Generac 50 04164-3, 50 05754-0 User Manual
Owner's Manual and
Installation Instructions
Air-cooled Recreational Vehicle Generators
• Model: 05754-0
PRIMEPACT 50
• Model: 04164-3
PRIMEPACT 50LP
INTRODUCTION
Thank you for purchasing this model manufactured by Generac
Power Systems Inc. This model is designed and manufactured to
supply electrical power for recreational vehicles.
READ THIS MANUAL THOROUGHLY
If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating and servicing
procedures.
Throughout this publication, and on tags and decals affixed to the
generator, DANGER, WARNING, CAUTION and NOTE blocks are
used to alert personnel to special instructions about a particular
operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:
The operator (driver) is responsible for proper and safe use of the
vehicle and its equipment, and the safety of all vehicle occupants.
We strongly recommend that the operator read this manual and
thoroughly understand all instructions before using this equipment.
We also strongly recommend instructing other occupants in the
vehicle to properly start and operate the generator. This prepares
them if they need to operate the equipment in an emergency.
CONTENTS
This manual contains pertinent owner’s information, including
warranty, electrical diagrams, exploded views and lists of repair
parts for this generator model. In addition, the latter portion of this
manual contains information necessary for the proper installation
of these generators.
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious personal injury, including death.
After this heading, read instructions that, if not
strictly complied with, could result in serious personal injury, including death.
After this heading, read instructions that, if not
strictly complied with, might result in minor or
moderate injury.
NOTE:
After this heading, read instructions that, if not strictly
complied with, may result in damage to equipment and/or
property.
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:
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, 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.
Model No. _________________ Serial No. ______________
This symbol points out important safety informa-
tion that, if not followed, could endanger personal safety and/or property of others.
This symbol points out potential explosion haz-
ard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
or locate us on the web at:
www.generac.com
Table of Contents
Recreational Vehicle Generator
Part I – Owner’s Manual
Introduction .................................. Inside Front Cover
Read This Manual Thoroughly .......................................................IFC
Contents .......................................................................................IFC
Operation and Maintenance ...........................................................IFC
How to Obtain Service ..................................................................IFC
Authorized Service Dealer Locator Number ....................................IFC
Safety Rules ...............................................................2
Section 1 – General Information ...............................4
1.1 Generator Identification ............................................................4
1.2 Generator Applicability .............................................................5
1.3 Safety ......................................................................................5
1.4 Generator AC Connection System ............................................5
1.5 Specifications ..........................................................................5
1.6 Evaporative Emissions Information ...........................................7
1.7 Exhaust Emissions Information (Gasoline) ................................7
1.8 Exhaust Emissions Information (Propane) ................................7
Section 2 – Operation ................................................8
2.1 Generator Control Panel ...........................................................8
2.2 Optional Remote Start/Stop Panel.............................................8
2.3 Automatic Choke (Gasoline Only) .............................................8
2.4 Before Starting the Engine ........................................................9
2.5 Starting the Generator ..............................................................9
2.6 Stopping the Generator ..........................................................10
2.7 Applying Loads to Generator ..................................................10
2.8 Summer/Winter Heat Riser System ........................................10
2.9 Protection Systems ................................................................11
2.10 Additional Information ............................................................12
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 Clean Air Intake ......................................................................13
3.5 Checking the Engine Spark Plug .............................................14
3.6 Fuel Filter (Gasoline Only) .......................................................14
3.7 Spark Arrestor Muffler ............................................................14
3.8 Cleaning the Generator ...........................................................14
3.9 Battery Maintenance ..............................................................15
3.10 Major Service Manual ............................................................15
3.11 Drive Belt ...............................................................................15
3.12 Exercising the Generator ........................................................15
3.13 Out of Service Procedure .......................................................16
Part II – Installation Instructions
Safety Rules .............................................................18
Notice to Installer ...............................................................................18
Section 1 – General Information .............................20
1.1 Purpose and Scope of the Manual ..........................................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 ............................................22
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 LP Gas Fuel System ...............................................................28
2.6 Exhaust System .....................................................................30
2.7 Electrical Connections ............................................................31
2.8 Battery Installation .................................................................32
2.9 Optional Accessories .............................................................34
Section 3 – Post-installation Start-up
Adjustments ..........................................34
3.1 Post Installation Tests .............................................................34
3.2 Before Initial Start-up .............................................................34
3.3 Initial Start .............................................................................34
3.4 Testing Under Load ................................................................35
3.5 Installation Checklist ..............................................................36
Section 4 – Troubleshooting ....................................37
Troubleshooting Guide ........................................................................37
Section 5 – Electrical Data .......................................38
Section 6 – Exploded Views and Parts Lists ..........40
Section 7 – Notes .....................................................54
Section 8 – Warranty ................................................56
1
Safety Rules
Recreational Vehicle Generator
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in
potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of
this equipment.
