oil Pressure (Drops below the 5 psi threshold
of the switch)
NOTE:
There is a five second delay of the alarm when the engine is first started up.
6 Flashes = High Oil Temperature (Unit shuts down when tem-
perature switch limit is reached)
NOTE:
As the unit cools down it will attempt to restart automatically when the temperature switch opens again.
7 Flashes = Underspeed (Alternator spins less than 3240
rpm/54 Hz for three (3) seconds)
NOTE:
After a fault is indicated, press stop momentarily to clear the alarm once the problem is fixed.

2.2 OPTIONAL REMOTE START/STOP PANEL

A remote mounted Start/Stop Panel is available that allows start­ing and stopping the generator engine conveniently from inside the vehicle. The remote panel includes a Start/Stop switch, hourmeter, generator run lamp, and a wire harness.

2.3 AUTOMATIC CHOKE

This engine is equipped with an automatic choke that consists of two main components: a choke solenoid and prechoke (Gasoline only.).
2.3.1 CHOKE SOLENOID
During engine cranking (Start/Stop switch at START), a solid-state choke module signals the choke solenoid to activate and cycle (choke on/choke off) until the engine starts. The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking. When the engine starts, the choke stops cycling (Gasoline only.).
2.3.2 PRECHOKE
The choke system also has a temperature-sensitive metal strip that adjusts choke valve angle according to ambient temperatures (i.e., in cold ambient temperatures, choke valve closes more). Once the engine starts, an element heats the temperature-sensitive strip to a normal operating condition, opening the choke valve. This may take about three minutes in cooler weather (Gasoline only.).

2.4 BEFORE STARTING THE ENGINE

NOTE:
Instructions and information in this manual assume the genera­tor has been properly installed, connected, serviced, tested and adjusted by a qualified installation technician or installation contractor.
2.4.1 INSTALLATION
Generator installation must have been properly completed so it complies with all applicable codes, standards and regulations and with the manufacturer's recommendations. (See Part II ­Installation Instructions.)
2.4.2 ENGINE LUBRICATION
Have the engine crankcase properly serviced with the recommend­ed oil before starting. Refer to sections "Engine Specifications", "Checking the Engine Oil Level" and "Changing the Engine Oil and/ or Oil Filter" for oil servicing procedures and recommendations.
Any attempt to crank or start the engine
n
before it has been properly serviced it with the recommended oil may result in an engine failure.
2.4.3 FUEL SUPPLY
The engine must have an adequate supply of proper fuel to oper­ate. Before starting it, check that sufficient fuel is available.
NOTE:
Depending on the installation, the generator may have either a separate fuel tank, or it may “share” the vehicle engine’s fuel tank.
2.4.4 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. Without sufficient cooling and ventilating airflow, the engine/generator quickly overheats, which causes it to shut down and may damage the generator.
9
Operation
2.4.5 ENGINE EXHAUST GAS
Before starting the generator engine, be sure there is no way for exhaust gases to enter the vehicle interior and endanger people or animals. Close windows, doors and other openings in the vehicle that, if open, might permit exhaust gases to enter the vehicle.
The generator engine releases DEADLY
n
carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentrations, can cause uncon­sciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED. Shut down the generator and do not operate it until it has been inspected and repaired. SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a) inability to think coherently, (b) nausea, (c) vomiting, (d) twitching muscles, (e) throbbing temples, (f) dizziness, (g) headaches, (h) weakness, and (i) sleepiness. IF EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET MEDICAL HELP.
Never sleep in the vehicle while the genset
n
is running unless the vehicle has a working carbon monoxide detector. The exhaust sys­tem must be installed in accordance with the genset installation manual. Make sure there is ample fresh air when operating the genset in a confined area.

2.5 STARTING THE GENERATOR

NOTE:
Read the vehicle manufacturer’s instructions. The owner/ operator should become familiar with the vehicle in which this generator is installed. Differences exist between vehicles. For example, some vehicles may use a transfer switch to isolate dockside power from the generator, while other vehicles may use an isolating receptacle. Some vehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads.
To crank and start the generator engine, proceed as follows:
1. Turn OFF electrical loads using the means provided in the vehicle (such as a main line circuit breaker or transfer switch).
NOTE:
If starting from the generator control panel, turn OFF loads by setting the generator’s main circuit breaker to the OFF (or open) position. If starting from a remote panel, turn OFF loads using the means provided in the vehicle (such as a main circuit breaker). Electrical load circuits should be turned ON after the generator has started, stabilized and warmed up.
2. To crank and star t the engine, push up on the Star t/Stop switch momentarily and release. There is a delay as the fuel pump primes and the generator automatically begins the start sequence (Note the flashing light on the switch.).
3. Let the engine run at no-load for a few minutes to stabilize and warm up.
4. Turn ON electrical loads using the means provided (such as a main circuit breaker or transfer switch).

2.6 STOPPING THE GENERATOR

1. Turn OFF all electrical loads using the means provided (such as a main circuit breaker or transfer switch).
2. 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. The engine will come to a complete stop.
2.7 APPLYING LOADS TO
GENERATOR
When applying electrical loads to the generator, observe these guidelines:
Before applying electrical loads, let the generator stabilize and
warm up for a minute or two.
DO NOT overload the generator.
2.7.1 LETTING THE ENGINE STABILIZE
The generator supplies correct rated voltage only at the proper governed speed. Some electrical appliances may be extremely sensitive to voltage. Incorrect voltages can damage such appli­ances.
If electrical loads are applied at reduced operating speeds, such loads imposed on the engine when sufficient power is not available may shorten engine life. Never turn ON electrical loads until after the generator engine has started and stabilized at no-load.
2.7.2 DO NOT OVERLOAD THE GENERATOR
Read the rated wattage/amperage capacity of the generator on the generator data label (See the "Generator Identification" section.).
Applying electrical loads in excess of the unit’s rated capacity will cause the engine/generator to automatically shut down.
To avoid overloading, add up the wattage of all connected electrical lighting, appliance, tool and motor loads. This total should not be greater than the generator’s rated wattage capacity.
10
Operation
Most lighting, appliance, tool and motor loads indicate their
required watts on their nameplate or data plate. For light bulbs, simply note the wattage rating of the bulb.
If a load does not show its rated wattage, multiply that load’s
rated VOLTS times AMPS to obtain WATTS.
Induction type motors (such as those that run the vehicle’s
furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2 times more watts of power for starting than for running (for a few seconds during motor starting). Be sure to allow for this when connecting electrical loads to the generator. First, figure the watts needed to start electric motors in the system. To that figure, add the running wattages of other items that will be oper­ated by the generator.
Do not apply heavy electrical loads for the first two or three
hours of operation.

2.8 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 during cranking and operat­ing. Should oil pressure drop below a preset level, switch contacts close, and the engine automatically shuts down. The unit should not be restarted until oil is added.
2.8.2 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 270º F (132º C) for gasoline mod­els.
Figure 2.2 – Low Oil Pressure and
High Temperature Switches
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 a diode, resistor, brushes, slip rings, and the generator rotor. Application of this voltage to the rotor “flashes the field” whenever it is started. Flashing of the field each time the generator starts makes sure that a sufficiently strong magnetic field is available to produce “pickup” voltage in the stator windings.
Figure 2.3 – 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 supplies an excitation current to the rotor. By regulating the rotor’s excitation current, the strength of its magnetic field is regulated and, in turn, the voltage delivered to connected electrical loads is controlled. When the AC frequency is 60 Hertz, voltage is regulated at 125 to 120 volts.
Figure 2.4 – Solid State Voltage Regulator
11
Oil DipstickOil Drain HoseOil Fill

Maintenance

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

3.1 CHECKING THE ENGINE OIL LEVEL

For oil capacities and requirements, see the “Engine Oil Requirements” section. Check the engine crankcase oil level at least every eight hours of operation, or before it is used. To check the engine oil level, proceed as follows (see Figure 3.1):
1. Be sure the generator is as level as possible.
2. Remove the dipstick and wipe it dry with a clean, lint-free
cloth.
3. Install and tighten the dipstick cap; then, remove it again. The
oil level should be at the dipstick “Full” mark.
4. If necessary, remove the oil fill cap on the rocker cover and
slowly add oil until it reaches the dipstick “Full” mark. DO NOT FILL ABOVE THE “FULL” MARK.
Never operate the engine with the oil level
n
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 oper-
ating the engine.
Figure 3.1 — Oil Dipstick/Fill Tube and
Location of Oil Drain Plug

