Generac Power Systems 004703-1, 004705-1, 004706-1, 004707-1, 005750-0 Owner's Manual

...

Download

Models: 004703-1, 004705-1, 004706-1,

004707-1, 005750-0. 005854-0, 005858-0, 005859-0, 005860-0

Owner's Manual

This manual should remain with the unit.

Air-cooled Recreational

Vehicle Generators

Quietpact

55, 65 and 75

Part I — Operating Instructions

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 Evaporative Emissions Information .........................................7

1.8 Exhaust Emissions Information (Gasoline) ..............................7

1.9 Exhaust Emissions Information (Propane) ..............................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) .....................................................14

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 ........................................................................20

Notice to Installer .........................................................................20

Section 1 — General Information ........................................22

1.1 Purpose and Scope of the Installation Instructions................22

1.2 Safety ..................................................................................22

1.3 Standards Booklets ..............................................................22

1.4 Equipment Description .........................................................22

1.5 Generator Engine Operating Speed .......................................22

1.6 Generator AC Connection System ........................................22

Major Features and Dimensions ...........................................23

Section 2 — Installation ......................................................24

2.1 Location and Support...........................................................24

2.2 Generator Compartments .....................................................25

2.3 Cooling and Ventilating Air ....................................................27

2.4 Gasoline Fuel System ...........................................................29

2.5 LP Gas Fuel System .............................................................30

2.6 Exhaust System ...................................................................31

2.7 Electrical Connections ..........................................................33

2.8 Battery Installation ...............................................................34

2.9 Optional Accessories ...........................................................36

Section 3 — Post Installation ..............................................36

3.1 Post Installation Tests ...........................................................36

3.2 Before Initial Start-up ...........................................................36

3.3 Initial Start ...........................................................................36

3.4 Testing Under Load ..............................................................37

3.5 Installation Checklist ............................................................38

Section 4 – Troubleshooting ................................................39

4.1 Troubleshooting Guide ..........................................................39

Section 5 – Electrical Data ..................................................40

Section 6 – Exploded Views and Parts Lists ........................42

Section 7 – Warranty ...........................................................52

Section 4 – Notes ................................................................17

Introduction

INTRODUCTION

Thank you for purchasing this model by Generac Power Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles.

READ T HIS 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:

Indicates a hazardous situation or action which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation or action which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation or action which, if not avoided, could result in minor or moderate injury.

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.

C ONTENTS

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.

NOTE:

Notes contain additional information important to a procedure and will be found within the regular text body of this manual.

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

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

This symbol points out important safety 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.

HOW TO OBTAIN SERVICE

When the generator requires servicing or repairs, simply contact an Authorized Service Dealer for assistance. Service technicians are factory-trained and are capable of handling all service needs.

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

Model No. _________________ Serial No. ______________

AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest AUTHORIZED SERVICE

DEALER, please call this number:

1-800-333-1322

or locate us on the web at:

www.guardiangenerators.com

Safety Rules

 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.

Study these SAFETY RULES carefully before installing, operating or servicing this equipment. Become familiar with this manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.

The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and on tags and decals affixed to the unit, are, therefore, not all-inclusive. If using a procedure, work method or operating technique the manufacturer does not specifically recommend, ensure that it is safe for others. Also make sure the procedure, work method or operating technique utilized does not render the generator unsafe.

Despite the safe design of this generator, operating this equipment imprudently, neglecting

its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to operate or maintain this equipment.

Potentially lethal voltages are generated by



these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot during operation. Exercise care near running

generators.

GENERAL HAZARDS

For safety reasons, the manufacturer recommends that the •

installation, initial start-up and 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. DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED. SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a) inability to think coherently, (b) nausea, (c) vomiting, (d) twitching muscles, (e) throbbing temples, (f) dizziness, (g) headaches, (h) weakness, and (i) sleepiness. IF EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET MEDICAL HELP. Shut down the generator and do not operate it until it has been inspected and repaired.

Never sleep in the vehicle while the genset is running unless the •

vehicle has a working carbon monoxide detector. The exhaust system must be installed in accordance with the genset installation manual. Make sure there is ample fresh air when operating the genset in a confined area.

The engine exhaust fumes contain carbon monoxide, which can •

be DEADLY. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death. This exhaust system must be installed properly, in strict compliance with applicable codes and standards. Following installation, do nothing that might render the system unsafe or in noncompliance with such codes and standards. The generator compartment must be completely vapor sealed from the vehicle interior. There must be no possibility of exhaust fumes entering the vehicle interior. Never operate this equipment with a leaking or defective exhaust system.

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

and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

Adequate, unobstructed flow of cooling and ventilating air is •

critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment. Without sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to the generator. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can seriously affect safe operation of the generator.

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.

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.

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.

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 __________________________

CONTROL CENTER

FUSE

7.5A

IF GENERATOR DOES NOT START, REMOVE

AND INSPECT FUSE.

(SEE OWNER'S MANUAL TROUBLE SHOOTING

GUIDE.)

PRESS PRIME SWITCH FOR 10 SECONDS BEFORE STARTING. WHEN STARTING, DO

NOT PRESS START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT.

SERVICEACCESSPA NEL

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE

AIR FILTER:

CLEAN PREFILTER EVERY 100 HOURS.

REPLACE ELEMENT EVERY 250 HOURS.

CHANGE EVERY 100

OIL & OIL FILTER:

HOURS. (OR ANNUALLY)

PERFORM MORE OFTEN IN DUSTY CONDITIONS

OIL CAPACITY

1.8L/1.9QT

WITH FILTER:

(SAE VISCOSITY)

TEMPERATURE:

SAE 30 OR 10W-30

40°F AND HIGHER

-20°F TO 40°F

5W-30 OR 5W-20

WHEN SERVICE OR PARTS ARE NEEDED IN THE USA OR CANADA,

CONTACT THE GUARDIAN SERVICE LOCATOR AT 1-800-333-1322.

CIRCUIT BREAKER

FUEL

START

STOP

PRIME

INSPECT & CLEAN

SPARK PLUGS:

PLUGS EVERY 100 HOURS.

REPLACE PLUGS EVERY 500 HOURS. (IF NECESSARY)

FUEL FILTER:

CHANGE EVERY 400 HOURS. (OR ANNUALLY)

CHECK DAILY

OIL LEVEL:

PREFILTER P/N:

0D4511 REPLACEMENT INFORMATION:

0D9723

AIR FILTER P/N:

070185

OIL FILTER P/N:

072347

SPARK PLUG P/N:

FUEL FILTER P/N:

087769

11, 15 (Behind Access Panel)

1. Generator Air Intake Screen

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

10. Fuel Primer Switch

9, 18

REFERENCE NUMBER IDENTIFICATION

11. Fuel Pump (Behind access panel.)

12. Oil Filter

13. Oil Drain Plug

14. Oil Dipstick and Filler Tube

15. Air Filter (Behind access panel.)

16. Spark Plugs

17. Exhaust Outlet

18. Fuel Filter

19. LP Fuel Inlet

20. Evaporative Port

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:

QUIETPACT 55G & LP: 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.

QUIETPACT 65G & LP: 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.

QUIETPACT 75G & LP: 120 and/or 240 volts, single phase, 60 •

Hz electrical loads. These loads can require up to 7500 watts (7.5 kW) of total power, but cannot exceed 62.5 AC amperes of current at 120 volts or exceed 31.2 AC amperes at 240 volts.

Do not overload the generator. Some installations may require that electrical loads be alter-

nated 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 — one load with a maximum total watt-

age requirement equal to 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

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 seperate 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

CB1

RED

WHITE

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.

LP Fuel Consumption (lb./hour)

The LP powered range of generators are fitted with a nonadjustable, factory set system. These systems are tamper-proof to meet 1997 California Air Resources Board requirements for engine emission.

Model Idle 50% Load 100% Load

QuietPact 55LP 2.34 3.96 5.07

QuietPact 65LP 2.34 4.20 6.50

QuietPact 75LP 2.34 4.44 8.75

STATOR POWER WINDINGS

CB2

GROUNDED NEUTRAL

BLACK

1.6 SPECIFICATIONS

1.6.1 FUEL REQUIREMENTS

This generator is equipped with a gasoline or LP fuel system. Specific installations may provide either a separate fuel tank for the generator, or the generator may “share” the vehicle engine’s fuel tank.

Gasoline Fuel Consumption (gph)

Model 10% Load 50% Load 100% Load

QuietPact 75G 0.51 0.80 1.28

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.

1.6.2 ENGINE OIL REQUIREMENTS

Use only high quality detergent oil rated with American Petroleum Institued (API) Classification SF, SG, SH or SJ. The recommended oil viscosity weights include the following:

During summer months (40 deg. F and higher), SAE 30 or SAE •

10W-30

During winter months (40 deg. F to -20 deg. F), SAE 5W-30 or •

SAE5W20

DO NOT USE SAE 10W-40•

Crankcase and oil filter capacity is approximately 1.8 L or 1.9 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.

