Guardian QUIETPACT 85D Owner's Manual And Installation Instructions

Owner’s Manual and

Installation Instructions

Liquid-cooled Recreational Vehicle Generator

• Model: 005432-0 QUIETPACT™ 85D

This manual should remain with the unit.

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 THIS MANUAL THOROUGHLY 

If any portion of this manual is not understood, contact the nearest Authorized Service Dealer for starting, operating, and servicing procedures.

Throughout this publication, and on tags and decals affixed to the generator, DANGER, WARNING, CAUTION, and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. Their definitions are as follows:

DANGER

After this heading, read instructions that, if not

strictly complied with, will result in serious personal injury, including death, or property damage.

After this heading, read instructions that, if not

strictly complied with, may result in personal injury or property damage.

After this heading, read instructions that, if not

strictly complied with, could result in damage to equipment and/or property.

NOTE:

After this heading, read explanatory statements

that require special emphasis.

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

Four commonly used safety symbols accompany the Danger, Warning, and Caution blocks. Here are the types of information indicated by each symbol:

This symbol points out important safety infor-



mation that, if not followed, could endanger personal safety and/or property to self and others.

This symbol points out potential explosion



hazard.

This symbol points out potential fire hazard.



This symbol points out potential electrical shock



hazard.

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

CONTENTS 

This manual contains pertinent owner’s information, including warranty, electrical diagrams, exploded views, and lists of repair parts for generator model number 005432-0. In addition, the latter portion of this manual contains information necessary for the proper installation of these generators.

OPERATION AND MAINTENANCE 

It is the operator's responsibility to perform all safety checks, to make sure that all maintenance for safe operation is performed promptly, and to have the equipment checked periodically by an Authorized Service Dealer. Normal maintenance service and replacement of parts are the responsibilities 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 minimizes problems and operating expenses. See the Authorized Service Dealer for service aids and accessories.

HOW TO OBTAIN SERVICE 

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

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

Model No. ____________ Serial No. ______________

AUTHORIZED SERVICE

DEALER LOCATION

To locate the nearest AUTHORIZED

SERVICE DEALER, please call this number:

1-800-333-1322

or locate us on the web at

www.generac.com

Table of Contents

Recreational Vehicle Generator

Part I – Owner’s Manual

Introduction ...................................... Inside Front Cover

Read This Manual Thoroughly ................................... IFC

Contents .....................................................................IFC

Operation and Maintenance ....................................... IFC

How to Obtain Service ................................................IFC

Authorized Service Dealer Locator Number .................. IFC

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

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

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

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

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

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

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

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

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

2.2 Optional Remote Start/Stop ............................... 8

2.3 Before Starting the Engine .................................. 8

2.4 Starting the Generator ........................................ 9

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

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

2.7 Protection Systems ............................................ 10

2.8 Additional Information ...................................... 10

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

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

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

3.3 Servicing the Engine Air Filter .......................... 12

3.4 Spark Arrestor Muffler ...................................... 12

3.5 Cleaning the Generator ..................................... 13

3.6 Battery Maintenance .......................................... 13

3.7 Cooling System.................................................. 14

3.8 Engine Coolant .................................................. 14

3.9 Major Service Manual ........................................ 14

3.10 Drive Belt ......................................................... 14

3.11 Exercising the Generator ................................... 14

3.12 Out-of-Service Procedure ................................... 15

3.13 Service Schedule ............................................... 16

Part II – Installation Instructions

Safety Rules .................................................................... 18

Section 1 – General Information ............................... 20

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

1.2 Safety ................................................................ 20

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

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

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

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

Major Features and Dimensions ........................ 21

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

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

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

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

2.4 Diesel Fuel System ............................................ 27

2.5 Exhaust System................................................. 29

2.6 Electrical Connections ....................................... 30

2.7 Battery Installation ............................................ 33

2.8 Optional Accessories ......................................... 34

Section 3 – Post-installation Startup Checks ......... 35

3.1 Post Installation Tests ....................................... 35

3.2 Before Initial Startup......................................... 35

3.3 Initial Start ........................................................ 35

3.4 Testing Under Load ........................................... 35

3.5 Installation Checklist ......................................... 36

Section 4 – Troubleshooting ....................................... 37

4.1 Troubleshooting Guide ...................................... 37

Section 5 - Electrical Data ........................................... 38

Section 6 – Exploded Views and Parts Lists ........... 44

Section 7 – Warranty .................................................... 68

Safety Rules

Recreational Vehicle Generator

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

operation be copied and posted in potential hazard areas of the recreational vehicle.