The engine exhaust from this product contains
chemicals known to the state of California to cause
cancer, birth defects or other reproductive harm.
This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
Study these SAFETY RULES carefully before installing, operating
or servicing this equipment. Become familiar with this manual and
with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many
accidents are caused by failing to follow simple and fundamental
rules or precautions.
The manufacturer cannot 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.
WARNING:
WARNING:
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
Generator exhaust gases contain DEADLY
carbon monoxide gas. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death.
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.
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.
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.
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.
ENGINE EXHAUST HAZARDS
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglecting its maintenance or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
2
Generator engine exhaust contains DEADLY carbon monox-•
ide, an odorless, colorless poisonous gas. Breathing carbon
monoxide can cause: dizziness, throbbing temples, nausea,
muscular twitching, headache, vomiting, weakness and sleepiness, inability to think clearly, fainting, unconsciousness or
even death. If you experience any carbon monoxide poisoning
symptoms, move into fresh air and immediately seek medical
attention.
Never operate the generator set with the vehicle inside any •
garage or other enclosed area.
Safety Rules
Recreational Vehicle Generator
Adequate, unobstructed flow of cooling and ventilating air •
is critical for expelling toxic carbon monoxide gas and fuel
vapors from the generator compartment and for proper generator operation. Without sufficient cooling airflow, deadly carbon
monoxide gas can accumulate and the engine/generator may
quickly overheat, causing serious damage to the generator. Do
not operate the genset in any confined space.
The exhaust system must be installed in accordance with the •
genset installation manual. Do not alter the installation or permit
even partial blockage of ventilation systems, as this can seriously affect the safe and proper operation of the generator.
Do not operate the generator if the exhaust system is leaking or •
has been damaged or if you have experienced carbon monoxide
poisoning symptoms during use. Shut down the generator and
do not operate it until it has been inspected and/or repaired.
Never sleep in the vehicle while the genset is running unless the •
vehicle has a working carbon monoxide detector.
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.
3
Section 1 – General Information
Recreational Vehicle Generator
1.1 GENERATOR IDENTIFICATION
Please record the following information from the generator DATA DECAL or information decal.
1. Model Number _____________________ 2. Serial Number __________________
3. kW Rating _________________________ 4. Rated Voltage __________________
Model: 05754-0
1. Generator Air Intake
2. Engine Start/Stop Switch
3. Fuse
4. Optional Remote Panel Receptacle
(behind control panel)
5. Generator AC Output Leads (behind
control panel)
6. Fuel Primer Switch
18
19
7. Circuit Breaker
8. Circuit Breaker
9. Star ter Contactor
10. Fuel Inlet
11. Fuel Pump
12. Fuel Filter
13. Oil Filter
14. Oil Drain Cap
15. Oil Dipstick
16. Data Decal
17. Oil Fill
18. Spark Plug
19. External Vacuum Port
4
Model: 04164-3
1. Generator Air Intake
2. Engine Start/Stop Switch
3. Fuse
4. Optional Remote Panel Receptacle
(behind
control panel)
5. Generator AC Output Leads (behind
control panel)
17
6. Fuel Primer Switch
7. Circuit Breaker
8. Circuit Breaker
9. Star ter Contactor
10. Fuel Solenoid
11. Demand Regulator
12. Oil Filter
13. Oil Drain Cap
14. Oil Dipstick
15. Data Decal
16. Oil Fill
17. Spark Plug
Section 1 – General Information
Recreational Vehicle Generator
1.2 GENERATOR APPLICABILITY
These generators have been designed and manufactured for supplying electrical power for recreational vehicles. Do not modify the
generator or use it for any application other than for what it was
designed. If there are any questions pertaining to its application,
write or call the factory. Do not use the unit until advised by a
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 this generator to supply electrical power for operating
120/240-volt, single-phase, 60 Hertz, AC electrical loads. These
loads can require up to 4,800 watts (4.8 kW) of power, but cannot
exceed 40 AC amperes of current at 120 volts, or 20 AC amperes
at 240 volts for model 05754-0. For model 04164-3, the loads can
require up to 4,500 watts (4.5 kW) of power, but cannot exceed
37.5 amperes of current at 120 volts, or 18.8 amperes at 240
volts.
Do not overload the generator. Some installations
may require that electrical loads be alternated
to avoid overloading. Applying excessively high
electrical loads may damage the generator and
may shorten its life. Add up the rated watts of
all electrical lighting, appliance, tool and motor
loads the generator will power at one time. This
total should not be greater than the wattage
capacity of the generator. If an electrical device
nameplate gives only volts and amps, multiply
volts times amps to obtain watts (volts x amps =
watts). Some electric motors require more watts
of power (or amps of current) for starting than
for continuous operation.