3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER

Hot oil may cause burns. Allow engine to
n
cool before draining oil. Avoid prolonged or repeated skin exposure with used oil. Thoroughly wash exposed areas with soap.
Oil Change Intervals – see Section “RV Generator Service Interval”.
To change the oil and oil filter, proceed as follows:
1. Run the engine until it is thoroughly warmed up (at least five
minutes) then shut off the engine.
2. With the engine still warm from running, remove the round
access grommet from underneath the front of the generator. Place a suitable container underneath to catch all the drain oil.
3. Use the 0G4818 tool (supplied with the generator) to turn the
old filter counter-clockwise and remove. Let oil drain into the container located directly below.
4. Locate the oil drain hose inside and pull the yellow drain plug
out of the access hole (Figure 3.1).
5. Turn the yellow cap counter-clockwise to remove and finish
draining the old oil.
6. After the oil has been drained, replace the oil drain plug by
tightening it clockwise and return.
7. Clean off the oil filter bracket and any old oil that may have
spilled while draining.
8. Apply a light coating of clean engine oil the gasket of the new
oil filter (Figure 3.2).
9. Screw the new oil filter on by hand until its gasket lightly con-
tacts the oil filter adapter. Then, tighten the filter an additional ¾ to one turn. Replace and secure the round access grom­met.
Figure 3.2 — Engine Oil Filter
12
Engine Oil Filter
Twist Counter-clockwise to Loosen
Maintenance
10. Remove the dipstick, valve cover plug and add new oil (see “Engine Oil Requirements”) to engine. DO NOT FILL ABOVE THE “FULL” MARK.
11. Install and tighten plug and dipstick before starting the engine.
12. Start 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
Replace the paper air filter element after every 200 hours of opera­tion. (Perform more often when operating in dusty conditions)
1. At the Air Cleaner Cover, turn the yellow plastic knob ¼ turn counter-clockwise.
2. Pull the top of the Cover out as it hinges on the bottom of the Air Cleaner Base.
3. Separate the Cover by lifting up and out from the Base.
4. Pull the old filter out and discard safely.
5. Install the new filter in place on the Air Cleaner Base (Figure
3.3).
6. Interlock the Air Cleaner Cover to hinge with the Air Cleaner Base.
7. Align the Cover and gently push the top closed.
8. Engage the yellow plastic knob and turn ¼ turn clockwise to secure.
Figure 3.3 – Engine Air Cleaner
Air Cleaner Base

3.4 CHECKING THE ENGINE SPARK PLUG

Reset the spark plug gap or replace the spark plugs as necessary. See the Service Schedule section for maintenance requirements.
1. Clean the area around the base of the spark plugs to keep dirt
and debris out of the engine.
2. Remove the spark plugs and check the condition. Replace the
spark plugs if worn or if reuse is questionable. See the Service Schedule section for recommended interval. Clean by scrap­ing or washing using a wire brush and commercial solvent. Do not blast the spark plugs to clean.
3. Check the spark plug gap using a wire feeler gauge. Adjust the
gap to 0.76mm (0.030 inch) by carefully bending the ground electrode if necessary (Figure 3.4).
Figure 3.4 – Setting the Spark Plug Gap
Sparking can occur if the wire terminal does
n
not fit firmly on the spark plug terminal end. If necessary, re-form the wire terminal to obtain a tight fit.
Air Cleaner Cover
Air Cleaner
Knob
3.5 FUEL FILTER
Remove and replace the fuel filter (Figure 3.5) every 400 hours of operation.
(GASOLINE ONLY)
Figure 3.5 – Fuel Filter
FUEL FILTER
CUSTOMER FUEL CONNECTION
13
TO FUEL PUMP
Maintenance

3.6 CLEAN SPARK ARRESTOR

The engine exhaust muffler has a spark arrestor screen. Inspect and clean the screen every 200 hours of operation or once each year, whichever comes first.
NOTE:
If using the generator on any forest-covered, brush-covered or grass-covered unimproved land, it must equipped with a spark arrestor. The spark arrestor must be maintained in good condi­tion by the owner/operator.
Clean and inspect the spark arrestor as follows:
Remove the screen by removing the screw.• Slide the spark arrestor screen out from the tail pipe.• Inspect screen and replace if torn, perforated or otherwise
damaged. DO NOT USE a defective screen. If screen is not damaged, clean it with commercial solvent.
Replace the screen and the screw.
Figure 3.6 - Spark Arrestor
Do NOT use a forceful spray of water to
n
clean the generator. Water will enter the gen­erator interior and cause problems, and may also contaminate the generator fuel system.

3.8 BATTERY MAINTENANCE

NOTE:
This generator is not equipped with an internal battery charger. It is intended for use in systems where an external battery char­ger is installed by the RV O.E.M. or an aftermarket installer.
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 corro-
sion. Tighten and clean as necessary.
Check the battery fluid level of unsealed batteries and, if nec-
essary, fill with Distilled Water Only. Do not use tap water in batteries.
TAILPIPE P/N 0G5857
SPARK ARRRESTOR
SCREEN P/N 089680
RETAINING SCREW P/N 056892

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 moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings.
When moisture is allowed to remain in contact with windings, some of the moisture will be retained in voids and cracks in the insulation. This causes a reduced insulation resistance and will eventually cause problems. Dirt will make the problem worse, since dirt tends to hold moisture in contact with windings. Salt (as from sea air) also will worsen the problem since it tends to absorb moisture from the air. Salt and moisture, when combined, form a good electrical conductor which is detrimental to the generator.
3.8.2 EVERY SIX MONTHS
Have the state of charge and condition checked. This should be
done with an automotive-type battery hydrometer.
NOTE:
Servicing of the battery is to be performed or supervised by personnel knowledgeable of batteries and the required precau­tions. Keep unauthorized personnel away from batteries.
Damage will result if the battery connections are made in reverse.
Do not dispose of the battery in a fire. The
battery is capable of exploding. Storage bat­teries give off explosive hydrogen gas. This gas can form an explosive mixture around the battery for several hours after charging. The slightest spark can ignite the gas and cause an explosion. Such an explosion can shatter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open flame, sparks, or any spark producing tools or equipment near the battery. Discharge static electricity from body before touching the battery by first touching a grounded metal surface.
14
Maintenance
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 connect-
ing 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
n
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 electri-
n
cally conductive and corrosive. The follow­ing procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off immediately with water;
• Where electrolyte contacts the eyes, flush thoroughly and immediately with water and seek medical attention; and
• Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of 1 pound (500 grams) bicarbonate of soda to 1 gallon (4 liters) or water. The bicarbonate of soda solution is to be added until the evidence of reaction (foam­ing) has ceased. The resulting liquid is to be flushed with water and the area dried.
Make sure the piston is at Top Dead Center (TDC) of its com-
pression stroke (both valves closed). To get the piston at TDC, remove the intake screen at the front of the engine to gain access to the flywheel nut. Use a large socket and socket wrench to rotate the nut and hence the engine in a clockwise direction. While watching the piston through the spark plug hole. The piston should move up and down. The piston is at TDC when it is at its highest point of travel.
To adjust valve clearance (if necessary):
Make sure the engine is at 60° to 80° F.• Make sure that the spark plug wire is removed from the spark
plug and out of the way.
Remove the four screws attaching the valve cover with a #2 or
#3 Phillips screwdriver.
Loosen the rocker jam nut. Use an 10mm allen wrench to turn
the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge. Correct clearance is 0.002-0.004 inch (0.05-0.1 mm). (Figure 3.7).
Figure 3.7 - Valve Clearance Adjustment
Rocker
Pivot Ball
Stud
Jam Nut
Arm
Valve Stem

3.9 ADJUSTING VALVE CLEARANCE

After the first 50 hours of operation, check the valve clearance in the engine, adjust if necessary.
Important: If feeling uncomfortable about doing this procedure or
the proper tools are not available, please contact the Authorized Dealer for service assistance. This is a very important step to insure longest life for the engine.
To check valve clearance:
The engine should be cool before checking. If valve clearance is
0.002" - 0.004" (0.05 - 0.1mm), adjustment is not needed. Remove spark plug wires and position wires away from plugs.• Remove spark plugs.
NOTE:
Hold the rocker arm jam nut in place as the pivot ball stud is turned.
When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten the jam nut to 174 in/lbs. torque. After tightening the jam nut, recheck valve clearance to make sure it did not change.
Install new valve cover gasket.• Re-attach the valve cover.
NOTE:
Start all four screws before tightening or it will not be possible to get all the screws in place. Make sure the valve cover gasket is in place.
Install spark plugs.• Re-attach the spark plug wire to the spark plug.• On the GT-530, repeat the process for the other cylinder.
15
Maintenance

3.10 MAJOR SERVICE MANUAL

To obtain a service manual for the generator, contact the near­est Authorized Service Dealer. Make sure to identify the MODEL NUMBER and SERIES.

3.11 DRIVE BELT

The engine drives the generator rotor by means of a pulley and drive belt arrangement. Drive belt tension was properly adjusted before the unit was shipped from the factory. If suspect that drive belt tension is incorrect, contact an Authorized Service Dealer.

3.12 EXERCISING THE GENERATOR

The manufacturer recommends starting and operating the genera­tor at least once every seven days. Let the unit run for at least 30 minutes to “exercise” the engine.

3.13 OUT OF SERVICE PROCEDURE

3.13.1 REMOVAL FROM SERVICE
If the generator cannot be exercised every seven days, and it is to be out of service longer than 30 days, prepare the generator for storage as follows:
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line and allow the unit to shut down.
3. While the engine is still warm from running, drain the oil completely. Refill the crankcase with SAE 5W-30 oil having API classification “For Service SJ/SL.”
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.
3.13.2 RETURN TO SERVICE
To return the unit to service after storage, proceed as follows:
1. Check the tag on the engine for oil viscosity and classification. Verify that the correct recommended oil is used in the engine (see "Engine Oil Requirements"). If necessary, drain and refill with the proper oil.
2. Check the state of the battery. Fill all cells of unsealed batter­ies to the proper level with distilled water. DO NOT USE TAP WATER IN THE BATTERY. Recharge the battery to 100 percent state of charge, or, if defective, replace the battery.
3. Clean and wipe the entire generator.
4. Reconnect the battery. Observe battery polarity. Damage may occur if the battery is connected incorrectly.
5. Turn OFF all electrical loads. Add fuel if necessary and then start the engine.
6. Allow the unit to warm up thoroughly.
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.
3.14 RV GENERATOR SERVICE
INTERVAL
1st 8 Hours,
then every 200 Hours ......................... Change Engine Oil/Filter
1st 50 Hours,
then every 500 Hours .................................. Adjust Valve Lash
200 Hours ..................................................Clean Spark Arrestor
200 Hours .................................Replace Paper Air Filter Element
400 Hours ......................................................Replace Fuel Filter
500 Hours ..................................................Replace Spark Plugs
16

Part II - Installation Instructions

Part II –
Installation
Instructions
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!