Safety should be stressed to all operators and potential operators of this equipment.

• The generator engine releases DEADLY carbon



The engine exhaust from this product

contains chemicals known to the state

defects, or other reproductive harm.



This product contains or emits chemicals known to the state of California to cause

cancer, birth defects or other reproductive harm.

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

The manufacturer cannot 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 that 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.

WARNING:

of California to cause cancer, birth

WARNING:



DANGER

Despite the safe design of this generator,



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

Parts of the generator are rotating and/or hot



during operation. Exercise care near running generators.

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.

GENERAL HAZARDS



• For safety reasons, the manufacturer recommends that the installation, initial startup, and maintenance of this equipment be performed by an Authorized Service Dealer.



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. Thus, the 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 seriously damages the generator. Do not alter the installation or permit even partial blockage of ventilation provisions, as this can also seriously affect the safe operation of the generator.



Safety Rules

Recreational Vehicle Generator

• When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

• Inspect the generator regularly, and contact the nearest Authorized Service Dealer immediately for parts needing repair or replacement.

• Before performing any maintenance on the generator, disconnect its battery cables to prevent accidental startup. First, disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–). Reconnect this cable last.

• Never use the generator, or any of its parts, as a step. Stepping on the unit can stress and break parts, resulting in dangerous operating conditions due to leaking exhaust gases, fuel leakage, oil leakage, etc.

• Never insert any tool or other object through openings in the generator interior, even if the unit is not running. Serious injury or damage to the equipment could be done.

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. Before operating the generator, ensure all appropriate covers, guards, and barriers are in place . If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• During installation onto the vehicle, have the generator properly grounded (bonded), either by solid mounting to the vehicle frame or chassis, or by means of an approved bonding conductor. DO NOT disconnect the bonding conductor, if so equipped. DO NOT reconnect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 American Wire Gauge (AWG) copper wire minimum.

• In case of an 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 dry 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 must always comply with NFPA 70 (latest edition), “National Electrical Code”, Article 551, and NFPA 1192 (latest edition), “Standard for Recreational Vehicles”, along with all applicable codes, standards, laws, and regulations. Adhere strictly to local, state, and federal 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. After proper installation, do nothing that might alter the 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 off any fuel or oil spills immediately. Ensure that no combustible material is 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 of debris.

• All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels. Inspect the unit’s fuel system frequently and correct any leaks immediately. Before placing this equipment into service, the fuel supply lines must be properly installed, purged, and leaktested according to applicable fuel-gas codes.





Section 1 – General Information

Recreational Vehicle Generator

1.1 GENERATOR IDENTIFICATION

Please record the following information from the generator DATA LABEL or information label, located below the user control panel.

1. Model Number _____________________ 2. Serial Number __________________

3. kW Rating _________________________ 4. Rated Voltage __________________

5. Phase ______________________________ 6. Hertz __________________________

Model: 005432-0 

1. 2-Pole, 40-amp Circuit Breaker

2. Hourmeter

3. Oil Fill Opening and Plug

4. Oil Dipstick

5. Engine Start/Stop Switch

6. 15-amp Fuse

7. Engine Preheat Switch

8. Fuel Filter

9. Air Filter

10. Oil Filter

11. Starter Motor

12. Preheat Contactor

13. Starter Contactor

14. Radiator

15. Coolant Recovery Tank

16. Muffler

17. Battery Connections

18. Fuel Connections

19. Alternator

20. Fuel Pump

21. Centrifugal Cooling Fan and Housing

22. Alternator Drive Belt

23. Alternator Drive Belt Tensioner

24. Cooling Fan Drive Belt

25. Cooling Fan Drive Belt Tensioner

26. Engine

Section 1 – General Information

Recreational Vehicle Generator

1.2 GENERATOR APPLICABILITY

These generators have been designed and manufactured for supplying electrical power to recreational vehicles. DO NOT modify the generator nor use it for any application other than for what it was designed. If there are any questions pertaining to its application, write or call the factory. Do not use the unit until advised by a competent authority.