DANGER
1.3 SAFETY
Before attempting to use the generator set, carefully read the
“Safety Rules” section of this manual. Comply strictly with these
rules to prevent accidents and damage to equipment and/or
property. We suggest copying and posting the “Safety Rules” in
potential hazard areas of the vehicle. Stress safety to all operators
and potential operators of this equipment.
1.4 GENERATOR AC CONNECTION SYSTEM
This generator set is equipped with dual stator AC power windings.
These two-stator windings supply electrical power to customer
electrical loads by means of a dual two-wire connection system.
Note, however, that the neutral is grounded.
The generator may have been installed so that it powers 120-volt
AC loads (Figure 1.1). It can be wired to connect both 120- and/or
240-volt AC electrical loads. This procedure should be done by an
Authorized Service Dealer or other qualified installer.
Figure 1.1 – Connections for 120 Volts Only
1.5 SPECIFICATIONS
1.5.1 FUEL REQUIREMENTS
This generator is equipped with a gasoline fuel system. Depending
on the installation, the generator may have either a separate fuel
tank, or it may “share” the vehicle engine’s fuel tank.
NOTE:
Some installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine’s
pickup tube. Such an arrangement causes the generator engine
to “run out of gas” while adequate fuel for the vehicle remains
in the tank.
To reduce lead and carbon deposits use high quality UNLEADED
gasoline with the generator. Leaded REGULAR grade gasoline is an
acceptable substitute.
NOTE:
Using unleaded gasoline contributes to longer engine valve life
by reducing lead and carbon deposits.
5
Section 1 – General Information
Recreational Vehicle Generator
The manufacturer does not recommend using
any gasoline containing alcohol (such as “gasohol”). If using any gasoline containing alcohol, it
must not contain more than 10 percent ethanol,
and it must be removed from the generator during storage. Do NOT use any gasoline containing methanol. If using gasoline with alcohol,
inspect more frequently for fuel leaks and other
abnormalities.
1.5.2 OPTIONAL PROPANE FUEL SYSTEM
This generator is equipped with a liquid propane (LP) gas fuel system. LP gas is usually supplied as a liquid in pressure tanks.
The generator requires a vapor withdrawal type fuel system. This
type of gaseous fuel system uses the vapors forming above the liquid fuel in the storage tank. Air temperature around the storage tank
must be high enough to sustain adequate fuel vaporization. In colder
climates, it may be necessary to use an independent heat source to
be sure the fuel sufficiently vaporizes in the storage tank.
LP gas may consist of propane, butane or a mixture of the two
gases. Propane vaporizes at temperatures as low as -20° F (-29°
C), but butane returns to its liquid state when the temperature
drops below about 32° F (0° C). For that reason, a higher ratio
of propane is desired in the gas mixture when temperatures drop
below freezing.
1.5.3 FUEL CONSUMPTION
Model No Load 1/2 Load Full Load
05754-0 0.32 0.46 0.76
04164-3 0.47/17.05 0.72/3.06 1.25/45.35
Gasoline is in gal/h.
LP is in gal/h and cf/h.
1.5.4 ENGINE OIL REQUIREMENTS
Use only high quality detergent oil rated with American Petroleum
Institute (API) Service Classification SF, SG or SH. The recommended oil weights include the following:
During summer months: SAE 30. An acceptable substitute is •
SAE 10W-30.
During winter months: SAE 5W-30. DO NOT USE SAE •
10-W40.
Crankcase and oil filter capacity is approximately 1,400 mL or
1.5 U.S. quarts. Do NOT use special additives. See "Checking the
Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter"
sections for oil level check and fill procedures.
1.5.5 ENGINE
Type of Engine ............................................................GN-410, Single-cylinder
Cooling Method ................................................................................Air-cooled
Rated Horsepower ................................................................15 @ 4,200 rpm
Displacement ......................................................................................... 407cc
Cylinder Block ....................................................Aluminum w/Cast Iron Sleeve
Type of Governor ......................................................Mechanical, Fixed Speed
Air Cleaner ................................................. Paper Element w/Foam Precleaner
Starter .................................................................................12-volt DC Electric
Ignition System ..............................................Solid-state w/Flywheel Magneto
Recommended Spark Plug
Champion ......................................................................................... RC14YC
AC ..........................................................................................................R45S
Fram Autolite .............................................................................................. 65
Spark Plug Gap ................................................................ 0.030 inch (76 mm)
Recommended Minimum Battery ....................................... 400 Cold-cranking
Amperes
ClassII Emission Compliant
1.5.6 GENERATOR
Rated Maximum Continuous
AC Output (Gasoline) ...................................................4,800 Watts (4.8 kW)
AC Output (LP Fuel) .....................................................4,500 Watts (4.5 kW)
Rated Voltage .............................................................................120 Volts AC*
Rated Maximum Continuous
AC Current (Gasoline).............................................................40 Amperes**
AC Current (LP Fuel)............................................................37.5 Amperes**
Phase ...................................................................................................... Single
Rotor RPM .............................................................................................. 3,600
Number of Rotor Poles ...................................................................................2
Engine RPM ............................................................................................ 2,571
Rated AC Frequency ...............................................................................60 Hz
Battery Charge Voltage ..................................................................14 Volts DC
Battery Charge Current .........................................................2 Amperes (max)
Weight
Gasoline ...................................................................................... 198 Pounds
LP Fuel ........................................................................................ 200 Pounds
Length .......................................................................... 25.5 inches (648 mm)
Width .........................................................................18.88 inches (479 mm)
Height ........................................................................16.75 inches (425 mm)
* All units are reconnectable to 120- and/or 240-volt, dual voltage output. Units
are no longer listed per RVIA/ANSI when reconnected for dual voltage output.