Safety Rules

DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly with
n
article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the man­ufacturer’s instructions and recommendations.

NOTICE TO INSTALLER

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

GENERAL HAZARDS

For safety reasons, the manufacturer recommends that the
installation, initial start-up and maintenance of this equipment is carried out by an Authorized Service Dealer.
The generator engine releases DEADLY carbon monoxide gas
through its exhaust system. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. Shut down the generator and do not operate it until it has been inspected and repaired.
DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM
IS LEAKING OR HAS BEEN DAMAGED.
SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a)
inability to think coherently, (b) nausea, (c) vomiting, (d) twitching muscles, (e) throbbing temples, (f) dizzi­ness, (g) headaches, (h) weakness, and (i) sleepiness. IF EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET MEDICAL HELP.
Never sleep in the vehicle while the genset is running unless
the vehicle has a working carbon monoxide detector. The exhaust system must be installed in accordance with the genset installation manual. Make sure there is ample fresh air when operating the genset in a confined area.
Keep hands, feet, clothing, etc., away from drive belts, fans,
and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.
Adequate, unobstructed flow of cooling and ventilating air is
critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment. Without sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to the generator. Do not alter the installation or permit even partial blockage of ven­tilation provisions, as this can seriously affect safe operation of the generator.
When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally fatigued.
Before performing any maintenance on the generator, discon-
nect its battery cables to prevent accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (–) first. Reconnect that cable last.
Never use the generator or any of its parts as a step. Stepping
on the unit can stress and break parts, and may result in dan­gerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.
Never insert any tool or other object through openings in the
generator interior, even if the unit is not running. Serious injury or damage to the equipment could be done.
18
Safety Rules

ELECTRICAL HAZARDS

The generator covered by this manual produces dangerous
electrical voltages and can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards and bar­riers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.
Do not handle any kind of electrical device while stand-
ing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.
During installation onto the vehicle, properly ground (bond) the
generator either by solid mounting to the vehicle frame or chas­sis, or by means of an approved bonding conductor. DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 American Wire Gauge (AWG) copper wire minimum.
If the vehicle electrical circuits can be powered by any other
source of electricity (such as a “dockside” power receptacle), there must be no possibility of connecting the different power sources to the vehicle circuits at the same time. The dockside (utility) power source must be positively isolated from the vehicle circuits whenever the generator is operating. Failure to isolate the vehicle circuits from the dockside power supply when the generator is running may result in damage to the generator or serious injury or death to dockside (utility) power workers due to backfeed of electrical energy.
In case of accident caused by electric shock, immediately shut
down the source of electrical power. If this is not possible, attempt to free the victim from the live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a nonconducting implement, such as a rope or board, to free the victim from the live conduc­tor. If the victim is unconscious, apply first aid and get immediate medical help.
Never wear jewelry when working on this equipment. Jewelry
can conduct electricity resulting in electric shock, or may get caught in moving components causing injury.

FIRE HAZARDS

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

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any fuel or oil spills
immediately. Ensure that no combustible materials are left in the generator compartment, or on or near the generator, as FIRE or EXPLOSION may result. Keep the area surrounding the generator clean and free from debris.
Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE.
Do not permit smoking, open flame, sparks or any source of heat in the vicinity while handling gasoline. Comply with all laws governing the storage and handling of gasoline.
Fuel lines must be properly installed and fastened, and free of
leaks. There must be no possibility of gasoline vapors entering the vehicle interior.
It is required that an approved, flexible, nonconductive fuel line
between the generator fuel connection point and rigid fuel lines be installed.
If the generator is equipped with a liquid propane (LP) gas fuel
system, install the unit so it complies with all codes, standards and regulations pertaining to such systems. LP gas is highly explosive. The gas tends to settle in low areas where even the slightest spark can ignite it and cause an explosion. Do not allow gas vapors to enter the vehicle.
19

General Information

1.1 PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS

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

1.2 SAFETY

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

1.3 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/RVIA EGS-1, available from the Recreational
Vehicle Association, 1896 Preston White Drive, Reston, VA
22090.
5. California Administrative Code, Title 25, available from the
State of California, Documents Section, P.O. Box 1015, North Highlands, CA 95660.
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 per tain to air-cooled generators. These generators are designed specifically for install­ing in recreational vehicles. They operate 120-volt, single-phase, 60-Hertz, AC electrical loads.

1.5 GENERATOR ENGINE OPERATING SPEED

The generator’s revolving field (rotor) is driven by a two-cylinder, four-cycle engine through a pulley and drive belt arrangement. The generator supplies 120 volts AC at 60 Hertz when the rotor is oper­ating at 3,600 rpm. The drive belt arrangement allows the engine to operate at a lower speed than the rotor.

1.6 GENERATOR AC CONNECTION SYSTEM

These air-cooled generator sets are equipped with dual stator AC power windings. These two stator windings supply electrical power to customer electrical loads by means of a dual 2-wire connection system.
Generators may be installed to provide the following outputs:
1. 120 VAC loads only — two loads each, with a maximum total
wattage requirement equal to half of the generator’s rated power output (in watts), and 120V across the generator out­put terminals (see Fig. 1.1).
2. 120/240 VAC loads — one load with a maximum total wattage
requirement equal to the generator’s rated power output, and 240V across the generator output terminals; or two separate loads, each with a maximum total wattage requirement equal to half of the generator’s rated power output (in watts), and 120V across the generator output terminals (see Fig. 1.3).
Figure 1.1 – Connection for 120 Volts Only
20
Figure 1.2 - Major Features and Dimensions (Drawing No. 0G5519-D)
Installation
21

Installation

Figure 1.3 - Connection for 120/240 Volts
T1
CB1
CB2
STATOR POWER WINDINGS
GROUNDED NEUTRAL
The AC connection system on air-cooled generators uses a
GROUNDED neutral.
A separate green ground wire is connected to the recreational
vehicle’s junction box.
Total load connected across T1 (Red) to T2 (White), and T3
(Black) to T2 (White), must not exceed rating for the specific generator (see "Generator Specifications").
NOTE:
Do NOT connect loads in excess of circuit breaker ratings.
RED
T2
WHITE
T3
BLACK
The location must provide sufficient room to allow minimum
clearances as outlined in "Generator Compartments". If sound insulation is to be used on the compartment walls and ceiling, the minimum recommended applies to the space between the generator and such insulation.
The location must provide adequate cooling and ventilating
airflow for the generator without a great deal of work and expense.
If mounting the generator in an enclosed compartment, the base
of the generator must rest flat on the floor without any gaps.
When using a suspended mounting system, ensure the base of
the generator is flush with the surrounding bodywork. If the unit is mounted higher in the structure, heated air may recirculate into the generator causing it to overheat.
2.1.2 GENERATOR SUPPORT
The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding. The metal framework on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams. These beams should consist of (a) 1-1/2-inch square, 11-gauge steel tubing OR (b) 1-1/2-inch, 11-gauge angle iron. A typical supporting frame with horizontal support tubing, is shown in Figure 2.1.
Figure 2.1 – Typical Horizontal Support Frame

2.1 LOCATION AND SUPPORT

2.1.1 GENERATOR LOCATION
NOTE
Be sure the installation complies with all standards and codes listed in the "Standards Booklets" section of this manual.
The most desirable location for the generator set is between the vehicle's main frame members. However, this is seldom possible. Most units must be installed on the side of the vehicle and are difficult to reinforce.
Many recreational vehicles have been factory equipped with an area for the generator set. Some vehicles may even have a genera­tor compartment provided by the vehicle manufacturer.
Plan the generator location based on the following:
The generator set must be installed on a framework that is
part of the recreational vehicle, as outlined in the "Generator Support" section.
The location must provide an access opening that is large
enough to permit generator removal (unless the generator is to be removed from underneath the supporting framework).
The location must provide easy access to frequently serviced
components, such as filters, oil drains, spark plugs and other common maintenance parts.
The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits. Another method is to suspend the generator below the horizontal support tubing by means of suitable, structurally sound metal framework. The fol­lowing general rules apply:
Vehicle construction MUST be capable of supporting the weight
of the generator.
Whether the generator is mounted above the horizontal support
tubing or suspended below the tubing, the supporting frame used must be structurally sound.
If the generator cannot be bolted directly to the supporting
frame or support tubing, consider using additional tubing, angle brackets or other supports to give the supporting frame sufficient strength.
22
Installation
2.1.3 SUSPENDED MOUNTING
If planning to suspend the generator below the horizontal sup­port tubing, the suspension method to use with the vehicle frame members must (a) be able to support the weight of the generator AND (b) provide sufficient restraint for the generator. One typical suspended mounting system is shown in Figure 2.2. The location of a suspended mounting system must be carefully planned, keep­ing the following general rules in mind:
Protect the generator against road splash and debris. Baffles or
splash guards may be required to protect certain areas of the generator. To make sure the generator is adequately protected, road test the installation through mud, water and slush.
Figure 2.2 – Typical Suspended Mounting System