For fire safety, the generator must have been



properly installed in compliance with NFPA 70 (latest edition), “National Electrical Code”, Article 551, and NFPA 1192 (latest edition), “Standard for Recreational Vehicles”. The generator also must have been installed in strict compliance with the manufacturer’s detailed installation instructions. After installation, do nothing that might render the unit in noncompliance with such codes, standards, and instructions.

Use this generator to supply electrical power for operating 120/240-volt, single-phase, 60-Hertz, AC electrical loads. These loads can require up to 8,500 watts (8.5 kW) of power, but cannot exceed 70.8 AC amps of current at 120 volts, or 35.4 AC amps at 240 volts.

DANGER

1.4 GENERATOR AC CONNECTION SYSTEM

This generator is equipped with dual-stator AC power windings. These two-stator windings supply electrical power to customer electrical loads by means of a dual, two-wire connection system. Note, however, that the neutral is grounded.

The generator may have been installed so that it powers 120-volt AC electrical loads only (Figure 1.1). It can be rewired to connect 120/240-volt AC electrical loads. This procedure should be done by an Authorized Service Dealer or other qualified installer. Refer to the installation portion of this manual for more information.

Figure 1.1 – Connections for 120 Volts Only —

Dual Circuits

Do not overload the generator. Some installa-



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

1.3 SAFETY

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

1.5 SPECIFICATIONS

1.5.1 FUEL REQUIREMENTS 

The generator is equipped with a diesel fuel system. Use clean, fresh No. 1D or No. 2D diesel fuel with minimum Cetane number of 40. The diesel fuel must also conform to American Society of Testing and Materials (ASTM) specifications. Never use any dirty or contaminated fuel. When adding fuel, DO NOT overfill the tank. Allow room at the top of the tank for fuel expansion. Depending on the installation, the generator may have either a separate fuel tank or “share” the vehicle’s engine fuel tank.

Section 1 – General Information

Recreational Vehicle Generator

NOTE:

Some installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter than the vehicle’s engine pickup tube. Such an arrangement causes the generator engine to “run out of fuel”, while adequate fuel for the vehicle engine remains in the tank.

Also, appropriate care should be taken in applications where extremely low ambient temperatures are possible, to ensure the temperature of the diesel fuel is not allowed to fall below levels where “gelling” could occur.

1.5.2 FUEL CONSUMPTION (GAL/HR) 

Model No Load Half Load Full Load

005432-0 0.28 0.49 0.78

1.5.3 ENGINE OIL REQUIREMENTS 

Use a high-quality detergent oil with American Petroleum Institute (API) classification “For Service CC.” Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change:

Temperature Oil Grade (Recommended)

Above 100° F (38° C) SAE 15W-40* or SAE 40

40° to 100° F (4.4° to 38° C) SAE 10W-30 or SAE 30

Below 40° F (4.4° C) SAE 5W-20 or 5W-30

* - in units from the factory

Crankcase and oil filter capacity is approximately

4.35L or 4.6 U.S. quarts. Do NOT use special additives. See "Checking the Engine Oil Level" and "Changing the Engine Oil and/or Filter" sections for oil level checking and changing procedures.

1.5.4 COOLANT 

Use a 50:50 mixture that is half low silicate, ethylene glycol base antifreeze and half soft water. Use only soft water and only low silicate antifreeze. If desired, a high-quality rust inhibitor to the recommended coolant mixture may be added. When adding coolant, always add the recommended 50-50 mixture.

Ethylene glycol base antifreeze is poisonous.



Do not use mouth to siphon coolant from the radiator, recovery bottle, or any container. Wash hands thoroughly after handling. Never store used antifreeze in an open container because animals are attracted to the smell and taste of antifreeze, even though it is poisonous to them.

Do not use any chromate base rust inhibitor



with ethylene glycol base antifreeze; or else, chromium hydroxide (“green slime”) will form and cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base antifreeze. Using any highsilicate antifreeze boosters or additives will also cause overheating. DO NOT use any soluble oil inhibitor for this equipment.