1.6.3 ENGINE SPECIFICATIONS

Type of Engine ..................................................................................... GT-760

Cooling Method ...............................................................................Air-cooled

Rated Horsepower ..................................................................27 at 3600 rpm

Displacement ......................................................................................... 760cc

Compression Ratio ..............................................................................8.6 to 1

Cylinder Block ................................................... Aluminum w/Cast Iron Sleeve

Type of Governor ......................................................Mechanical, Fixed Speed

Engine Governor Speed

QUIETPACT 55 .............................................................................. 2200 rpm

QUIETPACT 65/75 ......................................................................... 2571 rpm

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

General Information

1.6.4 GENERATOR SPECIFICATIONS

SERIES QP55LP QP65LP QP75G QP75LP

Rotor RPM 3600 3600 3600 3600

Rotor Poles 2 2 2 2

Engine RPM 2200 2571 2571 2571

Rated Max. Continuous AC Output Watts*/**

Voltage* 120 120 120 120

Rated Max. Continuous Current Amps (240V)** 45.8 (22.9) 54.1 (27.0) 62.5 (31.2) 62.5 (31.2)

Phase 1 1 1 1

Frequency 60 Hertz 60 Hertz 60 Hertz 60 Hertz

Battery Charging Current (Max.) 2 amps 2 amps 2 amps 2 amps

Weight 329 lbs. 331 lbs. 330 lbs. 333 lbs.

Length 33.7 in. 33.7 in. 33.7 in. 33.7 in.

Width 22.2 in. 22.2 in. 22.2 in. 22.2 in.

Height 19.6 in. 19.6 in. 19.6 in. 19.6 in.

* All units are reconnectable 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.

5500 6500 7500 7500

Spark Plug Gap .............................................................0.040 inch (1.02 mm)

Recommended Min. Battery ....................................400 Cold Cranking Amps

Class II Emission Certified

1.7 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.

1.8 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)•

Operation

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

1.9 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)•

2.1 GENERATOR CONTROL PANEL

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

2.1.1 FUEL PRIMER

Before starting a cold engine (if it has not been started in more than two weeks), press this switch for approximately ten seconds to bring fuel from the tank to the fuel pump. This rocker type switch springs back into its original position when it is released.

2.1.2 START/STOP SWITCH

To crank and start the engine, hold this switch in the START position. Release the switch when the engine starts. To stop an operating engine, press and hold the switch in the STOP position until the engine shuts off. The switch center position is the RUN position.

2.1.3 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.

Figure 2.1 – Typical Control Panel

CONTROL CENTER

CIRCUIT BREA KER

FUS E

7.5A

IF GENERATOR DOES NOT START.

REMOVE AND INSPECT FUSE.

(SEE OWNER'S MANUAL TROUBLE SHOOTING GUIDE.)

PRESS PRIME SWITCH FOR 10 SECONDS

BEFORE STARTING. WHEN STARTING, DO NOT PRESS

START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT.

STA RT

STOP

FUEL

0E0580 REV. B

PRIM E

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

2.1.4 LINE BREAKERS

Protects generator’s AC output circiut against overload, i.e., prevents unit from exceeding wattage/amperage capacity. The circuit breaker ratings are as follows:

Model Circuit Breaker 1 Circuit Breaker 2 240 Volt

QuietPact 55 30A 20A 25A 2P

QuietPact 65 30A 30A 30A 2P

QuietPact 75 35A 35A 35A 2P

Operation

NOTE:

If this 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 above. 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 or CSA listed.

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, a fuel prime switch, 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.

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.

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.

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 before it has been properly serviced it with the recom-

mended oil may result in an engine failure.

2.4.3 FUEL SUPPLY

The engine must have an adequate supply of proper fuel to operate. Before starting it, check that sufficient fuel is available.

NOTE:

Depending on the installation, the generator may have either a separate fuel tank, or it may “share” the vehicle engine’s fuel tank.

2.4.4 COOLING AND VENTILATING AIR

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

2.4.5 ENGINE EXHAUST GAS

Before starting the generator engine, 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.

Generator engine exhaust contains DEADLY carbon Monoxide, an odorless, colorless poi-

sonous 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.

Operation

Adequate, unobstructed flow of cooling and ventilating air is critical for expelling toxic car-

bon 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 car-

bon monoxide detector.

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 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 seconds. However, if the engine is warm, skip Step 2.

3. To crank and start the engine, hold the start/stop switch at

START. 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 wait 1 minute before trying 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).

2.6 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 "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.

Operation

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 2.3) 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 2.3), 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, and 284° F (140° C) for LP models, initiating an engine shutdown.

Figure 2.4 – Field Boost Circuit

2.8.4 OVERVOLTAGE PROTECTION

A solid-state voltage regulator (Figure 2.5) 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 115 volts.

Figure 2.5 – Solid State Voltage Regulator

Figure 2.3 – 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 2.4). 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.

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

2.8.5 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.

Maintenance

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 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 repeat-

ed 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.

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:

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 oil drain

plug (Figure 3.1). Drain the oil into a suitable container.

3. After the oil has drained, replace the oil drain plug. (If only

changing the oil, go to step 7.)

4. With the oil drained, remove the old oil filter by turning it coun-

terclockwise (Figure 3.2).

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.

3. After the oil has drained, replace the oil drain plug. (If only

changing the oil, go to step 7.)

4. With the oil drained, remove the old oil filter by turning it coun-

terclockwise (Figure 3.2).

Figure 3.1 — Oil Dipstick/Fill Tube and

Location of Oil Drain Plug

Oil Dipstick

Oil Drain Hose

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 fill crankcase with the proper type and amount of recommended oil (see "Engine Oil Requirements"). The engine crankcase can hold about 1.8 liters or 1.9 quarts with oil filter change. DO NOT FILL ABOVE THE “FULL” MARK.

8. Install and tighten the dipstick before operating the engine.

9. Start the engine and check for leaks.

10. Dispose of used oil at a proper collection center.

NOTE:

Check the oil level and fill to the “FULL” mark after checking for leaks. The filter will retain some oil.

Figure 3.2 — Engine Oil Filter

Maintenance

3.3 MAINTAINING THE ENGINE AIR CLEANER

3.3.1 CLEANING THE FOAM PRECLEANER

Clean and re-oil the foam pre-cleaner every three months or every 100 hours of operation, whichever occurs first. Service the foam pre-cleaner more frequently if operating the generator in extremely dusty or dirty conditions. Use the following procedure (Figure

3.3).

1. At the Air Box Cover, turn the plastic wing screw counter-

clockwise to loosen.

2. Remove the Air Box Cover by pulling up and left to clear the

three locating tabs.

3. Turn the exterior steel wing nut on the left side of the Air Box

Compartment counterclockwise and remove.

4. Pull the Air Filter Assembly to the right and out of the front of

the compartment.

5. Remove the foam pre-cleaner from the air filter.

6. Wash the foam pre-cleaner in liquid detergent and water.

7. Wrap the foam pre-cleaner in a clean cloth and gently squeeze

it dry.

8. Saturate the foam pre-cleaner in clean engine oil. Gently

squeeze it in a clean cloth to remove excess oil and to distribute the oil evenly (DO NOT TWIST).

9. Slide the foam pre-cleaner onto the air filter.

10. With your right hand on the air filter end, angle the assembly

into the compartment and insert the Offset Stud into the hole on the left side of the Air Box Compartment. Before the air filter gasket contacts the sheet metal wall, ensure the rubber snout of the carburetor intake adapter is "captured" within the footprint of the Air Filter.

11. Replace the steel wing nut onto the Offset Stud and tighten

clockwise.

12. Replace the Air Box Compartment Cover back into all three

locating tabs and replace the plastic wing screw (Tighten clockwise carefully).

Figure 3.3 – Engine Air Cleaner

GASKET

LOCK WASHER

FLAT WASHER

STEEL WING NUT

PLASTIC WING SCREW

AIR BOX COVER

OFFSET STUD

PRE-CLEANER

AIR FILTER

2. Remove the Air Box Cover by pulling up and left to clear the three locating tabs.

3. Turn the exterior steel wing nut on the left side of the Air Box Compartment counterclockwise and remove.

4. Pull the Air Filter Assembly to the right and out of the front of the compartment.

5. Twist the steel wing nut counterclockwise while holding the offset stud. Set aside and save all this hardware for use with the new air filter and pre-cleaner.

6. Discard old air filter and pre-cleaner safely.

7. Insert the flanged end of the Offset Stud into the new air filter and through the hole in the end plate.

8. Install the gasket, flat washer, lock washer and wing nut in that order. Tighten the wing nut clockwise while aligning the Offset Stud as in Figure 3.3.

9. Saturate the foam pre-cleaner in clean engine oil. Gently squeeze it in a clean cloth to remove excess oil and to distribute the oil evenly (DO NOT TWIST).

10. Slide the foam pre-cleaner onto the air filter.

11. With your right hand on the air filter end, angle the assembly into the compartment and insert the Offset Stud into the hole on the left side of the Air Box Compartment. Before the air filter gasket contacts the sheet metal wall, ensure the rubber snout of the carburetor intake adapter is "captured" within the footprint of the Air Filter.

12. Replace the steel wing nut onto the Offset Stud and tighten clockwise.

13. Replace the Air Box Compartment Cover back onto all three locating tabs and replace the plastic screw (Tighten clockwise carefully).