2.2 GENERATOR COMPARTMENTS

Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compart­ment that the installer constructs, the compartment MUST meet certain specifications as outlined in the following sections:
2.2.1 COMPARTMENT SIZE
Plan the compartment size carefully. Provide a minimum clearance of 1/2 inch (13 mm) on the front top, sides, and from the back for air circulation AFTER the compartment has been lined with metal and sound insulation (Figure 2.4).
NOTE:
Refer to “Figure 1.2 – Major Features and Dimensions”.
Figure 2.4 – Clearances
Plywood
Compartment
1/2" Clearance on Top
1/2" Clearance
in Back
The installer must make certain that the selected location will
permit adequate cooling and ventilating airflow to be supplied.
2.1.4 GENERATOR RESTRAINT
Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing. These bolts must pass through (a) the generator mounting base, (b) the compartment floor (if a compartment is used) and (c) the support­ing framework (Figure 2.3). All bolts must be long enough so that when tight, at least three threads are visible past the retaining lock nuts. Refer to "Generator Compartments" for the location of the generator mounting holes. Torque Bolts to 31 ft./lbs..
Figure 2.3 – Typical Generator Restraint
1/2" Each Side
Insulation
1/2"
in Front
18" Clearance Recommended
Below (Minimum 12")
2.2.2 COMPARTMENT CONSTRUCTION
The generator compartment should be either constructed of, or
lined with, 26-gauge galvanized steel.
NOTE:
Aluminum is NOT an acceptable alternative to galvanized steel due to aluminum’s low melting point.
If the compartment is lined with galvanized steel, it may be
constructed of any material. The manufacturer recommends that the compartment be constructed of 1/2-inch thick plywood (not strandboard), with the floor made of a double thickness of 1/2-inch plywood with the grain of the wood at cross section for added strength (Figure 2.5).
If constructing a compartment, line the exterior (underside) of
the compartment floor with 26-gauge galvanized steel.
All seams, splices and joints of the compartment walls (unless
vapor tight by design) should be caulked to prevent poison­ous, flammable or explosive vapors from entering the vehicle interior.
23
Installation
Figure 2.5 – Typical Compartment Construction
Figure 2.6 – Types of Lock Seams
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 insulating materials in high tempera­ture areas.
NOTE:
Caulking must be done so that the caulking material will stay in place permanently. Pressing such materials as putty tape onto joints and seams is not acceptable. A high quality silicone rub­ber base sealant is recommended.
Holes and openings made in the compartment walls to allow for
the passage of electrical conduit, conductors, hoses, cables, etc., into the vehicle living area must be sealed vapor tight with silicone rubber base sealant.
If flexible metal conduit is used, it must be sealed internally at
the end where it terminates inside the compartment’s electrical junction box.
NOTE:
Flexible metal conduit, due to its unique construction, is NOT vapor tight along its entire length.
Seams and joints of the galvanized steel (whether used as a liner
or for the compartment itself) must be lapped and mechanically secured. Such seams may be manufactured, welded, bolted, riveted or screwed. Manufactured lock seams are shown in Figure 2.6. Installer constructed compartments typically utilize a standard lap joint.
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 "Sound Insulating Materials".
2.2.3 SOUND INSULATING MATERIALS
Once installers have determined that a compartment is properly constructed and metal lined, they can add acoustical material. This may include additional sealant or insulating material, to reflect noise away from the vehicle interior.
Sound insulating materials should be of a nonflammable type. One excellent insulating material is a 1-inch (25 mm) thick fiberglass having a 2-pound density. When fiberglass is used, its coated side should face toward the compartment interior.
Do not install sound insulation or any absor-
bent material on the compartment floor inte­rior. Such materials will become soaked with combustible or explosive vapors and liquids and will become a fire hazard.
Using a combination of sound insulating materials can often reduce noise more effectively than a single material. For example, a sheet of lead or visco-elastic material, along with a layer of other acoustical material, is more effective than when a single material is used.
24
Installation
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 2.7):
Use 5/8-inch thick or 3/4-inch thick plywood in the compart-
ment.
Construct the compartment floor of a double thickness of 5/8-
inch or 3/4-inch plywood.
Line the compartment interior walls and floor, as well as the
underside of the floor, with 26-gauge galvanized steel. Vapor seal all compartment seams and joints.• Over the galvanized steel lining, install a combination of acousti-
cal materials as mentioned in "Sound Insulating Materials".
2.2.5 COMPARTMENT FLOOR CUTOUTS
Provide openings in the generator compartment for the following items (Figure 2.9):
Engine exhaust and cooling air outlets• Generator cooling air inlet• Four holes for passage of generator mounting bolts. See
"Generator Restraint".
Fuel lines and exhaust piping must not pen-
n
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 available to the generator for cooling, ventilat­ing and combustion. The installer also must provide for a path for exhausting the cooling air to the exterior of a compartment, if so equipped.
To prevent fire or explosion, do not install
any insulation or other absorbent materials on the interior or underside of the compart-
ment floor.
Seal all compartment door edges to prevent noise leakage
around the door perimeter.
Figure 2.7 – Typical Noise Abatement
Never use discharged cooling air for heating
or permit such air to enter the vehicle inte­rior. This air contains deadly carbon monox-
ide gas and other poisonous, flammable or explosive gases.
2.3.1 GENERATOR AIRFLOW
Engine operation drives cooling fans for the two-stage cooling air system. A pressure fan draws cooling air into the top of the generator (Figure 2.8). This airflow cools the engine/generator and electronic components. The second part of the cooling system, a suction fan, draws air that is heated from a hot engine into a col­lector pan at the base of the unit. This heated air (although cooler than exhaust muffler) is then deflected out the bottom toward the ground.
Figure 2.8 – Airflow Through Engine/Generator
COOLING AIR IN
ENGINE AIR IN
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).
COOLING
AIR OUT
25
Installation
Figure 2.9 — Compartment Floor Cutout (Drawing 0G4432-A)
26
da, b
e
Installation
6.3.2 TESTING THE INSTALLATION
The manufacturer recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, enlarge the air openings. Never place a unit into service until absolutely certain that cooling and ventilation is adequate.
NOTE:
The installation must be tested, especially if bringing in air from below the generator set.

2.4 GASOLINE FUEL SYSTEM

Gasoline is highly flammable, and its vapors
are explosive. Comply with all codes, stan­dards and regulations pertaining to gasoline
fuel systems used in recreational vehicle generators. Properly install and maintain the fuel system and keep it entirely free of leaks. Gasoline vapors must not enter the vehicle interior.
The installation of a gasoline fuel system (Figure 2.10) for a recreational vehicle generator set must comply with applicable codes, standards and regulations. The entire fuel system must be completely free of leaks. There must be no possibility of gasoline vapors entering the vehicle interior.
Figure 2.10 – Generator Fuel System
If the generator is to share the vehicle engine's tank, separate fuel pickup tubes are required for the engine and the generator. The manufacturer recommends that the fuel pickup tube be two to three inches (51 to 76 mm) shorter than the vehicle engine's pickup tube. This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods.
Gasoline generators are equipped with an Evaporative Emissions Port that may be used in conjunction with a certified fuel system where required by law.
Do NOT tee the generator fuel supply line
n
into the vehicle engine fuel supply line. If this is done, the generator will be starved of fuel when both engines are operating at the same time. Also, while the vehicle engine is not running, generator operation may drain the vehicle engine supply line, making it dif­ficult to start the vehicle engine.
2.4.2 GENERATOR FUEL SUPPLY LINE
2.4.2.1 Rigid Fuel Lines
Those lines used to supply fuel from a tank to the generator must comply with applicable codes, standards and regulations. The fol­lowing general rules apply to rigid fuel lines:
Rigid lines should be of annealed, seamless, drawn aluminum
or steel.
Lines and fittings must comply with SAE J512F, “Standard
Automotive Fittings,” or with ANSI B126.26 (latest edition).
Route the fuel line so that at least 2 inches (51 mm) of clear-
ance is maintained between the line and any exhaust system parts.
Do not attach electrical wiring to fuel lines. Route the wiring so
it cannot come into contact with any fuel line.
Route fuel lines so if they leak, fuel does not drip onto any
electrical or exhaust system parts.
Use nonferrous metal straps without sharp edges to secure
fuel lines.
Factory installed generator fuel system components include (a) fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and (d) interconnecting lines and fittings, (e) evaporative port. Connect a fuel supply line to the fuel filter inlet. Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines.
2.4.1 FUEL TANK
Either the generator must share the vehicle engine's fuel tank, or a separate fuel tank for the generator set must be installed. All fuel tanks installed on the vehicle must be constructed, installed and restrained so they comply with applicable codes, standards and regulations. The generator has an evaporative emissions port to evacuate accumulated gasoline vapors when necessary.
2.4.2.2 Flexible Fuel Line
Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines. This prevents breaking of the line caused by vibration, shifting, settling or movement. The following rules apply:
The flexible hose must comply with SAE J30R7, “Standard for
Fuel and Oil Hose.” It must be approved for use with gasoline and low permeability.
The hose should be at least 6 inches (152 mm) longer than
is needed to prevent the hose from rupturing if the generator shifts or settles.
27
Installation

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.
The generator engine gives off DEADLY
n
carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentrations, can cause uncon­sciousness or even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED. SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a) inability to think coherently; (b) 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.
Figure 2.11 - Spark Arrestor
TAILPIPE P/N 0E0683
SPARK ARRRESTOR SCREEN P/N 089680
RETAINING SCREW P/N 056892
Figure 2.12 — Spark Arrestor Installation
Never tee the generator engine exhaust pipe
n
into the vehicle engine exhaust piping. This causes excessive back pressure on the gen­erator engine. Also, water from one engine can damage the other engine.
2.5.1 MUFFLERS AND SPARK ARRESTORS
This muffler meets code and standard requirements of the U.S. Forest Service. Use only mufflers and parts approved by the manufacturer. Any person(s) installing an unapproved muffler, or an unapproved exhaust system part, or modifying an exhaust system in any way that might cause a hazard, is liable for any damage, injury or warranty expense that might be caused by such unapproved installation or 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, a spark arrestor must be provided. The vehicle owner or operator must maintain this device in good condition. In the state of California, the preceding is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.
When installing/replacing the tailpipe or spark arrestor compo­nents, verify that the tailpipe has a hole to securely fasten the spark arrestor components (see Figures 2.11 and 2.12). Use only manufacturer supplied hardware. Substitution of parts may cause damage to the screen or a loose fit to the tailpipe.
2.5.2 EXHAUST SYSTEM SAFETY
Maintain a clearance of at least 3 inches (76 mm) between
exhaust system parts and any combustible material (such as wood, felt, cotton, organic fibers or other like material). If the 3-inch (76 mm) clearance 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 temperature.
Extend the exhaust system at least 1 inch (25 mm) past the
outer edge of the vehicle. Do not terminate the exhaust system under the vehicle.
Terminate the exhaust tailpipe such that exhaust gases will not
be drawn back into the generator compartment and recircu­lated.
If there is any possibility of the tailpipe or muffler being dam-
aged, protect these damage-prone areas by means of a protec­tive device (such as a skid bar).
Install the generator exhaust system according to safe automo-
tive 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.
28
Installation
Do not terminate the exhaust system under any opening, win-
dow 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 appli-
cable codes, standards and regulations.