** If reconnected for dual voltage, the ampere rating for 240 volts is 20 AC
amperes for model 05754-0, and 18.8 AC amperes for model 04164-3.
*** 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.
6
Section 1 – General Information
Recreational Vehicle Generator
1.6 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.
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
≥ 225 cc
B 250 Hours
C 125 HOurs
A 1000 Hours
B 500 Hours
C 250 Hours
1.8 EXHAUST EMISSIONS INFORMATION (PROPANE)
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 propane fuel (LP). The emission
control system on the generator consists of the following:
Fuel Metering System•
~ Mixer assembly
~ Fuel regulator 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
≥ 225 cc
7
B 250 Hours
C 125 HOurs
A 1000 Hours
B 500 Hours
C 250 Hours
Section 2 – Operation
Recreational Vehicle Generator
2.1 GENERATOR CONTROL PANEL
The following features are mounted on the generator control panel
(Figure 2.1):
Figure 2.1 – Generator Control Panel
2.1.1 FUEL PRIMER
Before starting a cold engine (if it has not been started in more
than two weeks), this switch must be pressed for approximately
10 to 15 seconds to bring fuel from the tank to the carburetor.
This rocker type switch springs back into its original position
when released. It is not necessary to press the primer switch for
LP units.
NOTE:
If the generator has been reconnected for dual voltage AC output (120/240 volts), install line breakers having an amperage
rating that is different than that stated in the "Generator AC
Connection System" section. The replacement line breakers
consist of two separate breakers (one 20 amp, and one 30
amp) with a connecting piece between the breaker handles (so
that both breakers will operate at the same time). If the unit is
reconnected for dual voltage, it is no longer RVIA listed.
2.2 OPTIONAL REMOTE START/STOP PANEL
A remote mounted Start/Stop Panel (Figure 2.2) 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. The
Prime switch is not connected, it must be used with jumper wire
0G7666.
Figure 2.2 — Optional Remote Panel
(Models 0H3068)
2.1.2 START/STOP SWITCH
To crank and start the engine, hold this switch in the START position. Release the switch when the engine starts. To stop an operating engine, press and hold the switch in the STOP position until the
engine shuts off. The switch center position is the RUN position.
2.1.3 FUSE
The fuse protects the engine’s DC control circuit against electrical
overload. If the fuse element has melted open due to overloading,
the engine cannot be cranked. If the fuse must be replaxed, use
only an identical replacement.
2.1.4 MAIN BREAKER
The main breaker protects the generator’s AC output circuit against
overload and provides a method of turning OFF the generator’s
120/240-volt AC output to the vehicle circuits. The generator has
one 20-amp breaker and one 30-amp breaker.
8
2.3 AUTOMATIC CHOKE
ONLY)
The engine is equipped with an automatic choke that consists of
two main components: a choke solenoid and prechoke.
(GASOLINE
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.
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.
Section 2 – Operation
Recreational Vehicle Generator
2.4 BEFORE STARTING THE ENGINE
NOTE:
Instructions and information in this manual assume the generator has been properly installed, connected, serviced, tested and
adjusted by a qualified installation technician or installation
contractor.
2.4.1 INSTALLATION
Generator installation must have been properly completed so it
complies with all applicable codes, standards and regulations and
with the manufacturer's recommendations.
NOTE
Be sure the installation complies with all standards and codes
listed in the "Standards Booklets" section of this manual.
2.4.2 ENGINE LUBRICATION
Have the engine crankcase properly serviced with the recommended oil before starting. Refer to the "Engine Oil Requirements"
section and "Checking the Engine Oil Level" and "Changine the
Engine Oil and/or Oil Filter" sections for oil servicing procedures
and recommendations.
Any attempt to crank or start the engine before
it hase been properly serviced with the recommended oil may result in an engine failure.
2.4.3 FUEL SUPPLY
The engine must have an adequate supply of proper fuel to operate. Before starting it, check that sufficient fuel is available.