3.4 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 0.040 inch (1.02 mm) by carefully bending the ground electrode (Figure 3.4).

Figure 3.4 – Setting the Spark Plug Gap

3.3.2 REPLACING THE PAPER AIR FILTER

Replace the Paper Air Filter Element after every 250 hours of operation. Use the following procedure (Figure 3.3).

1. At the Air Box Cover, turn the plastic wing screw counterclockwise to loosen.

Maintenance

Sparking can occur if the wire terminal does not fit firmly on the spark plug terminal end. If

necessary, re-form the wire terminal to obtain a tight fit.

3.5 FUEL FILTER

Remove and replace the fuel filter (Figure 3.5) once each year or every 400 hours of operation, whichever comes first.

Figure 3.5 – Fuel Filter

FUEL FILTER

(GASOLINE ONLY)

TO FUEL PUMP

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.

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.

CUSTOMER FUEL CONNECTION

3.6 CLEAN SPARK ARRESTOR

The engine exhaust muffler has a spark arrestor screen. Inspect and clean the screen every 50 hours of operation or once each year, whichever comes first.

NOTE:

If using the generator on any forest-covered, brush-covered or grass-covered unimproved land, it must equipped with a spark arrestor. The spark arrestor must be maintained in good condition by the owner/operator.

Clean and inspect the spark arrestor as follows (Figure 3.6):

Remove the screen retaining bracket by removing the screw.• Slide the spark arrestor screen out from the tail pipe.• Inspect screen and replace if torn, perforated or otherwise •

damaged. DO NOT USE a defective screen. If screen is not damaged, clean it with commercial solvent.

Replace the screen and the retaining bracket.•

Figure 3.6 - Spark Arrestor

3.8 BATTERY MAINTENANCE

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

3.8.1 WEEKLY

Inspect the battery posts and cables for tightness and 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.

3.8.2 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.

TAILPIPE

P/N 0E0907

RETAINER

P/N 0D5133A

SPARK ARRRESTOR SCREEN

RETAINING SCREW

P/N 0D5133

P/N 045764

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.

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.

Maintenance

3.9 ADJUSTING VALVE CLEARANCE

After the first six (6) months 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.• 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

NOTE:

Hold the rocker arm jam nut in place as the pivot ball stud is turned.

Arm

Valve Stem

Maintenance

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 and GT-990, repeat the process for the other •

cylinder.

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. Manuals can be obtained from the internet website or a service dealer.

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 SF.”

4. Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase.

5. Remove the spark plug and pour two or three tablespoons of clean, fresh engine oil into the spark plug threaded openings. Reinstall and tighten the spark plug.

6. Remove the battery and store it in a cool, dry room on a wooden board. Never store the battery on any concrete or earthen floor.

7. Clean and wipe the entire generator.

3.13.2 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

50 Hours ....................................................Clean Spark Arrestor

1st 50 Hours, then every 500 Hours ...............Adjust Valve Lash

100 Hours .............................................Change Engine Oil/Filter

100 Hours ......................................................Clean Air Pre-filter

100 Hours ...................................................Inspect Spark Plugs

250 Hours .................................Replace Paper Air Filter Element

400 Hours ......................................................Replace Fuel Filter

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

Notes

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 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.

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.

Despite the safe design of this generator, operating this equipment imprudently, neglect-

ing its maintenance or being careless can cause possible injury or death. Permit only responsible and capable persons to operate or maintain this equipment.

Potentially lethal voltages are generated by



these machines. Ensure all steps are taken to render the machine safe before attempting to work on the generator.

Parts of the generator are rotating and/or hot during operation. Exercise care near running

generators.

Generator exhaust gases contain DEADLY carbon monoxide gas. This dangerous gas,

if breathed in sufficient concentrations, can cause unconsciousness or even death.

ENGINE EXHAUST HAZARDS

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.

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 •

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.

Safety Rules

FIRE HAZARDS

For fire safety, the generator must be installed and maintained •

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

EXPLOSION HAZARDS

Do not smoke around the generator. Wipe up any fuel or oil spills •

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.

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/NFPA 501C, available from the Recreational

Vehicle Association, 1896 Preston White Drive, Reston, VA

22090.

5. California Administrative Code, Title 25, available from the

State of California, Documents Section, P.O. Box 1015, North Highlands, CA 95660.

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

Generators may be installed to provide the following outputs:

1) 120 VAC loads only — one load with a maximum total wattage

requirement equal to 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 240 V across the generator output terminals; or two seperate loads, each with a maximum total wattage requirement equal to half of the generator’s rated power output (in watts), and 120 V across the generator output terminals (see Fig. 1.3.)

Figure 1.1 – Connection for 120 Volts Only

General Information

Figure 1.2 - Major Features and Dimensions (Drawing No. 0E1058-H)

Installation

Figure 1.3 - Connection for 120/240 Volts

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.

Loads connected across T1 (Red) to T2 (White), and T3 (Black) •

to T2 (White), must not exceed ratings for the specific generator (see "Generator Specifications").

NOTE:

Do NOT connect loads in excess of circuit breaker ratings.

RED

WHITE

BLACK

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 location must provide sufficient room to allow minimum •

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.

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 and top, 1 inch (25 mm) on the 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" 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.

Figure 2.3 – Typical Generator Restraint

1" 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.

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 absorbent



material on the compartment floor interior. Such materials will become soaked with combus-



tible 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.

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 2.8):

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 penetrate 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 compartment floor.



Seal all compartment door edges to prevent noise leakage •

around the door perimeter.

Figure 2.7 – Typical Noise Abatement

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).

Never use discharged cooling air for heating or



permit such air to enter the vehicle interior. This air contains deadly carbon monoxide gas and



other poisonous, flammable or explosive gases.

2.3.1 GENERATOR AIRFLOW

Engine operation drives cooling fans for the two-stage cooling air system. A pressure fan draws cooling air into the top of the generator (Figure 2.9). This airflow cools the engine/generator and electronic components. The second part of the cooling system, a suction fan, draws air that is heated from a hot engine into a collector 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 2.9 – Airflow Through Engine/Generator

Installation

Figure 2.8 — Compartment Floor Cutout (Drawing 0G3529-A)

Installation

2.3.2 TESTING THE INSTALLATION

The manufacturer recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, enlarge the air openings. Never place a unit into service until absolutely certain that cooling and ventilation is adequate.

NOTE:

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 sys-



tems 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

0D4511

0D9723

070185

072347

087769

Fuel Pump (Behind Access Cover)

Fuel Filter (Side of Unit)

CONTROL CENTER

CIRCUIT BREAKER

FUSE

FUEL

START

7.5A

IF GENERATOR DOES NOT START, REMOVE

STOP

PRIME

AND INSPECT FUSE.

(SEE OWNER'S MANUAL TROUBLE SHOOTING

GUIDE.)

PRESS PRIME SWITCH FOR 10 SECONDS BEFORE STARTING. WHEN STARTING, DO

NOT PRESS START BUTTON LONGER THEN 15 SECONDS PER ATTEMPT.

SERVICEACCESSPANEL

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE

CLEAN PREFILTER

AIR FILTER:

SPARK PLUGS:

INSPECT & CLEAN

EVERY 100 HOURS.

PLUGS EVERY 100 HOURS.

REPLACE ELEMENT

REPLACE PLUGS EVERY

EVERY 250 HOURS.

500 HOURS. (IF NECESSARY)

CHANGE EVERY 400 HOURS.

FUEL FILTER:

CHANGE EVERY 100

OIL & OIL FILTER:

(OR ANNUALLY)

HOURS. (OR ANNUALLY)

PERFORM MORE OFTEN IN DUSTY CONDITIONS

OIL LEVEL:

CHECK DAILY

OIL CAPACITY

1.8L/1.9QT

WITH FILTER:

PREFILTER P/N:

REPLACEMENT

(SAE VISCOSITY)

TEMPERATURE:

INFORMATION:

AIR FILTER P/N:

SAE 30 OR 10W-30

40°F AND HIGHER

OIL FILTER P/N:

5W-30 OR 5W-20

-20°F TO 40°F SPARK PLUG P/N:

FUEL FILTER P/N:

WHEN SERVICE OR PARTS ARE NEEDED IN THE USA OR CANADA,

CONTACT THE GUARDIAN SERVICE LOCATOR AT 1-800-333-1322.

Fuel Line

Factory installed generator fuel system components include (a) fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and (d) interconnecting lines and fittings. Connect a fuel supply line to the fuel filter inlet. Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines.

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 whtn necessary.

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.

Do NOT tie the generator fuel supply line 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.

An evaporative emissions port model 05750 has a 5/16" hose barb provided for connection to a carbon canister as necessary for specific applications.

2.4.2 GENERATOR FUEL SUPPLY LINE

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.

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.

Installation

2.5 LP GAS FUEL SYSTEM

LP gas is highly EXPLOSIVE. The gas is heavier than air and tends to settle in low areas. Even



the slightest spark can ignite it and cause and



explosion. Only competent, qualified people should be allowed to install, test, adjust or service an LP gas fuel system. Install the optional fuel system in compliance with applicable codes, standards and regulations. After the installation, do not do anything that might render the system in noncompliance with applicable codes and standards.