2.6 ELECTRICAL CONNECTIONS

The following general rules apply to electrical connections in a recreational vehicle:
Qualified electricians who are familiar with applicable codes,
standards and regulations should install electrical wiring.
The wiring should comply with codes, standards and regula-
tions. 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 compartment
(if used) must be vapor-sealed to prevent entry of flammable, explosive or poisonous gases into the vehicle.
From the junction box, route power supply wires through
approved conduit to either (a) double-pole, double-throw trans­fer switch, or (b) approved isolation receptacle. Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being connected to two different power supplies at the same time (such as generator and dockside power).
Conductors must be rated 221° F (105° C) or must be of a
larger conductor size.
2.6.3 GENERATOR AC CONNECTIONS
Generator AC output leads T1 (red), T2 (white) and T3 (black) come out of the generator as shown in Figure 2.13. Leads T1 (red) and T3 (black) are “hot,” while T2 (white) is the grounded neutral lead. There is also a green lead that connects to ground in the junction box of the recreational vehicle.
Figure 2.13 – Generator AC Output Leads
2.6.1 ELECTRICAL JUNCTION BOX
Install an approved, square electrical junction box with a blank cover on the interior or exterior wall of the area planned for installa­tion of the generator (NOT on the generator). Route the generator's AC output leads into this junction box through approved flexible conduit. This is the point of first termination for generator AC output leads.
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.
If neutral conductors are used, they must be the same size as
other leg wires.
Route power supply conductors from generator AC output leads
T1 (red), T2 (white), T3 (black) and the green ground wire through approved flexible conduit to the electrical junction box on the compartment wall.
If flexible metal conduit is used between the generator and the
compartment junction box, the conduit end that terminates the compartment junction box must be vapor-sealed. Flexible metal conduit is NOT vapor tight along its entire length.
T3 T2
AC Output Leads
T1
Green (Ground)
4500 Watts
Line T1 (black) to T2 (white) is protected by circuit breaker a (CB1). Use this line to neutral connection to operate 120 volt, single-phase, 60 Hz, AC loads.
5500 and 6500 Watts
Line T1 (red) to T2 (white) is protected against overload by a cir­cuit breaker (CB1). Use this line-to-neutral connection separately to operate 120-volt, single-phase, 60 Hertz, AC loads. Line T3 (black) to T2 (white) also is protected against overload by a circuit breaker (CB2). Use this line-to-neutral connection separately to operate similar loads. However, be sure the total unit load does not exceed the maximum rating of the generator. The neutral line (T2, white) on all units is a grounded neutral.
29
Installation
Do NOT connect electrical loads in excess
of any circuit breaker rating or problems will develop with circuit breaker tripping, which causes a loss of AC output. Also, do NOT exceed the generator's rated wattage capac­ity. Add the watts or amperes of all lighting, appliance, tool and motor loads the generator will operate at one time. This total should be less than the unit's rated wattage/amperage capacity.
2.6.4 CONDUIT
Route the connections between the generator and the junction box through approved, flexible conduit. The following general rules apply:
Cut wiring to the required length and allow extra wire for junc-
tion box connections.
Carefully prepare conduit ends to prevent sharp edges from
cutting through wiring insulation.
Route conduit so it does not interfere with generator move-
ment.
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 vapor proof along its entire length.
2.6.5 ISOLATING DIFFERENT POWER SOURCES
Connections from the junction box must terminate in a double­pole, double-throw transfer switch (Figure 2.14). An alternate method for isolating different power sources is by using an isolat­ing receptacle (Figure 2.15). Whichever method is used, be certain that both power sources are NOT connected at the same time.
2.6.6 POWER SUPPLY CORD
The power supply cord must comply with all applicable codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected.
2.6.7 GROUND FAULT CIRCUIT INTERRUPTERS
The National Electrical Code (NFPA 70, article 551) requires that ground fault circuit interrupters (GFCIs) on all external and some internal electrical receptacles be installed. Contact the manufac­turer or dealer for recommendations.

2.7 BATTERY INSTALLATION

NOTE:
This generator is not equipped with an internal battery charger. It is intended for use in systems where an external battery char­ger is installed by the RV O.E.M. or an aftermarket installer.
2.7.1 RECOMMENDED BATTERY
Install a battery that meets the following requirements:
The battery must be a 12-volt, automotive type storage bat-
tery.
For prevailing ambient temperatures above 32° F (0° C), use
a battery rated 70 amp-hours and capable of delivering 400 cold-cranking amperes.
For prevailing ambient temperatures below 32° F (0° C), use
a battery rated 95 amp-hours and capable of delivering 400 cold-cranking amperes.
NOTE:
If the battery is to be used to power other vehicle accessories, as well as start the generator, a battery with a larger capacity may be needed.
2.7.2 BATTERY CABLES
Using battery cables that are too long or too small in diameter may cause a drop in voltage, which causes starting problems. For the best cold weather starting, the voltage drop between battery terminals and the generator connection point should not exceed
0.12 volts per 100 amperes of cranking current.
These generators are rated at about 100 DC amperes of cranking current.
Select battery cables based on (a) cable length and (b) prevail­ing ambient temperatures. Generally, the longer the cable and the colder the weather, the larger the cable size must be, as shown in the chart.
CABLE LENGTH in Feet (meters) 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
*For warm weather, use No. 2 cable up to 20 feet.
NOTE:
Where a minimum of 1025 CCA (cold cranking amps) battery current is available, up to 30 feet of AWG #2 battery cable is permitted.
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.
30
Figure 2.14 — Typical Transfer Switch Isolation Method
Installation
Figure 2.15 — Typical Installation With Isolation Receptacle
31
Installation
Figure 2.16 – Connecting Battery Cables
Positive Cable
Chasis Ground
Negative Cable
+
Battery
2.7.4 BATTERY COMPARTMENT
Install the generator battery in its own, vented compartment. Place the battery compartment away from any source of heat, sparks or flame.
Provide ventilation openings in the battery compartment. The minimum size of openings should be two (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.
Figure 2.17 – Remote Panel Plug-in Receptacle

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.
2.8.1 REMOTE PANEL MODELS
The remote panels mount a rocker type start/stop switch, a “Generator Run” advisory lamp and an hourmeter. The hourmeter should be used in conjunction with the maintenance operations found in Part I of this manual.
WIRE NO. WIRE COLOR FUNCTION
0 Black Ground
14 Blue Engine Run Signal
712 Blue 12 VDC
17 Brown/White Start
18 Brown/Black Stop
32

Post Installation

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.
n
Factory settings are correct for most applica­tions. When making adjustments, however, be careful to avoid overspeeding the engine.

3.2 BEFORE INITIAL START-UP

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

3.3 INITIAL START

When certain that the unit has been properly installed and prepared for use, start the engine as follows:
1. Turn off all electrical loads. Do this by setting the generator’s main circuit breakers to their “OFF” (or open) position.
2. Refer to Part I, “Starting the Generator”, for cranking and starting instructions. The engine may require more cranking for initial starting since the fuel lines have to be primed (use of the primer switch will shorten this time).
3. Let the engine warm up for about five minutes to allow internal temperatures to stabilize.
4. Carefully inspect the engine/generator for fuel, oil and exhaust system leaks. Before proceeding to the next step, correct any leakage immediately.
5. When all tests and adjustments at no-load are completed, apply electrical loads and check for proper operation under load (see "Testing Under Load"). Run the unit at least 30 min­utes with loads applied.
6. Turn off all electrical loads by setting the generator’s main circuit breakers to their “OFF” (or open) position.
7. Let the unit run at no-load for a few minutes to stabilize internal engine/generator temperatures. Then, shut down the engine.
NOTE:
The generator set was thoroughly tested and adjusted at the fac­tory before shipping. No additional adjustment should be neces­sary. Only qualified service technicians who have been trained should perform adjustments outlined in this manual.