NOTE:
Depending on the installation, the generator may have either a
separate fuel tank, or it may “share” the vehicle engine’s fuel
tank.
DANGER
Generator engine exhaust contains DEADLY
carbon Monoxide, an odorless, colorless poisonous gas. Breathing carbon monoxide can
cause: dizziness, throbbing temples, nausea,
muscular twitching, headache, vomiting, weakness and sleepiness, inability to think clearly,
fainting, unconsciousness or even death. If you
experience any carbon monoxide poisoning
symptoms, move into fresh air and immediately
seek medical attention.
Never operate the generator set with the vehicle
inside any garage or other enclosed area.
Adequate, unobstructed flow of cooling and
ventilating air is critical for expelling toxic carbon monoxide gas and fuel vapors from the
generator compartment and for proper generator operation. Without sufficient cooling airflow,
deadly carbon monoxide gas can accumulate
and the engine/generator may quickly overheat,
causing serious damage to the generator. Do
not operate the genset in any confined space.
The exhaust system must be installed in accor-
dance with the genset installation manual. Do
not alter the installation or permit even partial
blockage of ventilation systems, as this can
seriously affect the safe and proper operation of
the generator.
Do not operate the generator if the exhaust sys-
tem is leaking or has been damaged or if you
have experienced carbon monoxide poisoning
symptoms during use. Shut down the generator
and do not operate it until it has been inspected
and/or repaired.
Never sleep in the vehicle while the genset is
running unless the vehicle has a working carbon
monoxide detector.
2.4.4 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compartment must
be open and unobstructed for continued proper operation. Without
sufficient cooling and ventilating airflow, the engine/generator
quickly overheats, which causes it to shut down and may damage
the generator.
2.4.5 ENGINE EXHAUST GAS
Before starting the generator engine, be sure there is no way for
Before starting the generator engine, inspect for exhaust leaks and
ensure 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.
2.5 STARTING THE GENERATOR
NOTE:
Read the vehicle manufacturer’s instructions. The owner/
operator should become familiar with the vehicle in which this
generator is installed. Differences exist between vehicles. For
example, some vehicles may use a transfer switch to isolate
dockside power from the generator, while other vehicles may
use an isolating receptacle. Some vehicles may be equipped
with a DC converter, which allows the generator to power certain DC lighting and other DC loads.
To start the generator from either the generator control panel or
from the optional remote panel, proceed as follows:
1. Turn OFF electrical loads using the means provided in the
vehicle (such as a main line circuit breaker or transfer
switch).
9
Section 2 – Operation
Recreational Vehicle Generator
NOTE:
If starting from the generator control panel, turn OFF loads
by setting the generator’s main circuit breaker to the OFF (or
OPEN) position. If starting from a remote panel, turn OFF loads
using the means provided in the vehicle (such as a main circuit
breaker). Electrical load circuits will be turned ON after the
generator has started, stabilized and warmed up.
2. If the engine has not been star ted in more than two weeks,
press the Fuel Pump Primer switch and hold it for about 10 to
15 seconds to prime the fuel system. However, if the engine
is warm, skip Step 2.
3. Hold the engine Star t/Stop switch in the START position to
crank the engine. Release the switch when the engine starts.
If the engine does not start after it has been
cranking for 15 seconds, release the Start/Stop
switch and try again. Holding the switch for
longer than 15 seconds can damage the starter
motor.
4. Let the engine run at no-load for a few minutes to stabilize and
warm up.
5. Turn ON electrical loads using the means provided (such as a
main circuit breaker or transfer switch).
2.8 SUMMER/WINTER HEAT RISER SYSTEM
Under certain weather conditions, it is possible for ice to form
in the venturi area of the carburetor. This condition can be very
dangerous because it can prevent the governor system from functioning properly, which results in a “runaway” engine.
The most common weather conditions leading to this problem are
temperatures in the range of 25° F to 35° F (-4° C to 1.7° C), along
with high humidity. This ice formation also can be attributed to the
load being applied during these weather conditions. Generators
running with no-load or light loads applied usually have the most
problems.
The Summer/Winter Lever (Figure 2.3) should be in the WINTER
position for ambient temperatures below 40° F (4.4° C) and in the
SUMMER position for ambient temperatures above 40° F (4.4°
C).
Figure 2.3 – Heat Riser System
2.6 STOPPING THE GENERATOR
1. Turn OFF all electrical loads using the means provided (such
as a main circuit breaker or transfer switch).
2. Let generator run at no-load for a few minutes, to stabilize internal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position.
2.7 APPLYING LOADS TO
GENERATOR
When applying electrical loads to the generator, observe these
guidelines:
Before applying electrical loads, let the generator stabilize and •
warm up for a minute or two.
DO NOT overload the generator.•
2.7.1 LETTING THE ENGINE STABILIZE
The generator supplies correct rated voltage only at the proper
governed speed. Some electrical appliances may be extremely
sensitive to voltage. Incorrect voltages can damage such appliances.