2.5.1 PARTS NOT INCLUDED IN FUEL SYSTEM

The propane fuel system does NOT include such items as (a) gas tank, (b) gas piping, (c) fittings, (d) valves, and (e) primary regulator, used to store the gaseous fuel and deliver it to the gaseous fuel solenoid (Figure 2.11).

Use only approved components in the fuel sup-



ply system. All components must be properly installed in accordance with applicable codes.



Improper installation or use of unauthorized components may result in fire or an explosion. Follow approved methods to test the system for leaks. No leakage is permitted. Do not allow fuel vapors to enter the vehicle interior.

Figure 2.11 – Typical Propane Gas Fuel System

2.5.2 SOME IMPORTANT CONSIDERATIONS

When installing an LP gas system, consider seriously the following items:

All fittings, lines, hoses and clamps must be tight and free of •

leaks. Apply a pipe sealant to threads when assembling threaded connections. This reduces the possibility of leakage.

Test the entire fuel system for leaks using approved test meth-•

ods.

Optimum gas pressure at the inlet to the gaseous fuel solenoid •

valve and secondary regulator is 11 inches water column.

The installer’s fuel supply connection point is at the gaseous fuel •

solenoid valve. This is a 3/4-inch (female) connection. Provide a suitable 3/4-inch NPT (male) connector to attach to the fuel supply line.

Use a length of approved flexible fuel hose between the gaseous •

fuel solenoid valve and rigid gas piping. The flexible line should be at least 6 inches longer than necessary.

2.5.3 VAPOR WITHDRAWAL

LP gas is stored in pressure tanks as a liquid. The gas systems used with these generators were designed only for vapor withdrawal type systems. Vapor withdrawal systems use the gas vapors that form above the liquid fuel in the tank. Do NOT attempt to use the generator with any liquid withdrawal type system.

2.5.4 PRIMARY REGULATOR

Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regulator. Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank. The following rules apply:

For best results, the primary regulator supplies gaseous fuel to •

the secondary regulator at 11 inches water column. Do NOT exceed 14 inches water column.

The installer must be sure the primary regulator is rated at •

sufficient gas flow to operate the generator plus all other gas appliances in the circuit.

NOTE:

Recommended MINIMUM gas flow rate for air-cooled generators is 67 cubic feet per hour.

If an existing primary gas regulator does not have a sufficient flow capacity for the generator and other gas appliances in the circuit, (a) install a primary regulator with adequate flow rate, or (b) install a separate regulator only and rated at least 67 cubic feet per hour. The inlet side of any primary regulator that supplies the generator must connect directly to a gas pressure tank. Do NOT tee the generator line into a gas circuit feeding other areas.

2.5.5 GASEOUS CARBURETION

LP gas vapors should be supplied to the secondary regulator inlet at about 11 inches water column (positive pressure). The engine pistons draw air in during the intake stroke (Figure 2.12). This air passes through a carburetor venturi, which creates a low pressure that is proportional to the quantity of air being pumped. The low pressure from the carburetor venturi acts on the regulator diaphragm to pull the diaphragm toward the source of low pressure. A lever attached to the diaphragm opens a valve to permit gas glow through the carburetor.

Figure 2.12 – LP Gas Carburetion Diagram

The greater the airflow through the carburetor venturi, the lower the pressure at the venturi throat. The lower the pressure at the venturi throat, the greater the diaphragm movement, and the greater the movement of the regulator valve. The more the regulator valve opens, the greater the gas flow that is proportional to airflow through the generator.

The following facts about the secondary regulator must be emphasized:

The regulator must be sensitive to venturi throat pressure •

changes throughout the operating range.

The regulator must be properly adjusted so it will stop the flow •

of gas when the engine is not running (no air flow through the carburetor).

The slightest airflow (and vacuum in the venturi throat) should •

move the regulator valve off its seat and permit gas to flow.

Installation

Gaseous fuel lines between the tank and the



secondary regulator are under a positive pressure (about 11 inches water column). Gas pres-



sure at the outlet side of the secondary regulator, however, is a negative pressure and can draw flame inside a line or fitting and cause an explosion.

2.5.7 EXCESS FLOW VALVE

LP gas tanks should have an excess flow valve, according to NFPA 501C. This valve and the gas lines must be carefully sized so the valve will close when a fuel line is severed or broken. Consult the Natural-LP Gas Association for information and limitations of excess flow valves.

Manual shutoff valves on the supply tank and elsewhere in the system must be fully open when operating the generator. The excess flow valve functions properly only if all valves are fully open.

2.5.8 LEAKAGE TESTS

Do not place the generator into service until the gas system has been properly tested for leaks. To test the system, a separate source of 12 volts DC to open the gaseous fuel solenoid valve is needed.

The leak test must comply fully with NFPA, Paragraph 318. All connections, hoses, valve regulators, fittings, and other fuel system parts must be tested under gas or air pressure of not less than 90 psi (620 kPa), while using soap and water or an equivalent solution to check for leaks. Other approved methods of testing for leaks may be used, if appropriate. DO NOT USE ANY FLAME TO TEST FOR LEAKS.

2.6 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.

2.5.6 FUEL SUPPLY LINES

LP gas lines must be accessible, but protected against possible •

damage.

Do NOT connect electrical wiring to any LP gas fuel line or run •

wiring alongside the lines. Route gas lines away from hot engine exhausts.• Retain gas lines with metal clamps that do not have sharp •

edges. Install an approved length of flexible hose between the gaseous •

fuel solenoid valve and rigid fuel supply lines. The flexible line

must be nonmetallic, nonorganic and nonconductive. It must be

approved for use with LP gas.

Generator engine exhaust contains DEADLY carbon Monoxide, an odorless, colorless poi-

Never operate the generator set with the vehicle inside any garage or other enclosed area.

]

O.D. 38.1 [1.50"]

Installation

Adequate, unobstructed flow of cooling and ventilating air is critical for expelling toxic car-

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 car-

bon monoxide detector.

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.

2.6.1 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 Figure 2.13). Use only manufacturer supplied hardware. Substitution of parts may cause damage to the screen or a loose fit to the tailpipe.

Figure 2.13 — Spark Arrestor Installation

3.5 [9/64"] DRIL

24 [0.95"

BOTTOM SIDE ONL

2.6.2 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.

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.

Installation

2.7 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.

2.7.1 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.

2.7.2 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. From the junction box, route power supply wires through •

approved conduit to either (a) double-pole, double-throw trans-

fer 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.

2.7.3 GENERATOR AC CONNECTIONS

Generator AC output leads T1 (red), T2 (white) and T3 (black) come out of the generator as shown in Figure 2.14. 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.

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.

Figure 2.14 – Generator AC Output Leads

T3 T2 T1

Green (Ground)

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.

Installation

2.7.4 CONDUIT

Route the connections between the generator and the junction box through approved, flexible conduit. The following general rules apply:

Cut wiring to the required length and allow extra wire for junction •

box connections.

Carefully prepare conduit ends to prevent sharp edges from cut-•

ting 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 vaporproof along its entire length.

2.7.5 ISOLATING DIFFERENT POWER SOURCES

Connections from the junction box must terminate in a doublepole, double-throw transfer switch (Figure 2.15). An alternate method for isolating different power sources is by using an isolating receptacle (Figure 2.16). Whichever method is used, be certain that both power sources are NOT connected at the same time.

2.7.6 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.

2.7.7 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.

2.8.2 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)

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.

CABLE SIZE

2.8.3 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 2.17).

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

2.17).

3. Connect cables so the connectors are clean and tight.

2.8 BATTERY INSTALLATION

2.8.1 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 coldcranking amperes.

For prevailing ambient temperatures below 32° F (0° C), use a •

battery rated 95 amp-hours and capable of delivering 400 coldcranking 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.

Figure 2.17 – Connecting Battery Cables

Positive Cable

—

Battery

Negative Cable

Chassis Ground

IETPACT55

60cc O

Installation

Figure 2.15 — Transfer Switch Isolation Method

IETPACT55

HVI V-TWI

Figure 2.16 — Installation With Isolation Receptacle

12.00"

)

9099-B

Post Installation Start-up Adjustments

2.8.4 BATTERY COMPARTMENT

Install the generator battery in its own, vented compartment. Place the battery compartment away from any source of heat, sparks or flame.

Provide ventilation openings in the battery compartment. The minimum size of openings should be 2 square inches at the top of the compartment. Mount the battery on a strong, rigid supporting structure, where leaks and spills of battery fluid will not cause damage.

2.9 OPTIONAL ACCESSORIES

A plug-in receptacle (Figure 2.18) is provided on the generator set, above the muffler enclosure. Use this receptacle to connect an optional remote-mounted start/stop panel to the generator. Installation of such a panel will permit starting and stopping the generator engine from any convenient location inside the vehicle.

Figure 2.18 – Remote Panel Plug-in Receptacle

3.1 POST INSTALLATION TESTS

The air-cooled generator set was factory tested and adjusted. It should not be necessary to adjust the unit any further except under special circumstances.

Do not make any unnecessary adjustments. Factory settings are correct for most applica-

tions. When making adjustments, however, be careful to avoid overspeeding the engine.