3.4 TESTING UNDER LOAD

Apply electrical loads equal to about 75 to 100 percent of the unit's rated wattage/amperage capacity.
Let the unit run at least 30 minutes with load applied. During this part of the test, check that the unit is not running excessively hot and that adequate cooling airflow is available. Do not allow the unit to overheat during prolonged operation.
NOTE:
The generator engine is equipped with a high temperature switch. The switch has normally open (N.O.) contacts. When the engine temperature is too high, switch contacts close, and the engine shuts down automatically.
THE MANUFACTURER RECOMMENDS THAT THE GENERATOR BE TESTED FOR ADEQUATE COOLING.
33
Post Installation

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.
GASOLINE FUEL SYSTEM
Fuel tank complies with all applicable codes.
Fuel system is properly installed and checked for
leaks.
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.
Generator is always isolated from other power
sources.
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 _____________________________________________
34

Troubleshooting

4.1 TROUBLESHOOTING GUIDE

Problem Cause Correction
Engine won’t crank. 1. 7.5 amp fuse blown. 1. Replace blown fuse.
2. Loose, or corroded or defective 2. Tighten, clean or replace, battery cable(s). as necessary.
3. Battery is discharged or defective. 3. Recharge or replace battery.
4. Defective Star t/Stop switch. 4. Replace switch.
5. Defective star ter contactor. 5. Replace starter contactor.
6. Defective star ter motor. 6. Replace starter motor.
7. Defective Engine Control Board 7. Contact an authorized service dealer.
Engine cranks, won't start. 1. Out of fuel. 1. Refill fuel tank.
2. Fuel pump not operating. 2. Repair or replace pump.
3. Automatic choke not operating properly. 3. Repair, replace or adjust.
4. Engine is flooded. 4. Wait 5-10 minutes; try again.
5. Fuel filter is clogged. 5. Replace filter if clogged.
6. Engine spark plugs defective. 6. Clean, regap or replace as needed.
7. Bad ignition magneto on engine. 7. Replace if defective.
8. Bad carburetor. 8. Adjust, repair or replace.
9. Dir ty air cleaner. 9. Clean or replace as needed.
Engine starts hard, runs rough. 1. Dir ty engine air cleaner. 1. Clean or replace as needed.
2. Automatic choke is sticking. 2. Free choke linkage as needed.
3. Defective spark plugs. 3. Clean, regap or replace.
4. Defective ignition magneto. 4. Replace it if defective.
Engine starts, then shuts down. 1. Engine oil level is low. 1. Add oil as needed.
2. Bad low oil pressure switch. 2. Replace, if bad.
3. Defective high temp switch. 3. Replace, if bad.
4. Water in fuel. 4. Drain fuel tank and refill.
5. Defective remote harness. 5. Disconnect remote harness. Contact authorised service facility.
No AC output voltage. 1. Main breaker(s) open. 1. Close main breaker(s).
2. Transfer switch (if so equipped) is 2. Reset transfer switch. set to wrong position.
3. Failure in vehicle electrical system. 3. See vehicle manual.
4. Generator component failure. 4. Contact an authorized service facility.
35

Electrical Data Wiring Diagram Drawing No. 0G4221-C

36
Wiring Diagram Drawing No. 0G4221-C Electrical Data
37
Electrical Data Wiring Diagram Drawing No. 0H3633-A
38
Wiring Diagram Drawing No. 0H3633-A Electrical Data
39