1.5.5 ENGINE 

Type of Engine .........................................................ISM Diesel

Cylinder Arrangement ................................................3, in-line

Displacement ........................................... 69.02 in3. (1131 cc)

Bore .............................................................. 3.03 in. (77 mm)

Stroke ........................................................... 3.18 in. (81 mm)

Compression Ratio .................................................23.56-to-1

Combustion Chamber Type ...........................Pre-Combustion

Rated Horsepower ........................................15 @ 1,950 rpm

Cylinder Block ..........................................................Cast Iron

Number of Main Bearings ......................................................4

Number of Teeth on Flywheel ............................................104

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

Fuel Filter ..........................Full Flow Spin-On (Part # 69858)

Oil Filter ...................................... Full Flow with Bypass Valve

(Part # 126-70939)

Oil Pressure ...............................................................29-71 psi

Type of Cooling System ............ Pressurized, Closed Recovery

Cooling Method .................................................. Liquid-cooled

Type of Cooling Fan ......................................Centrifugal Puller

Cooling System Capacity .......................... 1.4 U.S. gals (5.3 L)

Air Cleaner .......................... Disposable Filter (Part # C4880)

Starter ....................................................... 12-volt DC Electric

Recommended Battery ................... 70 Ah, 360 Cold-cranking

Amps (Minimum ratings)

Maximum Cranking Current .................................. 220 Amps

Ground Polarity ...........................................................Negative

DANGER

Do not remove the radiator pressure cap while



the engine is hot; otherwise, serious burns from boiling liquid or steam could result.

Section 2 – Operation

Recreational Vehicle Generator

1.5.6 GENERATOR 

Rated Maximum Continuous AC Output at ...

85º F (29º C) Ambient ........................ 8,500 Watts (8.5 kW)

100º F (38º C) Ambient ......................7,500 Watts (7.5 kW)

120º F (49º C) Ambient ......................6,000 Watts (6.0 kW)

Rated Voltage .............................................. 120/240 Volts AC*

Rated Maximum Continuous AC Current at ... 8,500 Watts

120 Volts ..................................................... 70.8 Amps

240 Volts ..................................................... 35.4 Amps

7,500 Watts

120 Volts ..................................................... 62.5 Amps

240 Volts ................................................... 31.25 Amps

6,000 Watts

120 Volts ..................................................... 50.0 Amps

240 Volts ..................................................... 25.0 Amps

Phase .............................................................................. Single

Rotor Speed at No Load .........................................3,780 rpm

Number of Rotor Poles...........................................................2

Engine RPM .....................................................................1,950

Rated AC Frequency ....................................................... 60 Hz

Battery Charge Voltage ..........................................14 Volts DC

Battery Charge Current ..................................... 2 Amps (max)

Weight ....................................................................504 Pounds

Length ................................................... 36.6 inches (929 mm)

Width .................................................... 23.8 inches (604 mm)

Height ................................................... 23.8 inches (604 mm)

* All units are reconnectable to 240-volt only AC output.

2.1 GENERATOR CONTROL PANEL

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

Figure 2.1 – Generator Control Panel

STOPSTART

LINE BREAKER

SYSTEM

CONTROL

2.1.1 HOURMETER 

This indicates the length of time the engine/generator has operated, in hours and tenths of hours. Use the hourmeter to ensure that the periodic maintenance tasks for the generator are completed on a timely basis.

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’s center position is the RUN position.

2.1.3 FUSE 

The 15-amp fuse protects the engine’s DC control circuit against electrical overload. If the fuse element has melted open due to overloading, the engine cannot be cranked. If the fuse must be replaced, use only an identical replacement (i.e., AGC-15).

If a fuse element melts, find the cause of the



overload before replacing the fuse.

2.1.4 LINE BREAKER 

The line (i.e., main) breaker protects the generator’s AC output circuit against overload and provides a method of turning OFF the generator’s 120/240-volt AC output to the vehicle circuits. The generator has two 40-amp breakers.