3.2 BEFORE INITIAL START-UP

Before starting, complete the following:

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

If a liquid propane (LP) gas fuel system has been installed, it must be properly tested for

leaks before operating the system in compliance with ANSI A119.2/NFPA 501C. No leakage is permitted. Be sure that gasoline fuel vapors do not enter the vehicle interior.

P/N: 0D

RAN

YELL

BROW

LENGTH (mm

12.0 (305

FUNCTION

GROUND

ENGINE RUN SIGNAL

12 VDC START STOP PRIME

2.9.1 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.

Part number 0H3068 includes the remote panel and a 30 foot •

long, 6 wire harness.

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, “Star ting 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.

Post Installation Start-up Adjustments

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.

OPTIONAL LP GAS FUEL SYSTEM

❑ Fuel system is properly installed and checked for leaks.

❑ Pressure at regulator inlet is correct.

❑ Rated flow of primary regulator is correct.

❑ All parts are properly installed.

❑ Fuel system is properly tested/adjusted.

EXHAUST SYSTEM

❑ Exhaust system complies with all applicable codes.

❑ Exhaust system is properly and safely installed.

ELECTRICAL CONNECTIONS

❑ Connections comply with local code requirements and all

National Electrical Codes.

❑ Junction box is properly installed.

❑ Wiring meets all standards.

❑ All connections are correct.

❑ Conduit is properly installed and sealed.

❑ Generator is properly bonded to the vehicle.

BATTERY INSTALLATION

❑ Recommended battery is installed.

❑ Recommended cables are installed.

❑ Cables are clean and tight.

❑ Cables are connected properly.

❑ Proper ventilation is provided.

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

covers are positioned.

OPTIONAL ACCESSORIES

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

properly.

❑ Check that hourmeter kit (if used) is installed properly.

❑ Check that any other options and accessories (if used) are

installed properly.

POST INSTALLATION TESTS

❑ Check that all tests are completed properly.

DATE OF INSTALLATION _______________________________________________________

NAME OF INSTALLER __________________________________________________________

SIGNATURE OF INSTALLER ____________________________________________________

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 Start/Stop switch. 4. Replace switch.

5. Defective starter contactor. 5. Replace starter contactor.

6. Defective starter 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 shutoff valve is closed. 2. Open fuel shutoff valve(s).

3. Fuel pump not operating. 3. Repair or replace pump.

4. Automatic choke not operating properly. 4. Repair, replace or adjust.

5. Engine is flooded. 5. Wait 5-10 minutes; try again.

6. Fuel filter is clogged. 6. Replace filter if clogged.

7. Engine spark plugs defective. 7. Clean, regap or replace as needed.

8. Bad ignition magneto on engine. 8. Replace if defective.

9. Bad carburetor. 9. Adjust, repair or replace.

10. Dirty air cleaner. 10. Clean or replace as needed.

Engine starts hard, runs rough. 1. Dirty 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.

Electrical Data Electrical Schematic - V-twin - Drawing No. 0E1057-F

Electrical Schematic - V-twin - Drawing No. 0E1057-F Electrical Data

Exploded Views & Parts Lists Base & Pulley Drawing No. 0E1323-H

Base & Pulley Drawing No. 0E1323-H Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

1 0E0196 1 FRAME, 760 ENGINE 2 022129 12 WASHER LOCK M8-5/16 3 022145 15 WASHER FLAT 5/16-M8 ZINC 4 022259 6 NUT HEX 5/16-18 STEEL 5 0C7758 4 VIB MNT 1.5 X 1.38 X 5/16-18 6 0C3168 1 WASHER LOCK SPECIAL 5/16 7 0C2417 1 EARTH STRAP 8 077603 2 SCREW HHC 5/16-18 X 3.5 SPC 9 0E0588 1 SPACER, SAFETY BOLT .375 I.D. 10 029451 1.5 FT. TAPE ELEC UL FOAM 1/8 X ½ 11 0D8912 1 DUCT, AIR OUT 12 0E0571 2 GASKET,AIR OUT DUCT 13 0D8911 1 BRACKET, MUFFLER SUPPORT 14 043107 7 SCREW HHC M8-1.25 X 25 G8.8 15 0D9021 1 MUFFLER, GTV760 RV 16 096289 1 CLAMP, EXHAUST 1.25" 17 0D8940 1 MANIFOLD, EXHAUST 18 070006 4 WASHER LOCK M8 SS 19 070008 4 WASHER FLAT M8 SS 20 040976 4 SCREW SHC M8-1.25 X 20 G12.9 21 056893 5 SCREW CRIMPTITE 10-24 X ½ 22 023897 5 WASHER FLAT #10 ZINC 23 0E1078 1 GASKET, EXH BASE, GTV760 RV 24 0C4138 2 GASKET,EXHAUST PORT 25 043116 3 SCREW HHC M6-1.0 X 12 G8.8 (5.5 KW

ONLY) 26 022097 4 WASHER LOCK M6-1/4 (5.5 KW ONLY) 022097 1 WASHER LOCK M6-1/4 (6.5 & 7.5 KW

ONLY) 27 022473 3 WASHER FLAT 1/4-M6 ZINC (5.5 KW

ONLY) 28 0C1751 1 FAN NYLON 7" DIA (5.5 KW ONLY) 29 0C1753B 1 PULLEY, ALTERNATOR 2200 RPM (5.5 KW

ONLY) 073106B 1 PULLEY, ALTERNATOR 2500 RPM (6.5 &

7.5 KW ONLY)

30 075224A 1 PULLEY, ENGINE 2100 RPM (5.5 KW

ONLY) 075224B 1 PULLEY, ENGINE 2500 RPM (6.5 & 7.5

KW ONLY)

ITEM PART NO. QTY. DESCRIPTION

31 0E0586 1 GASKET, BOTTOM AIR OUT QPRV 32 0D7176 4 WASHER SELF LOCKING 1"DIA 12GA 33 0E1334 1 SCREEN, BOTTOM AIR OUT 34 0D8824 1 TRAY, V-TWIN RV 35 081105 2 NUT FLG 5/16-18 LOCK 36 073118 1 SCREW HHC 3/8-24 X 2-1/4 G8 37 046526 1 WASHER LOCK M10 38 022131 1 WASHER FLAT 3/8-M10 ZINC 39 0C2824 7 SCREW TAP-R #10-32 X 9/1 40 0E1077 1 BLOWER HOUSING GTV760 RV 41 042633 1 SCREW HHC 3/8-24 X 1 G5 42 022237 1 WASHER LOCK 3/8 43 049451 1 WASHER FLAT .406ID X 1.62OD 44 0C1441 1 SET,BLOWER HOUSING GASKET 45 0C1112 1 BELT,V-RIB 4LX42.5" 46 023484T 1 BUSHING SNAP (GASOLINE ONLY) 0E1534 1 PLUG PLASTIC 0.687" (LP ONLY) 47 0D7530 1 STUD, M6-1.0 OFFSET 48 0D9723 1 ELEMENT AIR FILTER 49 50 0D8981 2 FILTER GASKET RV (GASOLINE ONLY) 0D8981 1 FILTER GASKET RV (LP ONLY) 51 0D8451 1 WASHER FLAT .281"ID X 1.25"OD 52 087680 2 NUT WING M6-1.0 53 0D3700 3 NUT FLANGE M6-1.0 NYLOK (GASOLINE

ONLY) 0D3700 1 NUT FLANGE M6-1.0 NYLOK (LP ONLY) 54 087769 1 FILTER FUEL (GASOLINE ONLY) 55 0E0570 1 ASSEMBLY,NON SHTOFF FUEL PUMP

(GASOLINE ONLY) 56 0D9919 1 ASSEMBLY, RV V-TWIN FUEL LINE

(GASOLINE ONLY) 57 0E1330 1 GROMMET, 38.1 DIA. CROSS SLIT

(GASOLINE ONLY) 0E1534A 1 PLUG PLASTIC 1.50" (LP ONLY) 58 0A1658 1 WASHER LOCK SPECIAL 1/4" 59 0D5133 1 SCREEN, SPARK ARRESTOR 60 0D5133A 1 RETAINER, SPARK ARREST SCREEN 61 045764 1 SCREW HHTT M4-0.7 X 8 BP 62 0E1078A 1 GASKET, EXHAUST BASE

Exploded Views & Parts Lists Enclosure Drawing No. 0G7865-C

Enclosure Drawing No. 0G7865-C Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

1 0D8827 1 PANEL, ENCLOSURE ROOF 2 0G4933 22 SCREW SWT 1/4-20 X 5/8 W/W 3 029451 11.5 FT. TAPE ELEC UL FOAM 1/8 X 1/2” 4 0D8825 1 PANEL, SIDE AND BACK ENCLOSURE 5 0D3700 14 NUT FLANGE M6-1.0 NYLOK (GASOLINE