Exploded Views & Parts Lists Enclosure Drawing No. 0G3881-F

40
Enclosure Drawing No. 0G3881-F Exploded Views & Parts Lists
ITEM PART NO. QTY. DESCRIPTION
1 0G3396 1 ENCLOSURE DOOR 2 0C5644 2 SLIDE LATCH, FLUSH 3 0G5236 1 FOAM ENCLOSURE DOOR 4 0D3700 23 NUT FLANGE M6-1.0 NYLOK 5 0G3401 1 DUCT, AIR IN DOOR 6 0G4077 1 GROMMET, OIL FILTER 7 0G4433 1 U CHANNEL 1/8” 8 0G3377 1 TRAY, 530 RV 9 0G3431 1 GASKET AIR IN BOTTOM DUCT 10 0F9199 1 PLUG PLASTIC 1.093-1.125 11 0G3430 1 GASKET AIR IN TOP DUCT 12 0G3402 1 DUCT AIR IN ROOF 13 090388 13 SCREW HHTT M6-1.0X12 ZINC 14 0G3422 1 TOP DIVIDER PANEL 15 0G5237 1 FOAM, SIDE ENCLOSURE 16 0G3399 1 ENCLOSURE SIDE / BACK 17 0D3472 1 GROMMET OVAL 31.75X50.8 18 0G4933 18 SCREW SWT 1/4-20X5/8 W/W 23 0G5238 1 FOAM BACK ENCLOSURE ALT SIDE 24 0G3397 1 ENCLOSURE ROOF 25 0G4391 1 ENCLOSURE, BACK PANEL 530 RV 26 0G5239 1 FOAM BACK PANEL ENCLOSURE 28 0G3392 1 UPPER BLOWER HOUSING 29 0G3754 1 UPPER BLOWER HOUSING GASKET 30 0G3398 1 EXHAUST DIVIDER PANEL 31 0G3912 1 MUFFLER HOLD DOWN BRACKET 32 0G3400 1 ENCLOSURE EXHAUST SIDE PANEL 33 0G5240 1 FBR GLASS, ENCLOSURE MFLR BACK 34 0G5242 1 FOAM EXHAUST END ENCL FRONT 35 0G5241 2 FBR GLASS, ENCLOSURE MFLR SIDE 36 045756 9 SCREW HHTT M6-1.0X10 ZYC 37 0G5755 1 BUMPER 38 0G5761 1 STAND OFF 39 022473 1 WASHER, FLAT 1/4” 40 022097 1 WASHER, LOCK 1/4” 41 022287 1 SCREW HHC 1/4-20 X 3/4” G5 42 0G3429 1 GASKET, SCROLL DUCT
SHEET METAL PAINT/MATERIAL CODE LEGEND
The following exploded views contain part numbers of various sheet metal components. Only the base par t number is listed. When ordering sheet metal, the
correct color and material information must be included as a suffix at the end of the part number as shown below.
Material Color Example: Desc. Part No. Material Color Order As" S = Steel G = Gray Roof 0G3397 S = Steel G = Gray 0G33970ST08 B = Black Upper Blower Hsg. 0G3392 S = Steel B = Black 0G33920ST03
41
Exploded Views & Parts Lists Control Panel Drawing No. 0H3635-C
42
Control Panel Drawing No. 0H3635-C Exploded Views & Parts Lists
ITEM PART NO. QTY. DESCRIPTION
1 045757 1 SCREW HHC M6-1.0 X 25 G8.8 2 0F5458 2 SCREW PLASTITE HI-LOW #10X3/8 3 023484S 1 BUSHING SNAP SB-1093-937 4 0G9081* 1 WIRE HARNESS C/PNL FRAME 5 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR 6 022473 2 WASHER FLAT 1/4-M6 ZINC 7 0A1658 1 WASHER LOCK SPECIAL 1/4" 8 0G3380 1 FUEL PUMP MOUNTING BRACKET 9 0F9176 28.75” HOSE,1/4" SAE30R7 10 0G3662A 1 CLAMP HOSE BAND .50 11 028414 1 BARBED STR 1/8NPT X 1/4 12 0D3700 5 NUT FLANGE M6-1.0 NYLOK 13 0G5225 1 FUEL PUMP 14 028916 1 ELBOW 90D STREET 1/8 BRASS 15 087769 1 FILTER FUEL 1/8P-1/4H 16 025965 1 SCREW HHC 1/4-20 X 2-1/4” G5 17 022097 2 WASHER LOCK M6-1/4 18 0G5318 1 AC HARNESS 530RV (5500 + 6500W) 0H3634 1 AC HARNESS 530RV EVAP (4500W) 19 0G4602 1 GROMMET, DOUBLE SLIT 20 0C7968 3 NUT HEX JAM 3/8-16 BRASS 21 022237 2 WASHER LOCK 3/8 22 0A4456 1 WASHER LOCK SPECIAL 3/8 23 0C7423 1 STUD 3/8-16 X 2-1/4 BRASS 24 022259 2 NUT HEX 5/16-18 STEEL 25 022129 2 WASHER LOCK M8-5/16 26 022145 1 WASHER FLAT 5/16-M8 ZINC 27 0E0593 1 STUD, 1/4-20 TO 5/16-18 28 0D8502 1 NEUTRAL CONNECTOR UL 29 0G5233 2 SCREW PPHTF #8-18 X 1/2 AB 30 0G3825 1 CONTROL PANEL COVER 31 0G3689 1 C/PNL FACE 32 092036 4 SCREW PPHM #6-32 X 1/4 SEMS 33 0A9611 1 FUSE 7.5AXBK/AGC7.5NX 34 032300 1 HOLDER FUSE 35 0G4215 1 SWITCH RKRSPDT(ON)OFF(ON)ILLUM
ITEM PART NO. QTY. DESCRIPTION
36 082025 4 NUT HEX LOCK M5-0.8 NYINS ZINC 37 0F9719 1 ASSY PCB VREG AIR COOLED 2006 38 0G3977 1 ASSY PCB RV CONTROLLER 39 0G3530 1 C/PNL FRAME RV 40 075476 2 SCREW PPHM M4-0.7 X 16 41 090987 2 SCREW PPHM M3-0.5 X 12 42 0C2174 1 RELAY 12V 25A SPST 43 031879 2 WASHER FLAT #4 ZINC 44 0D9784 2 NUT HEX LOCK M3-0.5 NY INS 45 075235 4 SCREW HHC M5-0.8 X 30 G8.8 46 074908 4 SCREW HHTT M5-0.8 X 10 BP 47 075210A 1 BLOCK 1 POSITION, 4 TAB 48 0E6480 2 NUT HEX LOCK M4-0.7 NY INS 49 090144 (5500W) 1 CIRCT BRK 20X1 MAG 10-32 CARL 090145 (6500W) 1 CIRCT BRK 30X1 MAG 10-32 CARL 50 090145 1 CIRCT BRK 30X1 MAG 10-32 CARL
(4500W, 5500W, 6500W) 51 0C2417A 1 EARTH STRAP 52 0G5986 1 NYLON SPACER .26 X 1.00 X 1.73 53 061669 1 PLUG, PLASTIC .75 (5410-1/5412-
1/5414-1 ONLY) 54 059502 1 BARBED EL 90 ¼ NPT X 5/16
(5751/5752/5753 ONLY) 55 069598 1 BULKHEAD ADAPTER
(5751/5752/5753 ONLY) 56 035579 1 BUSHING REDUCER HEX ¼ TO 1/8 NPT
(5751/5752/5753 ONLY) 57 035483 1 NIPPLE PIPE 1/8 NPT X 1 ½
(5751/5752/5753 ONLY) 58 0G0247 1 SOLENOID 12 VDC (5751/5752/5753
ONLY) 59 028740 1 BARBED EL 90 1/8 NPT X ¼
(5751/5752/5753 ONLY)
*HARNESS NOT SHOWN
43
Exploded Views & Parts Lists Base & Pulley Drawing No. 0G7720-B
44
Base & Pulley Drawing No. 0G7720-B Exploded Views & Parts Lists
ITEM PART NO. QTY. DESCRIPTION
1 0G3377 1 TRAY, 530 RV 2 081105 2 NUT FLANGE 5/16-18 LOCK 3 022259 8 NUT HEX 5/16-18 STEEL 4 022129 12 WASHER LOCK M8-5/16 5 022145 13 WASHER FLAT 5/16-M8 ZINC 6 0G5217 2 SCREW HHC 3/8-24 X 1-1/2 G8 7 0G3748 1 BELT V-RIBBED 4L X 43.75" LG 8 046526 2 WASHER LOCK M10 9 022131 2 WASHER FLAT 3/8-M10 ZINC 10 0G3384 1 ALTERNATOR PULLEY 11 0C7758A 4 VIB MNT 1.5X1.38X5/16-18 DR 45 12 0C1751 1 FAN 7" DIA (NYLON) 13 0C2824 11 SCREW HHTR #10-32 X 9/16 14 022473 7 WASHER FLAT 1/4-M6 ZINC 15 022097 7 WASHER LOCK M6-1/4 16 043116 7 SCREW HHC M6-1.0 X 12 G8.8 17 0G3383 1 ENGINE PULLEY 18 0G4350 1 FAN ENGINE PULLEY RV 19 0G3379 2 BRACKET MUFFLER SUPPORT 20 0C3062 2 BOLT CARR 5/16-18 X 1 21 0G4429 1 EDGE TRIM W/ 3/4" HOLLOW CYL. 22 0G3391 1 BLOWER HOUSING WALL 23 0G3742 1 GASKET, LOWER BLOWER HOUSING 24 0G7670 1 FRAME GT530 RV MOUNTING 25 0E0588 1 SPACER, SAFETY BOLT .375 I.D. 26 0G4702 2 SCREW HHC 5/16-18 X 3 SPC 27 029451 1.5ft TAPE ELEC UL FOAM 1/8 X 1/2 28 0G3426 1 DUCT AIR OUT 29 0G5676 1 GASKET,AIR OUT DUCT 0G5676A 1 GASKET, AIR OUT DUCT OPPOSITE SIDE 30 0G4692 1 SCREEN, BOTTOM AIR OUT 31 022473 3 WASHER FLAT 1/4-M6 ZINC 32 0A2110 3 SCREW SWAGE 1/4-20 X 1/2 ZYC 33 0G3410 5 ISOLATION SPRING 34 0G3393 1 MUFFLER, 530 RV 0G7887 1 MUFFLER. 530 RV (MODELS: 5410-1 / 5412-1 / 5414-1 ONLY) 35 025145 1 BOLT U 5/16-18 X 1.25 W/SADDLE 36 0C8565 4 SCREW SHC M8-1.25 X 18 G8.8 37 056892 1 SCREW CRIMPTITE 10-24 X 3/8 38 089680 1 SCREEN SPARK ARRESTOR 39 094670 2 CLAMP EXHAUST 40 0G3394 1 EXHAUST FLEX 41 0G3395 1 EXHAUST MANIFOLD 42 056893 6 SCREW CRIMPTITE 10-24 X 1/2 43 023897 6 WASHER FLAT #10 ZINC 44 0G4260 2 GASKET, EXH BASE, 530 RV 45 0E9369 2 GASKET, EXHAUST GT530
45
Exploded Views & Parts Lists Engine Accessories Drawing No. 0G7718-K
46
Engine Accessories Drawing No. 0G7718-K Exploded Views & Parts Lists
ITEM PART NO. QTY. DESCRIPTION
1 0G7670 1 FRAME 3 0G3404 1 ENGINE WRAPPER, STARTER SIDE 4 0E9507 8 SCREW HHFC M8-1.25 X 14 5 023484S 1 SNAP BUSHING 6 056893 14 SCREW CRIMPTITE 10-24 X 1/2 7 0G4129 1 SHIELD WRAPPER, CYLINDER #1 8 0C8563 12 SCREW HHFC M6-1.0 X 12 G8.8 9 0G3405 1 ENGINE WRAPPER, BACK 10 0G4985A 1 BACKPLATE 11 0E9525A 1 ASSY, FLYWHEEL & RING GEAR 29D 12 0E4997 1 ASSY, GROUND WIRE CONNECTOR 13 067198N 1 WASHER,BELV-20 X 2.2 14 067890 1 NUT HEX M20-1.5 G8 15 0G3911 1 BLOWER HOUSING 16 0G4130 1 SHIELD WRAPPER, CYLINDER #2 17 082774 1 KEY, WOODRUFF 4 X 19D 18 0G3454 1 BREATHER HOSE 19 022131 3 WASHER FLAT 3/8 – M10 ZINC 20 0G5221A 1 IGNITION COIL CYLINDER #1 21 0G5221B 1 IGNITION COIL CYLINDER #2 22 0G6432 4 SCREW HHFC M6-1.0 X 25 SEMS 23 0E9319 2 GASKET, INTAKE 24 0E9333 1 INTAKE MANIFOLD 25 040976 4 SCREW SHC M8-1.25 X 20 G12.9 26 0E9471 1 GASKET, MANIFOLD TO CARB/MIXER 27 0E9383D 1 CARBURETOR 28 0G9640 1 ROD, CHOKE CONTROL 29 0G3890 1 ASSY GOVERNOR ROD 30 0G4378 1 GASKET, AIRBOX/CARB 31 040173 1 CLAMP, HOSE WORM GEAR 32 0G3406 1 WRAPPER, ENGINE OIL ADAPTOR 33 0G3455 1 SNORKEL, AIR BOX 34 0G3413 1 AIRBOX BASE 35 078601 1 AIR FILTER 36 0G5057 1 AIRBOX SEAL 37 0E9511B 1 AIRBOX QUARTER KNOB 38 0G3414 1 AIRBOX COVER 40 0G3408 1 OIL DRAIN LINE 41 045756 4 SCREW HHTT M6-1.0 X 10 YELLOW
CHROME 42 0E0998 1 CLAMP, VINYL 9.5 O.D. 43 0G3432 2 3/4 NPT TO 3/8 O.D. FLARE 44 0E0393A 1 ASSY, CAP AND DIPSTICK 45 0E0361B 1 OIL DRAIN/DIPSTICK TUBE 46 043790 1 90 DEGREE ELBOW 3/8 NPT X 3/8
BARBED 47 0G3662B 2 HOSE OETIKER CLAMP 48 0F0452B 8” HOSE, 3/8” I.D. 49 0G4426 1 ASSY, OIL DRAIN FITTING
ITEM PART NO. QTY. DESCRIPTION
50 0G3386 1 OIL FILTER SUPPORT 51 0A2311 2 SCREW SWAGE 1/4-20 X 1 52 070185B 1 OIL FILTER 53 0D9235 1 OIL PRESSURE SWITCH 5 PSI 54 0G4793 1 SWITCH, THERMAL 270F 55 043182 2 WASHER, LOCK M3 56 0C1085 2 SCREW PPHM M3-0.5 X 8 58 0G4576 1 BRACKET, OIL CHECK TUBE 59 0A2110 1 SCREW SWAGE 1/4-20 X 1/2 60 0G3407 1 WRAPPER ENGINE VALLEY 61 0G3915 1 WRAPPER UPPER VALLEY 62 0G3840 1 WRAPPER INNER CYLINDER #2 63 0G3839 1 WRAPPER INNER CYLINDER #1 64 0E9368 2 SPARKPLUG 65 0G7671 1 OIL LINE OUT 66 0G3389 1 OIL LINE IN 67 0A7094 2 SCREW PPHM #4-40 X 1/4 68 0D8590 1 ASSEMBLY, BI-METAL/HEATER 69 0D8591 1 CHOKE SOLENOID 70 0G3984 1 CONTROLLER ASSEMBLY 71 043146 2 SCREW HHC M6-1.0 X 10 G8.8 72 022097 6 WASHER LOCK M6-1/4 73 0D6342 1 BALL STUD, 10 MM 74 0D9784 1 NUT HEX LOCK M3-0.5 75 0G4016 1 BRACKET, CONTROLLER SUPPORT 76 043116 2 SCREW HHC M6-1.0 X 12 G8.8 77 0F1177 1 ASSY, GROUNDING WIRE W/O DIODES 78 077091 1 COTTER PIN 80 075763A 1 BOOT, BATT. CABLE 81 0742600173 1 WIRE ASSY. BATT. POS. 83 022473 2 WASHER, FLAT 1/4-M6 84 061906 2 SCREW HHC M8-1.25 X 85 85 049813 2 NUT M6-1.0 86 056892 2 SCREW CRIMPTITE 10-24 X 3/8 87 0E9323 1 START MOTOR 88 022129 2 WASHER, LOCK M8-5/16 89 0A4456 1 WASHER, LOCK SPECIAL 3/8 90 022746 4 SCREW HHC 3/8-16 X 1-3/4 G5 91 055934M 1 CLAMP VINYL .75 X .343 92 0G6725 1 INSULATOR 93 0G6729 1 GASKET, MANIFOLD TO CARB/MIXER 94 078643C 2 BOLT,CARB MOUNT M6-1.0 X 95 95 096290A 2 STUD M6-1.0 X 100 96 046526 3 WASHER LOCK M10 97 0G9148 1 PLUG, RUBBER (4703, 5, 6 & 7) 98 0G7757A 1 HOSE MOLDED EVAP. PORT (05751,
05752 & 05753) 99 0H4269 1 SCREW, BHSC M6-1 X 8 100 0G9062 1 SCREW BHSC M6-1 X 8MM BLACK
47
Exploded Views & Parts Lists 530 RV Engine Drawing No. 0G7719-B
48
530 RV Engine Drawing No. 0G7719-B Exploded Views & Parts Lists
ITEM PART NO. QTY. DESCRIPTION
1 0E3812 2 SEAL D 35 X 48.2 2 0D4788 1 3/8” SQUARE HEAD PLUG 3 073144 9 SCREW HHFC M8 – 1.25 X 45 4 0G7260A 1 GEAR COVER 5 078699B 6 SLEEVE DOWEL PIN 6 0A5776 1 11/32 DIAMETER PRESSURE RELIEF BALL 7 0E9482 1 OIL PRESSURE SPRING 8 0C5315A 1 GEAROTOR, OUTER 9 0C5314A 1 GEAROTOR, INNER 10 0E9379 1 SCREEN, OIL PICK-UP 11 0E9382 1 COVER, GEROTOR 12 0G0919 3 SCREW, HHFCS M6-1.0 x 12 13 0E3372A 1 BREATHER SEPARATOR 14 0E9345 1 GEAR, GEAROTOR 15 076390 4 RETAINER RING 16 0G4379 2 PISTON RING SET 17 0G4331 2 PISTON 18 076389 2 PISTON PIN 19 0G1054 2 CONNECTING ROD ASSEMBLY 20 0G1063G 1 CRANKSHAFT 21 093064 1 OIL FILL CAP 22 0E9334F 1 COVER ROCKER W/FILL 23 080318 8 SCREW HHFC M6-1.0 X 25 24 0E9352 2 GASKET, VALVE COVER 25 0E9368 2 SPARK PLUG 26 077168 12 SCREW HHC M8-1.25 X 56 27 084186 4 WASHER, VALVE SPRING 28 088156 2 SEAL, VALVE STEM 29 0C4390 4 VALVE SPRING 30 0C3733 4 VALVE RETAINER 31 0C3592 8 KEEPER, VALVE SPRING 32 077161 4 STUD, ROCKER ARM 33 077160 4 ROCKER ARM 34 076307 4 JAM NUT, ROCKER ARM 35 0E9353A 2 PUSH ROD GUIDE PLATE 36 0E9304 1 CYLINDER HEAD CYL. 1 37 0C3591 2 INTAKE VALVE 38 0C3590 2 EXHAUST VALVE 39 0E9351 2 GASKET CYLINDER HEAD 40 0G5728 1 SCREEN 41 0E9455E 4 PUSHROD 42 083235 4 TAPPET 43 0G7679 1 CAM SHAFT & GEAR 44 0E9350 1 GASKET, CRANKCASE 45 0E9334G 1 COVER ROCKER 46 0E9305 1 CYLINDER HEAD CYL 2 47 0E9429C 1 CRANKCASE 48 0E9366 1 GASKET, BREATHER ASSEMBLY 49 0G5670 1 BREATHER ASSY 50 0C8566 1 SCREW HHFC M6-1.0 X 20 51 0C5943 1 SEAL, OIL PASSAGE 52 0G0273 1 GASKET KIT 53 0G5896 1 BREATHER KIT 54 0G0275 1 KIT HEAD ASSY CYLINDER #1 55 0G0276 1 KIT HEAD ASSY CYLINDER #2
49
Exploded Views & Parts Lists Rotor & Stator Drawing No. 0G3953-B
50
Rotor & Stator Drawing No. 0G3953-B Exploded Views & Parts Lists
ITEM PART NO. QTY. DESCRIPTION
1 052858 6 NUT TOP LOCK FL M8-1.25 2 075237 4 WASHER, SPRNG CENTER 3 075242 4 SPRING, GEN. MOUNT 4 0C1878 2 SUPPORT, SLIDE 5 073146 4 SLIDE, NYLON 6 052203 2 SCREW HHC M8-1.25 X 70 G8.8 7 022145 6 WASHER FLAT 5/16-M8 ZINC 9 0G3913 4 STUD, 530 RV STATOR 10 029459 2 TENSION SPRING 11 075215 2 WASHER, SPRING CENTR 12 0G3382 1 LOWER BEARING CARRIER 13 0G3877H 1 RTR 200 4.5AD1 RV 0G3878H 1 RTR 200 5.5AD1 RV 0G3879H 1 RTR 200 6.5AD1 RV 14 0G3893H 1 STR 200-4.5AD1 RV 0G3894H 1 STR 200-5.5AD1 RV 0G3895H 1 STR 200-6.5AD1 RV 15 0G3381 1 UPPER BEARING CARRIER 16 022129 4 WASHER LOCK M8-5/16 17 045771 4 NUT HEX M8-1.25 G8 CLEAR ZINC 18 066386 1 ASSEMBLY, BRUSH HOLDER 19 066849 2 SCREW HHTT M5-0.8 X 16 20 0G3542 1 FAN UPPER ALTERNATOR 21 022131 1 WASHER FLAT 3/8-M10 ZINC 22 042633 1 SCREW HHC 3/8-24 X 1 G5 23 022237 1 WASHER LOCK 3/8
51