If electrical loads are applied at reduced operating speeds, such
loads imposed on the engine when sufficient power is not available
may shorten engine life. Never turn ON electrical loads until after the
generator engine has started and stabilized at no-load.
When the heat riser is in the SUMMER (down) position (Figure
2.2), air is drawn into the air cleaner from the upper intake tube.
When the heat riser is in the WINTER (up) position, air is drawn
from the lower intake tube, which is positioned to draw the heated
air near the exhaust manifold.
To prevent carburetor icing, the owner/operator should physically
position the heat riser to the proper position dependent on the
temperature.
10
Section 3 – Maintenance
Recreational Vehicle Generator
2.8.1 DO NOT OVERLOAD THE GENERATOR
Read the rated wattage/amperage capacity of the generator on the
generator data decal (see "Generator Identification").
Applying electrical loads in excess of the unit’s rated capacity will
cause the engine/generator to 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.
Most lighting, appliance, tool and motor loads indicate their •
required watts on their nameplate or data plate. For light bulbs,
simply note the wattage rating of the bulb.
If a load does not show its rated wattage, multiply that load’s •
rated VOLTS times AMPS to obtain WATTS.
Induction type motors (such as those that run the vehicle’s •
furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2
time more watts of power for starting than for running (for a
few seconds during motor starting). Be sure to allow for this
when connecting electrical loads to the generator. First, figure
the watts needed to start electric motors in the system. To that
figure, add the running wattages of other items that will be operated by the generator.
Do not apply heavy electrical loads for the first two or three •
hours of operation.
2.9.3 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 2.5). During engine
cranking only, a positive DC (battery) voltage is delivered through
the diode, resistor, brushes and slip rings, and the generator rotor.
Application of this voltage to the rotor “flashes the field” whenever
it is started. Flashing of the field each time the generator starts
makes sure that a sufficiently strong magnetic field is available to
produce “pickup” voltage in the stator windings.
Figure 2.5 – Field Boost Circuit
2.9 PROTECTION SYSTEMS
2.9. LOW OIL PRESSURE SWITCH
This switch (Figure 2.4) has normally closed (N.C.) contacts that
are held open by engine oil pressure during cranking and operating.
Should oil pressure drop below a preset level, switch contacts close,
and the engine automatically shuts down. The unit should not be
restarted until oil is added.
2.9.2 HIGH TEMPERATURE SWITCH
This switch (Figure 2.4), which has normally open (N.O.) contacts,
is mounted near the oil filter. The contacts close if the temperature
should exceed approximately 293º F (145º C), initiating an engine
shutdown.
Figure 2.4 – Low Oil Pressure and
High Temperature Switches
2.9.4 OVERVOLTAGE PROTECTION
A solid-state voltage regulator (Figure 2.6) controls the generator’s
AC output voltage. This regulator supplies an excitation current to
the rotor. By regulating the rotor’s excitation current, the strength
of its magnetic field is regulated and, in turn, the voltage delivered
to connected electrical loads is controlled. When the AC frequency
is 60 Hertz, voltage is regulated at 120 volts (voltage-to-frequency
ratio is 2-to-1).
Figure 2.6 – Solid State Voltage Regulator
The voltage regulator also incorporates a “voltage surge protection
circuit.” This circuit prevents troublesome surges in the generator
AC output voltage. Voltage surge is a common cause of damage
to electronic equipment.
11
Section 3 – Maintenance
Recreational Vehicle Generator
2.10 ADDITIONAL INFORMATION
2.10.1 ATTENTION REQUIRED AFTER SUBMERSION
If the recreational vehicle generator has been submerged in water,
it MUST NOT be started and operated. Following any submersion
in water, have an Authorized Service Dealer thoroughly clean and
dry the generator.
2.10.2 OPERATION IN HIGH GRASS OR BRUSH
Never operate the generator while the vehicle is parked over high
grass, weeds, brush, leaves or any other combustible substance.
Such materials can ignite and burn from the heat of the exhaust
system. The generator exhaust system becomes extremely hot
during operation and remains hot for a long time after it has shut
down.
2.10.3 EFFECTS OF MOISTURE AND DIRT
Keep the generator set as clean and dry as possible. Protect the
unit against excessive dust, dirt, corrosive vapors, road splash,
etc. Permitting dirt and moisture to accumulate on generator
windings will have an adverse effect on the insulation resistance
of those windings.
When moisture is allowed to remain in contact with windings,
some of the moisture will be retained in voids and cracks in the
insulation. This causes a reduced insulation resistance and will
eventually cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with windings. Salt (as
from sea air) also will worsen the problem since it tends to absorb
moisture from the air. Salt and moisture, when combined, form a
good electrical conductor.