ONLY) 0D3700 17 NUT FLANGE M6-1.0 NYLOK (LP ONLY) 6 090388 8 SCREW HHTT M6-1.0 X 12 YC 7 0D8979 1 PANEL, AIR IN DUCT BASE 8 0D8960A 1 PANEL, CUSTOMER CONNECTION 9 023484D 1 BUSHING SNAP SB-875-11 10 0E0594 1 COVER, RV AIR CLEANER BOX 11 064113 1 STUD WINGNUT M6-1.0 X 20MM NY 12 0E0575 1 FOAM SEALING STRIP 1" X 12FT 13 0D8980 1 PANEL, AIR IN DUCT BACK 14 0E1376 1 BAFFLE, V-TWIN RV SHORT 15 0E1377 1 BAFFLE, V-TWIN RV LONG 16 0D8628 3.5 FOAM, AIR OUT COMPARTMENT 17 0D8910 1 PANEL, MUFFLER SHIELD 18 0D8826 1 PANEL, ENCLOSURE SIDE 19 0D9162 1 PANEL, FRONT & SIDE ENCLOSURE 20 0C5644 2 SLIDE LATCH,FLUSH 21 0D8828 1 PANEL, ENCLOSURE DOOR 22 0E0585 1 FOAM PANEL, DOOR 1/2"THK QP RV 23 0E1486 1 HARNESS, AC OUTPUT (5.5, 6.5, & 7.5

KW ONLY) 0E1774 1 HARNESS, AC OUTPUT (5.0 & 7.0 KW-50

Hz ONLY) 24 0D9099 1 CUST. CONN. 4KW RV REMOTE 25 074908 4 SCREW HHTT M5-0.8 X 10 BP 26 022473 1 WASHER FLAT 1/4-M6 ZINC 27 022097 1 WASHER LOCK M6-1/4 28 022507 1 SCREW HHC 1/4-20 X 1/2 G5 29 0742600149 1 WIRE ASM. BATT. (NEG.) QP RV 30 0C7968 4 NUT HEX JAM 3/8-16 BRASS 31 022237 2 WASHER LOCK 3/8

ITEM PART NO. QTY. DESCRIPTION

32 0C7423 1 STUD 3/8-16 X 2-1/4 BRASS 33 0742600151 1 GND WIRE C/PNL TO STUD V-T RV 34 0A4456 1 WASHER LOCK SPECIAL 3/8 35 0D8502 1 NEUTRAL CONNETCTOR UL 36 0E0593 1 STUD, 1/4-20 TO 5/16-18 37 0742600148 1 WIRE ASM BATT. (POS.) QP RV 38 022129 2 WASHER LOCK M8-5/16 (GASOLINE

ONLY) 022129 4 WASHER LOCK M8-5/16 (LP ONLY) 39 022259 2 NUT HEX 5/16-18 STEEL 40 045756 8 SCREW HHTT M6-1.0 X 10 YC 41 0A2115 1 WASHER NYLON .250 42 029451A 6.5 FT. TAPE, 1/2" X 1/16" CLOSED CELL 43 0E1534A 1 PLUG PLASTIC 1.50" (GASOLINE ONLY) 44 0A5606 1 ELBOW 90DEG 3/8X3/4 (LP ONLY) 45 0E1528 1 BRACKET, LP REGULATOR MOUNTING

(LP ONLY) 46 0A1495 2 SCREW HHTT M4-0.7 X 10 BP (LP ONLY) 47 039253 2 SCREW HHC M8-1.25 X 20 G8.8 (LP

ONLY) 48 022145 1 WASHER FLAT 5/16-M8 ZINC (GASOLINE

ONLY) 022145 3 WASHER FLAT 5/16-M8 ZINC (LP ONLY) 49 0D8979A 1 PANEL, AIR IN DUCT 50 061669 1 PLUG, PLASTIC (GASOLINE ONLY) 51 069598 1 BULKHEAD ADAPTER ¼ x ¼ x ¾-16

(MODEL 05750 ONLY) 52 058043 1 BARBED STRAIGHT ¼ NPT x 5/16

(MODEL 05750 ONLY) 53 035579 1 BUSHING, REDUCER HEX ¼ TO 1/8

(MODEL 05750 ONLY) 54 035578 1 NIPPLE, CLOSE 1/8 NPT (MODEL 05750

ONLY) 55 0G0247 1 SOLENOID VALVE 12 VDC (MODEL

05750 ONLY) 56 028414A 1 BARBED STRAIGHT 1/8 NPT x ¼ (MODEL

05750 ONLY)

Exploded Views & Parts Lists Engine Accessories Drawing No. 0G7866-E

Engine Accessories Drawing No. 0G7866-E Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

1 045756 15 SCREW HHTT M6-1.0 X 10 YC 2 0D1131 1 GUARD,FAN 12KW HSB 3 0F1169G 1 HOUSING, BLOWER V-TWIN RV 4 0C9763 4 NUT,GROMMET 1/4 PLUG 5 0D9782A 1 HOSE, BREATHER 6 0C3034 1 NUT HEX M24-2.0 G8 YEL CHR 7 0C3033 1 WASHER,BELLEVILLE 25MM BOLT 8 051754 2 SCREW HHC M8-1.25 X 12 G8.8 9 0A5992 2 WASHER SHAKEPROOF INT M8 SS 10 0C3032 1 PLATE, FAN 11 0C3031 1 FAN NYLON 12 0C3725D 1 FLYWHEEL ASSY 13 0G4928C 1 PLATE,BACKING WITH CUT OUT 14 023484S 1 BUSHING SNAP 15 0D9679A 1 WRAP, CRANKCASE RV SPCC 16 0E8775 1 VERTICAL SHAFT RV ENGINE 17 0F1167A 1 WRAP, CYL 1 RV SPCC 18 056893 13 SCREW CRIMPTITE 10-24 X ½ 19 0E7585A 2 SPARK PLUG 20 0E0998 1 CLAMP VINYL 9.5 O.D. TUBE 21 0G4853 1 TUBE, OIL DRAIN & CHECK 22 043790 1 BARBED EL 90 3/8NPT X 3/8 23 0G4403 1 ASSEMBLY, OIL DRAIN HOSE 24 0E0361B 1 OIL DRAIN / DIPSTICK 25 0E0393 1 ASSEMBLY, CAP & DIP STICK 26 0C2824 1 SCREW TAP-R #10-32 X 9/16 (GASOLINE

ONLY) 27 0G6950 1 BARBED TEE ¼” NYLON (05750 ONLY) 28 075246 4 SCREW HHTT 3/8-16 X 1-1/4 CZ 29 0A4456 1 WASHER LOCK SPECIAL 3/8 30 0A2311 2 SCREW SWAGE 1/4-20 X 1 Z/YC 31 070185B 1 OIL FILTER 32 0D9235 1 SWITCH OIL PRESSURE HOBBS 33 0A5360 1 SUPPORT OIL FLTR,FLARE 34 043182 2 WASHER LOCK M3 35 0C1085 2 SCREW PPHM M3-0.5 X 8 36 0E1497 1 SWITCH, OIL HIGH TEMP (GASOLINE

ONLY) 075281 1 SWITCH, OIL HIGH TEMP (LP ONLY) 37 0D9399 1 ASSEMBLY, GOVERNOR LEVER 38 0D9513 1 SPRING, GOV.(5.5 KW & 5.0 KW-50HZ

ONLY) 0E1498 1 SPRING, GOV.(6.5/7.5 KW & 7.0 KW-50HZ

ONLY) 39 0D1366 2 BUSHING, GOVERNOR ROD 40 0D9395 1 ROD, GOVERNOR 41 077075 1 BOOT CHOKE SOLENOID (GASOLINE ONLY) 42 0A7094 2 RHMS 4-40 X 1/4 SEMS (GASOLINE ONLY) 43 0D8590 1 ASSY, BI-METAL/HEATER (GASOLINE

ONLY) 44 0D8591 1 SOLENOID, CHOKE (GASOLINE ONLY) 45 045770 1 SCREW HHC M5-0.8 X 10 G8.8 46 049226 1 WASHER LOCK M5 47 051713 1 WASHER FLAT M5 48 0D9402 1 LINKAGE, CHOKE (GASOLINE ONLY) 49 077091 1 COTTER PIN (GASOLINE ONLY) 50 082025 1 NUT LOCK HEX M5-0.8 SS NYL INS 51 0E1247 1 ASSEMBLY, GOV. ADJUSTMENT 52 055173 2 SCREW HHC M8-1.25 X 20 G10.9 53 022129 2 WASHER LOCK M8-5/16 54 022145 2 WASHER FLAT 5/16-M8 ZINC 55 0D9403 1 LINKAGE CHOKE BELLCRANK/CARB 56 0E1246 1 ASSEM., CHOKE BRACKET (GASOLINE