Warranty

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 2008 and later generator. New equip­ment that use small spark-ignited 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 generator for the period of time listed below provided there has been no abuse, neglect, unapproved modification or improper maintenance of your equipment.
Your emission control system may include parts such as the: carburetor, ignition system, fuel system catalytic converter, and other associ­ated emission-related components (if equipped).
MANUFACTURER’S WARRANTY COVERAGE:
This emission control system is warranted for two years. If, during such warranty period, any emission-related part on your equipment is found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Dealer.
OWNER'S WARRANTY RESPONSIBILITIES:
As the generator 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 generator, but Generac cannot deny warranty solely due to the lack of receipts.
As the generator owner, you should be aware that Generac may deny any and/or all warranty coverage or responsibility if your generator, or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or the use of counterfeit and/or "grey market" parts not made, supplied or approved by Generac.
You are responsible for contacting a Generac Authorized Warranty Dealer 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 Dealer. To locate the Generac Authorized Warranty Service Dealer 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. Note that this warranty shall not apply to 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). 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.
The ECS Warranty applies only to the emission control system of your new equipment. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the Generac Warranty shall apply. Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented showing the date of the sale to the original purchaser/owner.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Par t 1
Part No. 0H1912 Rev. A 05/09
52
Warranty

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines:
(a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin on the date the new equip-
ment 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 sub-
sequent purchaser/owner that the ECS when installed was:
(1) Designed, built and equipped so as to conform with all applicable regulations; and
(2) Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS Warranty Period.
(c) The warranty on emissions-related parts will be interpreted as follows:
(1) Any warranted part that is 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 par t 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 the Owner’s Manual 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 part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the period of time prior
to first scheduled replacement point for that part. If the par t fails prior to the first scheduled replacement, the par t 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 period prior to the first scheduled replacement point for that part.
(4) Repair or replacement of any warranted, emissions-related par t under this ECS Warranty shall be performed at no charge to the owner at a
Generac Authorized Warranty Service Facility.
(5) Notwithstanding the provisions of subsection (4) above, warranty services or repairs must be provided at Generac Authorized Service Facilities.
(6) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for diagnostic
costs if the repair is deemed warrantable.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand
for such parts.
(8) Any Generac authorized and approved emission-related replacement parts 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 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 Generac equipment caused by the use of such an unapproved, add-on, modified, counterfeit and/or "grey market" par t.
EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING (IF EQUIPPED):
1) FUEL METERING SYSTEM A. CARBURETOR AND INTERNAL PARTS B. PRESSURE REGULATOR
2) AIR INDUCTION SYSTEM A. INTAKE MANIFOLD B. AIR FILTER
3) IGNITION SYSTEM A. SPARK PLUGS B. IGNITION COILS / MODULE
4) AIR INJECTION SYSTEM A. PULSE AIR VALVE
5) EXHAUST SYSTEM A. CATALYST B. THERMAL REACTOR C. EXHAUST MANIFOLD
Par t 2
Part No. 0H1912 Rev. A 05/09
53
Warranty
GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY
FOR GENERAC 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 mechani-
cal devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.
Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing, • lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
Damage related to rodent and/or insect infestation.• Products that are modified or altered in a manner not authorized by Generac in writing.• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement
of the defective part(s). Failure due to misapplication.• Telephone, cellular phone, facsimile, internet access or other communication expenses.• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty
period. Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.• Rental equipment used while warranty repairs are being performed.• Overnight freight costs for replacement part(s).• Overtime labor.• Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you. This warranty gives you specific legal rights. You also have other rights from state to state.
GENERAC® POWER SYSTEMS, INC.
P.O. BOX 297 • WHITEWATER, WI 53190
Part No. 0H3467 Revision B (04/15/10) Printed in U.S.A.
Rev. A 06.09
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