NOTE:

Refer to section “Generator AC Connection System,”. Individual installations will differ. If an overload occurs, the dual breakers will open the ungrounded (i.e., hot) stator leads (11 and 33 in Figure 1.1). When the generator has been connected for 120/240 dual voltage (Figure 2.16), the line breakers will operate on the ungrounded (i.e., hot) stator leads (11 and 44 in Figure 2.16).

ONON

15 AMP

PREHEAT

30 SEC. MAX

2.1.5 PREHEAT SWITCH 

The diesel engine is equipped with glow plugs, one for each cylinder. When the preheat switch is pressed, the glow plugs heat the engine combustion chamber, allowing for quicker starts when the engine is cold. Pressing the preheat switch also operates the fuel pump.

Section 2 – Operation

Recreational Vehicle Generator

2.2 OPTIONAL REMOTE START/STOP

This generator is equipped with a plug-in connector that can be interfaced with an optional remote panel provided inside the vehicle. This option allows for starting and stopping the generator conveniently from within the vehicle. Refer to Part II - "Installation Instructions", for details on the remote start/stop option.

2.3 BEFORE STARTING THE ENGINE

NOTE:

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

2.3.1 INSTALLATION 

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

NOTE:

Be sure the installation complies with all standards and codes listed in the "Standards Booklets" section of this manual.

2.3.2 ENGINE LUBRICATION 

Before starting the engine, have the engine crankcase properly serviced with the recommended oil. Refer to the "Engine Oil Requirements", "Checking the Engine Oil Level" and Changing the Engine Oil and/or Filter" sections for oil servicing procedures and recommendations.

Any attempt to crank or start the engine before



it has been properly serviced it with the recommended oil may result in an engine failure.

2.3.3 FUEL SUPPLY 

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

NOTE:

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

2.3.4 COOLANT LEVEL 

Check the engine coolant level prior to initial use and at recommended intervals. Refer to the “Coolant” and “Engine Coolant” sections for procedures and recommendations.

2.3.5 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 may overheat, causing engine shutdown and damage to the generator.

2.3.6 ENGINE EXHAUST GAS 

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

DANGER

The generator engine releases DEADLY carbon



Section 2 – Operation

Recreational Vehicle Generator

DANGER

Never sleep in the vehicle while the genset is



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

2.4 STARTING THE GENERATOR

NOTE:

Read the vehicle manufacturer’s instructions. The owner/operator should become familiar with the vehicle in which this generator is installed. Differences exist between vehicles. For example, some vehicles may use a transfer switch to isolate dockside power from the generator, while other vehicles may use an isolating receptacle. Some vehicles may be equipped with a DC converter, which allows the generator to power certain DC lighting and other DC loads.

To start the generator from either the generator control panel or from the optional remote panel, proceed as follows:

1. Turn OFF electrical loads using the means provided in the vehicle (such as, a main-line circuit breaker or transfer switch).

NOTE:

If starting from the generator control panel, turn OFF loads by setting the generator’s main-line 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 is cold, press the Preheat switch for a maximum of 15 to 30 seconds.

3. While pressing the Preheat switch to crank the engine, hold the engine Start/Stop switch in the START position. When the engine starts, release the switches.

If the engine does not start after it has been



cranking for 15 seconds, release the Start/Stop switch, wait 15 seconds, and try again. Holding the switch for longer than 15 seconds can damage the starter motor.

4. Let the engine run at no-load for a few minutes to stabilize and warm up.

5. Turn ON electrical loads, using the means provided in the vehicle (such as, a main-line circuit breaker or transfer switch).

2.5 STOPPING THE GENERATOR

1. Turn OFF all electrical loads, using the means provided in the vehicle (such as, a main-line circuit breaker or transfer switch).

2. Let the generator run at no-load for a few minutes, to stabilize internal engine generator temperatures.

Do not stop the engine/generator immediately



after running under load. This can overheat and damage the engine and/or generator.

3. Press and hold the Start/Stop switch in the STOP position, until the engine shuts off.

2.6 APPLYING LOADS TO GENERATOR

When applying electrical loads to the generator, observe these guidelines:

• Before applying electrical loads, let the generator

stabilize and warm up for a minute or two.

• DO NOT overload the generator.