ONLY) 0D9400 1 BRACKET, CHOKE (LP ONLY) 57 0A7095 2 RHMS 4-40 X 5/16SEMS

ITEM PART NO. QTY. DESCRIPTION

58 0D9404 1 SPRING, CHOKE RETURN 59 0D9801A 1 WRAP, VALLEY UPPER SPCC 60 0C3018A 1 WRAPPER,UPR #1 W/ M8 WELD NUT 61 0D9680A 1 WRAP, VALLEY RV SPCC 62 0D1143A 1 WRAPPER,UPR #2 W/ M8 WELD NUT 63 0F1177 1 ASSY, GROUNDING WIRE 64 0E4997 1 ASSY,GROUND WIRE CONNECTOR 65 0G3222 2 ASSY, IGN COIL W/DIODE NO ADV 66 022097 4 WASHER LOCK M6-1/4 67 0G3110 4 SCREW HHTT M6-1.0 X 20 ZINC 68 0C1546 1 O-RING 59.92 X 66.98 X 3.53MM 69 0C1547 1 O-RING 21.89 X 27.13 X 2.62MM 70 082774 1 KEY, WOODRFF 4 X 19D 71 0A5358 1 ADPTR OIL PAD, FLARE 72 0D9312 1 TUBE, ENGINE OIL RETURN 73 0D9314 1 TUBE, ENGINE OIL OUT 74 0C1557 1 O-RING 20.35 X 23.91 X 1.78MM 75 0A9028 1 BOLT, OIL ADAPTOR 76 0D9682A 1 WRAP, CYL 2 GTV760 RV SPCC 77 0D9270 1 INTAKE TUBE 1.25" X 20 GA 78 048031A 2 HOSE CLMP-BAND 1 5/8 79 0D9269 1 BOOT, INTAKE AIRBOX 80 0E0142A 1 BOOT, CARB ADAPTOR 81 078643B 2 BOLT,CARB MOUNT M6 X 1.0 -85LG 82 0D9219 1 ADAPTER, AIR INTAKE CARB 83 0E0573 1 GASKET,CARB TO ADAPTOR 84 0D8807 1 CARBURETOR, (GASOLINE ONLY) 0E1217 1 CARBURETOR, (LP ONLY) 85 0E0572 1 GASKET,CARB TO INTAKE MANIFOLD 86 0C3043 2 GASKET INTAKE PORT 87 0D8836 1 MANIFOLD, INTAKE RV 88 0G3730A 4 SCREW SHC M8-1.25 X 30 SEMS 91 035461 2 BARBED STR 1/4NPT X 3/8 92 0G3662 5 CLAMP, HOSE OETIKER STEPLESS 17mm 93 0G4695A 2 HOSE,3/8"IDX6"L BRAIDED-WRAPPED 94 0E9506 1 COOLER, OIL 95 0D9683A 1 DUCT, OIL CLR RV SPCC 96 0C9764 4 PLASTITE,1/4-15 X ¾ 97 036933 1 SCREW PPHM #10-32 X 3/8 98 0E0246 1 SCREW HHTT #4-40 X ¼ 99 0D9394 1 PLATE, THROTTLE 100 022152 1 WASHER LOCK #10 101 022158 1 NUT HEX #10-32 STEEL 102 043116 2 SCREW HHC M6-1.0 X 12 G8.8 103 049811 4 WASHER FLAT M6 104 047411 2 SCREW HHC M6-1.0 X 16 G8.8 105 066849B 2 SCREW HHTT M5-0.8 X 8 BP 106 048031M 2 CLAMP HOSE #8 .53 - 1.00 (LP ONLY) 107 0F7065 2.25 FT. HOSE 1\2 ID (LP ONLY) 108 075476 1 SCREW PPHM M4-0.7 X 16 (GASOLINE

ONLY)

109 082121A 1 CLIP-J VINYL COAT .375 ID (GASOLINE

ONLY) 110 038150 1 WASHER FLAT #8 (GASOLINE ONLY) 111 022264 1 WASHER LOCK #8 (GASOLINE ONLY) 112 051715 1 NUT HEX M4-0.7 G8 YC (GASOLINE ONLY) 113 0D6029 2 SCREW HHTT M6-1.0 X 16 ZYC 114 055934D 1 CLAMP VINYL 1.06 X .406 (LP ONLY) 115 022473 1 WASHER FLAT 1/4-M6 (LP ONLY) 116 090388 1 SCREW HHTT M6-1.0 X 12 (LP ONLY) 117 0E3200 1 CLAMP VINYL .437” X .281” 118 0A2110 1 SCREW SWAGE 1/4-20 X 1/2 119 0G4576 1 OIL CHECK TUBE BRACKET 120 0G3432 1 3/8 NPT TO INVTD FLR 3/8 OD

Exploded Views & Parts Lists Control Panel Drawing No. 0E1013-B

Control Panel Drawing No. 0E1013-B Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

1 0C2375 2 SCREW HHC M8-1.25 X 90 G8.8 2 022145 2 WASHER FLAT 5/16-M8 ZINC 3 029459 2 TENSION SPRING 4 075215 2 WASHER, SPRING CENTER 5 052858 6 NUT LOCK FL M8-1.25 6 047411 7 SCREW HHC M6-1.0 X 16 G8.8 7 022097 13 WASHER LOCK M6-1/4 8 022473 10 WASHER FLAT 1/4-M6 ZINC 9 080925 8 WASHER NYLON .404 10 0D9921 4 STANDOFF, 1/2" HEX 11 066849 2 SCREW HHTT M5-0.8 X 16 12 066386 1 ASSY, BRUSH HOLDER 13 0C9674 1 BEARING CARRIER, UP 14 0E0363H 1 STATOR ASSEMBLY (5.5 KW ONLY) 0E0364H 1 STATOR ASSEMBLY (6.5 KW ONLY) 0E0362H 1 STATOR ASSEMBLY (7.5 KW ONLY) 15 073159 1 BEARING BALL 16 077005H 1 ROTOR ASSEMBLY (5.5 KW ONLY) 077004H 1 ROTOR ASSEMBLY (6.5 KW ONLY) 073163H 1 ROTOR ASSEMBLY (7.5 KW ONLY) 17 031971 1 BEARING 18 077006 4 STUD,RV STATOR D/C 19 0C9675 1 BEARING CARRIER, LOW 20 0A5351 1 NYLON SLIDE 21 073146 2 SLIDE, NYLON 22 0C1878 2 SUPPORT, SLIDE 23 075242 4 SPRING, GEN. MOUNT 24 075237 4 WASHER, SPRING CENTER 25 090145 1 CIRCUIT BREAKER 30 X 1 (5.5 & 6.5 KW

ONLY) 0E1529 1 CIRCUIT BREAKER 35 X 1 (7.5 KW ONLY) 26 090144 1 CIRCUIT BREAKER 20 X 1 (5.5 KW ONLY) 090145 1 CIRCUIT BREAKER 30 X 1 (6.5 KW ONLY) 0E1529 1 CIRCUIT BREAKER 35 X 1 (7.5 KW ONLY) 27 025105 4 SCREW RHM 6-32 X 1/4 SIMS 28 0A9611 1 FUSE 7.5 AMP 29 032300 1 HOLDER FUSE 30 092113 1 SWITCH SPDT ON-MOM-ON 31 087798 1 SWITCH 6A SPDT 32 055440 2 SCREW HHC M5-0.8 X 25 G8.8 33 0D9377 1 PANEL, TOP CONTROL

ITEM PART NO. QTY. DESCRIPTION

34 054502 1 CIRCUIT BREAKER 3 X 1 35 031879 4 WASHER FLAT #4 ZINC 36 043182 4 WASHER LOCK M3 37 051714 4 NUT HEX M3-0.5 G8 YEL CHR 38 092234 1 ASSY POTTED RV CNTL 39 049226 5 WASHER LOCK M5 40 051716 3 NUT HEX M5-0.8 G8 YEL CHR 41 023484R 2 BUSHING SNAP 42 0D3700 1 NUT FLANGE M6-1.0 NYLOK 43 0D9378 1 PANEL, BOTTOM CONTROL 44 052619 1 SCREW HHC M5-0.8 X 20 G8.8 45 075476 2 SCREW PPHM M4-0.7 X 16 46 065795 1 RECTIFIER-BATTERY CHARGE 47 0C2174 1 RELAY 12V 25A SPST 48 092120 4 NUT LOCK TRIC M6 X 1.0 Y/ZNC 49 049721 2 SCREW HHC M6-1.0 X 35 G8.8 BLK 50 0A1658 2 WASHER LOCK SPECIAL 1/4" 51 074260-146 1 WIRE ASM GRD STD CONN. 52 049813 4 NUT HEX M6 X 1.0 G8 YEL CHR 53 023484D 1 BUSHING SNAP 54 074260-151 1 GROUND WIRE C/PNL TO STUD V-T RV 55 084867 1 RUBBER U-CHANNEL 56 043181 2 SCREW PHM M3-0.5 X 10MM 57 075210A 1 BLOCK 1 POSITION 58 022264 2 WASHER LOCK #8-M4 59 051715 2 NUT HEX M4-0.7 G8 YEL CHR 60 0C7605 2 SCREW HHC M5-0.8 X 60 G8.8 61 0F9719 1 ASY POTTED REG W/FIN 62 089047 2 SPACER .25 X .43 X .55 ST/ZNC 63 075234 1 RESISTOR WW LUG 1R 5% 25W 64 0A2053 1 SCREW HHC M6-1.0 X 65 G8.8 65 058000K 2 NUT TRIC M5 X .8 66 0D8941 1 COMPARTMENT, AIR BOX 67 029451A 2.3 FT. TAPE, 1/2" X 1/16" CLOSED CELL 68 0E0583 1 WIRE HARNESS, QP RV (GASOLINE