3.1 CHECKING THE ENGINE OIL LEVEL
For oil capacities and requirements, see section “Engine Oil
Requirements”. Check the engine crankcase oil level at least every
eight hours of operation, or before use. To check the engine oil
level, proceed as follows (see Figure 3.1):
1. Be sure the generator is as level as possible.
2. Remove the dipstick and wipe it dry with a clean, lint-free
cloth.
3. Install and tighten the dipstick cap; then, remove it again. The
oil level should be at the dipstick “Full” mark.
4. If necessary, remove the oil fill cap on the rocker cover and
slowly add oil until it reaches the dipstick “Full” mark. DO NOT
FILL ABOVE THE “FULL” MARK.
Never operate the engine with the oil level below
the “Add” mark on the dipstick. Doing this could
damage the engine.
5. Install and tighten the oil fill cap and the dipstick before oper-
ating the engine.
3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER
Hot oil may cause burns. Allow engine to cool
before draining oil. Avoid prolonged or repeated
skin exposure with used oil. Thoroughly wash
exposed areas with soap.
Change the engine oil after the first 25 hours of operation. •
Thereafter, change the oil every 100 operating hours. Change
the oil more frequently if operating consistently under heavy
load or at high ambient temperatures.
12
Figure 3.1 – Oil Maintenance Features
Section 3 – Maintenance
Recreational Vehicle Generator
Change the engine oil filter after the first 25 hours of operation, •
and every 100 operating hours thereafter.
To change the oil and/or oil filter, proceed as follows (see Figure •
3.1):
1. Run the engine until it is thoroughly warmed up (at least five
minutes) then shut OFF the engine.
2. Immediately after the engine shuts OFF, pull the oil drain hose
free of its retaining clip. Remove the cap from the hose and
drain the oil into a suitable container. Loosening the oil fill cap
will allow the crankcase to drain faster.
3. After the oil has drained, replace the cap onto the end of the oil
drain hose. Retain the hose in the clip.
4. With the oil drained, remove the old oil filter by turning it
counterclockwise.
5. Apply a light coating of clean engine oil to the gasket of the
new filter.
6. Screw the new filter on by hand until its gasket lightly contacts
the oil filter adapter. Then, tighten the filter an additional 3/4 to
one turn.
7. Remove the dipstick and wipe it dry with a clean, lint-free
cloth. This will be used later to check the oil level.
8. Remove the oil fill cap on the rocker cover and slowly add
the proper type and amount of recommended oil (see section
"Engine Oil Requirements"). Periodically use the dipstick to
check the oil level and continue to fill the crankcase until the
oil reaches the dipstick “Full” mark. DO NOT FILL ABOVE THE
“FULL” MARK.
9. Install and tighten the oil fill cap and the dipstick before operating the engine.
10. Start the engine and check for leaks.
NOTE:
Check the oil level and fill to the “FULL” mark after checking for
leaks. The filter will retain some oil.
3.3 MAINTAINING THE ENGINE
AIR CLEANER
3.3.1 CLEANING THE FOAM PRECLEANER
Clean and re-oil the foam precleaner every three months or every
25 hours of operation, whichever occurs first. Service the foam
precleaner more frequently if operating the generator in extremely
dusty or dirty conditions. Use the following procedure (Figure
3.2):
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover, foam precleaner and paper filter.
3. Remove the foam precleaner from the cover.
4. Wash the foam precleaner in liquid detergent and water.
5. Wrap the foam precleaner in a clean cloth and gently squeeze
it dry.
6. Saturate the foam precleaner in clean engine oil. Gently
squeeze it in a clean cloth to remove excess oil and to distribute oil (DO NOT TWIST).
7. Install the foam precleaner into the cover, followed by the
paper filter.
8. Install the cover, foam precleaner and paper filter.
9. Tighten the two screws to retain the filter in place.
Figure 3.2 – Engine Air Cleaner
PAPER
AIR FILTER
FOAM
PRECLEANER
AIR CLEANER
COVER
SCREWS
3.3.2 CLEANING OR REPLACING
THE PAPER FILTER
Once each year or every 100 hours of operation (whichever comes
first), clean or replace the paper filter. The new replacement filter
must be flame retardant. Service the paper filter more frequently if
operating the generator in extremely dusty or dirty conditions. Use
the following procedure (Figure 3.2):
1. Follow steps 1-3 in the "Cleaning the Foam Precleaner" section; service the foam precleaner if necessary.
2. Remove the paper filter.
3. Clean the air filter by tapping it gently on a solid surface. If the
filter is too dirty, replace it with a new one. Dispose of the old
filter properly.
4. Clean the air cleaner cover then reassemble following steps
7-9 in the "Cleaning the Foam Precleaner" section.
3.4 CLEAN AIR INTAKE
Clean all foreign material from the air intake (Figure 3.3) at least
once every 100 hours of operation. Clean more often if necessary.