2.6.1 LETTING THE ENGINE STABILIZE 

The generator supplies correctly rated voltage only at the proper governed speed. Some electrical appliances may be extremely sensitive to voltage. Incorrect voltages can damage such appliances.

Electrical loads applied on the engine 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.

2.6.2 DO NOT OVERLOAD THE GENERATOR 

Read the rated wattage/amperage capacity of the generator on the generator data label located below the user control panel.

Applying electrical loads in excess of the unit’s rated capacity may trip the line breaker or cause the engine/generator to 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.

Section 2 – Operation

Recreational Vehicle Generator

• Induction-type motors (such as, those that run the vehicle’s furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2 time more watts of power for starting than for running (for a few seconds during motor starting). Be sure to allow for this when connecting electrical loads to the generator. First, calculate 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.

• For the first two or three hours of operation, do not apply electrical loads over 75 percent of the unit’s rating.

2.7 PROTECTION SYSTEMS

The engine has several safety switches that cause it to automatically shut down, under the following conditions: low oil pressure, high coolant temperature, and engine overspeed. See Figure 2.2 for the location of these devices. If automatic shutdown does occur, refer to “Troubleshooting Guide”.

2.7.1 LOW OIL PRESSURE SWITCH 

This switch is normally closed (N.C.) but is held open by engine oil pressure during engine running. Should operating oil pressure drop below approximately 10 psi, the switch contacts close, and the engine shuts down automatically.

2.7.3 OVERSPEED SHUTDOWN 

A DC control circuit board senses engine speed from the frequency of the alternator AC output. Should the alternator output frequency exceed approximately 72 Hertz (4,320 alternator rpm), circuit board action initiates an automatic engine shutdown.

2.7.4 OVERVOLTAGE PROTECTION 

A solid-state voltage regulator (Figure 2.3) controls the generator’s AC output voltage. This regulator supplies an excitation current to the rotor. By regulating the rotor’s excitation current, the strength of its magnetic field is regulated and, in turn, the voltage delivered to connected electrical loads is controlled. When the AC frequency is 60 Hertz, voltage is regulated at 120 volts (voltage-to-frequency ratio is 2-to-1).

Figure 2.3 – Solid-state Voltage Regulator

2.7.2 HIGH COOLANT TEMPERATURE 

SWITCH

This normally-open (N.O.) thermostatic switch has a sensing tip that is immersed in captive coolant. Should the coolant temperature exceed approximately 115° C (240° F), the switch contacts close, and the engine shuts down automatically.

Figure 2.2 – Engine Protective Devices

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 ADDITIONAL INFORMATION

2.8.1 ATTENTION REQUIRED  AFTER SUBMERSION

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

Section 3 – Maintenance

Recreational Vehicle Generator

2.8.2 OPERATION IN HIGH GRASS  OR BRUSH

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

2.8.3 EFFECTS OF MOISTURE AND DIRT 

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

When moisture is allowed to remain in contact with windings, some of the moisture will be retained in voids and cracks in the insulation. This reduces insulation resistance and will eventually cause problems. Dirt will make the problem worse, since it tends to hold moisture in contact with windings. Salt (as from sea air) will also worsen the problem, since it tends to absorb moisture from the air. Salt and moisture, when combined, form a good electrical conductor.

3.1 CHECKING THE ENGINE OIL LEVEL

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

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

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

lint-free cloth.

3. Install the dipstick, and fully seat the T-handle;

then, remove it again. The oil level should be at the dipstick “Full” mark.

4. If necessary, remove the oil fill plug 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 the oil-fill plug and the dipstick before

operating the engine.

Figure 3.1 – Oil Maintenance Features

OIL FILL OPENING AND PLUG

OIL DRAIN PLUG

LATCHES

OIL DIPSTICK

FRONT SERVICE DOOR

REMOVABLE FRONT PANEL TRANSPARENT FOR VIEWING PURPOSES.

OIL FILTER

3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER

Never operate the engine with the oil level



below the “ADD” mark on the dipstick. Doing this could damage the engine.

Change the engine oil and oil filter after the first 25 hours of operation. See the “Service Schedule” section for subsequent oil and filter changes. Change the oil more frequently, if operating consistently under heavy load or at high ambient temperatures.