ONLY) (NOT SHOWN)

0E1812 1 WIRE HARNESS, QP RV (LP ONLY) (NOT

SHOWN)

69 0E1375 1 WIRE ASS'Y STARTER TO C/PNL (NOT

SHOWN)

Exploded Views & Parts Lists 760 V-twin Engine Drawing No. 0F1997-C

760 V-twin Engine Drawing No. 0F1997-C Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

1 0C5730A 1 ASSEMBLY, CRANKCASE RV 2 0E9843 1 SEAL, 38 I.D. CRANKCASE 3 090388 6 SCREW, HHTT M6-1.0 X 12mm 4 0C5372 1 ASSEMBLY, BREATHER 5 0C3005 1 GASKET, BREATHER COVER 6 0E3372A 1 SEPARATOR, OIL BREATHER 7 0D8067A 1 ASSEMBLY, HEAD #1 8 0C2981C 1 COVER, ROCKER 9 071983 4 RETAINER, PISTON PIN 20 10 0G2751 2 PISTON, FLAT TOP DIA 90 COATED 11 0G2565 2 RING SET, PISTON DIA 90 12 0E1466 2 PIN , PISTON 13 0D4041 1 ASSEMBLY, CAMSHAFT & GEAR 14 0C2983 1 SHAFT, GOVERNOR 15A 0C2985A 2 ROLLER BEARING, GOVERNOR PLATE 15B 0C2985B 1 ROLLER BEARING, GOVERNOR 16 0D4042 1 ASSEMBLY, GOVERNOR GEAR 17 0A7811 1 SPOOL, GOVERNOR MACHINED 18 0C2977 1 GASKET, CRANK CASE 19 0C5943 1 SEAL, OIL PASSAGE 20 0E3790A 1 ASSY,CRANK GTV-760 BELT DRIVE 21 0E3222 2 ASSEMBLY, CONNECTING ROD 22 0C2978 2 GASKET, HEAD 23 24 0G6431A 3 SCREW, SHC M6-1.0 X 30mm SEMS 25 0C2994 1 SCREEN, OIL PICKUP 26 0C2997 1 COVER, GEROTOR 27 0C2995 1 GEROTOR, INNER 28 0C2996 1 GEROTOR, OUTER 29 0C3011 2 COVER, OIL RELIEF 30 0C3009 2 SPRING, OIL RELIEF 31 0C3010 2 BALL, 1/2D OIL RELIEF 32 050873A 1 1/4” NPT PIPE PLUG

ITEM PART NO. QTY. DESCRIPTION

33 0C2991 2 E-RING, GOVERNOR ARM 34 0D1667A 1 ARM, GOVERNOR 35 0C2988 1 THRUST WASHER, GOVERNOR 36 0C2992 1 BUSHING, GOVERNOR LOWER 37 0C5732 1 ASSEMBLY, SUMP WITH SLEEVE 38 0C2993 1 SEAL, GOVERNOR SHAFT 39 0E9842 1 SEAL, 42 I.D. CRANKSHAFT 40 0D9756 1 CONNECTOR, 3/8NPT TO INVTD FLR

3/8OD 41 0C3006 10 SCREW, HHFC M10-1.5 X 55mm 42 080318 8 SCREW HHFC M6-1.0 X 25mm 43 0C2982 1 COVER, ROCKER WITH OIL FILL 44 093064 1 ASSEMBLY, OIL FILL CAP 45 0C2979 2 GASKET, VALVE COVER 46 086515 8 KEEPER, VALVE SPRING 47 0D2274 4 RETAINER, VALVE SPRING 48 0D3867 4 SPRING, VALVE 49 078672 2 SEAL, VALVE STEM D7 50 0C5371 4 WASHER, VALVE SPRING 51 0D3998 4 NUT HEX M8-1.0 G8 52 0E3273 1 SCREEN CRANKCASE BREATHER 53 0D5313 4 ROCKER ARM 54 072694 4 STUD, ROCKER ARM PIVOT 55 0G8552 2 PLATE, PUSH ROD GUIDE 56 0C2976 12 SCREW HHFC M8-1.25 X 65mm 57 0D8067B 1 ASSEMBLY, HEAD #2 58 0C2229 2 VALVE, INTAKE 59 086516 2 VALVE, EXHAUST 60 0D9853D 4 PUSHROD 147 61 083897 4 TAPPET, SOLID 62 0E9323 1 STARTER 63 022129 2 WASHER LOCK M8 64 061906 2 SCREW, HHC M8-1.25 X 85mm

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

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.

(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 part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for the ECS Warranty

Period. A statement in 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 part 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

Warranty

GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR

RECREATIONAL VEHICLE GENERATORS PURCHASED IN THE U.S.A. AND CANADA

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, Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Valve, Valve Lifter(s), Intake and Exhaust Manifolds.

INTERNATIONAL YEAR ONE (or 1000 hours, whichever occurs first) – Limited comprehensive coverage on labor and parts listed.

• All COMPONENTS Extended Warranties are not available on units sold into International Markets.

Generac RV generators manufactured after January 1, 2006, 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 Generac’s Warranty Policies and Procedures Guide.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

Generac generators that utilize non-Generac replacement parts.• Costs of normal maintenance, adjustments, installation and start-up.• Repairs or diagnostics performed by individuals other than Generac authorized dealers not authorized in writing by • Generac Power Systems. Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the Generac engines •

need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine. Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing, lightning, •

earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane. Damage related to rodent and/or insect infestation.• Products that are modified or altered in a manner not authorized by Generac in writing.• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).• Failure due to misapplication.• Telephone, cellular phone, facsimile, internet access or other communication expenses.• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.• Rental equipment used while warranty repairs are being performed.• Overnight freight costs for replacement part(s).• Overtime labor.• Starting batteries, fuses, light bulbs and engine fluids.•

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. Any implied warranties which are allowed by law, shall be limited in duration of the terms of the express warranty provided herein.

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.

Part No. 0H8812 Rev.A 06.02.10

Part No. 0H3466 Revision B (06/02/10) Printed in U.S.A.

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

Generac Power Systems 004703-1, 004705-1, 004706-1, 004707-1, 005750-0 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Introduction

READ T HIS MANUAL THOROUGHLY

C ONTENTS

OPERATION AND MAINTENANCE

HOW TO OBTAIN SERVICE

Safety Rules

GENERAL HAZARDS

ELECTRICAL HAZARDS

FIRE HAZARDS

EXPLOSION HAZARDS

General Information

1.1 GENERATOR IDENTIFICATION

1.2 GENERATOR APPLICABILITY

1.3 INSTALLATION

1.4 SAFETY

1.5 GENERATOR AC CONNECTION SYSTEM

1.6 SPECIFICATIONS

1.8 EXHAUST EMISSIONS INFORMATION (GASOLINE)

Operation

1.9 EXHAUST EMISSIONS INFORMATION (PROPANE)

2.1 GENERATOR CONTROL PANEL

2.2 OPTIONAL REMOTE START/STOP PANEL

2.3 AUTOMATIC CHOKE

2.4 BEFORE STARTING THE ENGINE

2.5 STARTING THE GENERATOR

2.6 STOPPING THE GENERATOR

2.8 PROTECTION SYSTEMS

Maintenance

3.1 CHECKING THE ENGINE OIL LEVEL

3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER

3.3 MAINTAINING THE ENGINE AIR CLEANER

3.5 FUEL FILTER

3.7 CLEANING THE GENERATOR

3.6 CLEAN SPARK ARRESTOR

3.8 BATTERY MAINTENANCE

3.9 ADJUSTING VALVE CLEARANCE

3.10 MAJOR SERVICE MANUAL

3.11 DRIVE BELT

3.12 EXERCISING THE GENERATOR

3.13 OUT OF SERVICE PROCEDURE

Notes

Safety Rules

NOTICE TO INSTALLER

GENERAL HAZARDS

ENGINE EXHAUST HAZARDS

ELECTRICAL HAZARDS

FIRE HAZARDS

EXPLOSION HAZARDS

General Information

1.1 PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS

1.2 SAFETY

1.3 STANDARDS BOOKLETS

1.4 EQUIPMENT DESCRIPTION

1.5 GENERATOR ENGINE OPERATING SPEED

1.6 GENERATOR AC CONNECTION SYSTEM

Installation

2.1 LOCATION AND SUPPORT

2.2 GENERATOR COMPARTMENTS

2.3 COOLING AND VENTILATING AIR

2.4 GASOLINE FUEL SYSTEM

2.5 LP GAS FUEL SYSTEM

2.6 EXHAUST SYSTEM

2.7 ELECTRICAL CONNECTIONS

2.8 BATTERY INSTALLATION

Post Installation Start-up Adjustments

2.9 OPTIONAL ACCESSORIES

3.1 POST INSTALLATION TESTS

3.2 BEFORE INITIAL START-UP

3.3 INITIAL START

3.4 TESTING UNDER LOAD

3.5 INSTALLATION CHECKLIST

Troubleshooting

4.1 TROUBLESHOOTING GUIDE

Electrical Data Electrical Schematic - V-twin - Drawing No. 0E1057-F

Exploded Views & Parts Lists Base & Pulley Drawing No. 0E1323-H