Inspect the area around the generator exhaust muffler periodically
and remove all grass, leaves, dirt, etc., from this area.
Figure 3.3 – Cleaning Air Intake
13
Fuel Filter
Section 3 – Maintenance
Recreational Vehicle Generator
3.5 CHECKING THE ENGINE SPARK PLUG
Clean the spark plug and reset the spark plug gap every 100 hours
of operation.
1. Clean the area around the base of the spark plug to keep dirt
and debris out of the engine. Clean by scraping or washing
using a wire brush and commercial solvent. Do not blast the
spark plug to clean.
2. Remove the spark plug and check the condition. Replace the
spark plug if worn or if reuse is questionable.
3. Check the spark plug gap using a wire feeler gauge. Adjust the
gap to 0.030 inch (0.76 mm) by carefully bending the ground
electrode (Figure 3.4).
Sparking can occur if the wire terminal does not
fit firmly on the spark plug terminal end. If necessary, re-form the wire terminal to obtain a
tight fit.
Figure 3.4 – Setting the Spark Plug Gap
3.7 SPARK ARRESTOR MUFFLER
If the generator is not equipped with a spark arrestor exhaust
muffler and is to be used on any forest covered, brush covered or
grass covered unimproved land, a spark arrestor may need to be
installed. The spark arrestor must be maintained in effective working order by the vehicle owner/operator.
For assistance in ordering, installing and maintaining spark arrestor
exhaust mufflers, contact the nearest Authorized Service Dealer.
Exhaust mufflers supplied by the manufacturer are spark arrestor
types. The manufacturer's exhaust mufflers for recreational vehicle
generators do not have a spark arrestor screen, but are of the more
efficient “toroid” or “swirl” type. To remove carbon and combustion deposits from such mufflers, remove the plug from the muffler
and run the engine for approximately 15 minutes. Shut down the
engine, let the muffler cool and install the plug.
Be sure to reinstall the muffler plug tightly.
Engine vibration could cause a loose plug to
fall out. Without the plug in place, hot engine
exhaust is directed out the opening. This hot
exhaust, depending on the installation, could
be directed to areas not able to withstand the
extreme heat such as wooden floor boards or
other flammable material. This could result in a
fire.
3.6 FUEL FILTER (GASOLINE ONLY)
Remove and replace the fuel filter (Figure 3.5) once each year or
every 100 hours of operation, whichever comes first.
Figure 3.5 – Fuel Filter
3.8 CLEANING THE GENERATOR
Keep the generator set as clean and dry as possible. Protect the
unit against excessive dust, dirt, corrosive vapors, road splash,
etc. Permitting dirt and moisture to accumulate on generator
windings will have an adverse effect on the insulation resistance
of those windings.
When moisture is allowed to remain in contact with windings,
some of the moisture will be retained in voids and cracks in the
insulation. This causes a reduced insulation resistance and will
eventually cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with windings. Salt (as
from sea air) also will worsen the problem since it tends to absorb
moisture from the air. Salt and moisture, when combined, form a
good electrical conductor.
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
interior and cause problems, and may also contaminate the generator fuel system.
14
3.9 BATTERY MAINTENANCE
All lead-acid batteries will discharge when not in use. The generator battery should be inspected as follows:
3.9.1 WEEKLY
Inspect the battery posts and cables for tightness and 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.
3.9.2 EVERY SIX MONTHS
Have the state of charge and condition checked. This should be •
done with an automotive-type battery hydrometer.
NOTE:
Servicing of the battery is to be performed or supervised by
personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.
Damage will result if the battery connections are made in
reverse.
DANGER
Section 3 – Maintenance
Recreational Vehicle Generator
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following
procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or water. The 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.
Do not dispose of the battery in a fire. The
battery is capable of exploding. Stored 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.
A battery presents a risk of electrical shock
and high short circuit current. The following precautions are to be observed when working on
batteries:
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery;
• Disconnect any charging source prior to connecting
or disconnecting battery terminals; and
• Do not use any jumper cables or booster battery to
crank and start the generator engine. If any battery
has discharged, remove it for recharging.
3.10 MAJOR SERVICE MANUAL
To obtain a service manual for the generator, contact the nearest
Authorized Service Dealer or, go to www.generac.com. 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. The drive belt and pulleys are warranted for the life
of the generator. Drive belt tension was properly adjusted before the
unit was shipped from the factory. If suspecting that the drive belt
tension is incorrect, contact an Authorized Service Dealer.
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.
15
Section 3 – Maintenance
Recreational Vehicle Generator
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 com-
pletely. Refill the crankcase with SAE 10W-30 oil having API
classification “For Service SF.”
4. Attach a tag to the engine indicating the viscosity and clas-
sification 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 the "Engine Oil Requirements" section). 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.
16
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