To change the oil and/or oil filter, proceed as follows (see Figure 3.1):

1. Run the engine until it is thoroughly warmed up (for

at least five minutes) then shut OFF the engine.

2. Immediately after the engine shuts OFF, remove

the front service door, located beneath the unit, by retracting the two latches and pivoting the door downward. If space allows, remove the front panel by removing the four retaining bolts. Be careful not to let the panel fall.

3. Remove the air filter (see "Servicing the Engine

Air Filter").

4. Remove the oil-drain plug and drain the oil into a

suitable container. Removing the oil-fill plug will allow the crankcase to drain faster.

5. After the oil has drained, replace the oil-drain

plug. Go to step 9 if changing oil only.

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

turning it counterclockwise.

7. Apply a light coating of clean engine oil to the

gasket of the new filter.

Section 3 – Maintenance

3/8" NPT HEX PIPE CAP

GASKET

ACCESS PLATE

Recreational Vehicle Generator

8. 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.

9. Remove the dipstick, and wipe it dry with a clean, lint-free cloth. This will be used later to check the oil level.

10. Remove the oil-fill plug, and slowly add the proper type and amount of recommended oil (see "Engine Oil Requirements"). Periodically use the dipstick to check the oil level and continue to fill the crankcase until the oil reaches the dipstick “FULL” mark. DO NOT FILL ABOVE THE “FULL” MARK.

11. Install the oil-fill plug and the dipstick.

12. Reinstall the air filter.

13. Reattach the front service door or front panel; make sure the latches are fully engaged and the bolts are fully tightened.

14. Start the engine, and check for leaks.

NOTE:

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

3.3 SERVICING THE ENGINE

3.4 SPARK ARRESTOR MUFFLER

The exhaust muffler supplied with the generator is a spark arrestor type. The exhaust mufflers for recreational vehicle generators do not have a spark arrestor screen, but are of the more efficient “toroid” or “swirl” type. To remove carbon and combustion deposits from the muffler, proceed as follows (see Figure 3.3):

1. Place the unit above a noncombustible surface, and ensure that the generator exhaust piping is cool.

2. Remove the two screws holding the spark arrestor access plate to the rear floor pan.

3. Remove the spark arrestor access plate and gasket.

4. Remove the hex pipe cap from the end of the spark arrestor cleanout pipe.

5. Thread on a 3/8” NPT pipe coupling and pipe nipple to extend the cleanout pipe at least 10 inches (250 mm) below the rear floor pan; additional piping may be added to direct the muffler exhaust away from the cooling air discharge flow beneath the unit.

Figure 3.3 – Spark Arrestor Muffler Maintenance

AIR FILTER

To access the engine air filter (Figure 3.2), remove the front service door, located beneath the unit, by retracting the two latches and pivoting the door downward. Loosen the hose clamp at the base of the air filter and remove the filter. Place the hose clamp on the new filter and install it, making sure it is positioned properly before reattaching the service door. Make sure the service door latches are fully engaged.

Figure 3.2 – Engine Air Filter

See the “Service Schedule” for recommended air cleaner maintenance.

REMOVABLE FRONT PANEL TRANSPARENT FOR VIEWING PURPOSES.

6. Start and run the engine for approximately 15 minutes.

7. Shut down the engine, and allow the piping to cool.

8. Remove the 3/8” NPT coupling and piping.

9. Apply a graphite-base, anti-seize compound to the cleanout pipe threads.

10. Reinstall the hex pipe cap, spark arrestor access plate, gasket, and two screws.

The exhaust system of this product gets



extremely hot and remains hot after shutdown. High grass, weeds, brush, leaves, etc., must remain clear of the exhaust. Such materials may ignite and burn from the heat of the exhaust system.

Failure to provide and maintain a spark arres-



tor may be in violation of the law. If this generator is used on any forest-covered, brushcovered, or grass-covered unimproved land, the vehicle owner or operator must maintain the spark arrestor 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.

Be sure to reinstall the hex pipe cap tightly to



the spark arrestor cleanout pipe. Vibration could cause a loose cap to fall out, resulting in hot engine exhaust being drawn through the centrifugal cooling fan and out beneath the unit. This could result in damage to the generator or in discharge of hot exhaust sparks beneath the unit.

3.5 CLEANING THE GENERATOR

Keep the generator as clean and as dry as possible. Dirt and moisture that accumulate on internal generator windings have adversely affect insulation resistance.

Periodically, clean the generator’s exterior surfaces. A soft brush may be used to loosen caked-on dirt. Use a vacuum system or dry, low-pressure air to remove any accumulations of dirt. The generator is housed inside an all-weather enclosure; clean the enclosure with a soft, damp cloth or with sponge and water.

Once each year, have the generator cleaned and inspected by an Authorized Service Dealer. Service technicians will use dry, low-pressure air to clean internal windings. Parts inside the control console should be cleaned and inspected at this time, as well.

Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are excessively low, the generator may require drying.

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.

Section 3 – Maintenance

Recreational Vehicle Generator

3.6 BATTERY MAINTENANCE

All lead-acid batteries will discharge when not in use. The generator battery should be inspected per the “Service Schedule”. The following procedure should be used for inspection:

• Inspect the battery posts and cables for tightness

and corrosion. Tighten and clean as necessary.

• Check the battery fluid level of unsealed batteries

and, if necessary, fill with Distilled Water Only. Do not use tap water in batteries.

• Have the state of charge and condition checked by

an Authorized Service Dealer.

NOTE:

Servicing of the battery is to be performed or supervised by knowledgeable personnel, according to the required precautions. Keep unauthorized personnel away from batteries.

Damage will result if the battery connections are made in reverse.

DANGER

Do not dispose of the battery in a fire. The



battery is capable of exploding. Storage batteries release 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 tool 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, and other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

• Do not lay tools or metal parts on top of the

battery;

• Disconnect any charging source prior to connect-

ing, or disconnecting, battery terminals; and

• Do not use any jumper cables or booster battery

to crank and start the generator engine. If any battery has discharged, remove it for recharging.

Section 3 – Maintenance

Recreational Vehicle Generator

DANGER

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;

• Immediately wash with water all skin areas that come into contact with the electrolyte.

• If the electrolyte contacts the eyes, immediately flush eyes thoroughly with water, and seek medical attention.

• 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) of 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.

3.7 COOLING SYSTEM

Air intake and outlet openings in the generator compartment must be open and unobstructed for continued proper operation. Avoid obstructions, such as, high grass, weeds, brush, leaves, and snow.

Without sufficient cooling and ventilating air flow, the engine/generator quickly overheats, which causes it to shut down.

3.8 ENGINE COOLANT

Check the coolant level in the coolant recovery tank at least once daily or prior to use. Add the recommended coolant mixture (see "Coolant"), as necessary; the tank should be kept within the levels indicated on the adjacent decal. If desired, a high-quality rust inhibitor to the recommended 50-50 coolant mixture may be added. If added consistently, the recommended mixture will protect the unit against freezing temperatures.

Periodically remove the radiator pressure cap, located behind the access cover above the user control panel, to make sure the coolant recovery system is functioning properly. Coolant should be at the bottom of the radiator filler neck. If the coolant level is low, inspect the gasket in the radiator pressure cap. Replace the cap, if necessary. To have the pressure cap tested, contact an Authorized Service Dealer. Inspect both the cooling system and coolant recovery system for leaks.

Do not remove the radiator pressure cap while



the engine is hot; otherwise, serious burns from boiling liquid or steam could result.

Ethylene glycol base antifreeze is poisonous.



Do not use any chromate base rust inhibitor



with ethylene glycol base antifreeze; otherwise, chromium hydroxide (“green slime”) will form and cause overheating. Engines that have been operated with a chromate base rust inhibitor must be chemically cleaned before adding ethylene glycol base antifreeze. Using any highsilicate antifreeze boosters or additives will also cause overheating. DO NOT use any soluble oil inhibitor for this equipment.

3.9 MAJOR SERVICE MANUAL

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

3.10 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.

3.11 EXERCISING THE GENERATOR

At least once every seven days, start and operate the generator. Let the unit run for at least 30 minutes to “exercise” the engine. If the generator cannot be exercised every seven days, and it is to be out of service longer than 30 days, see "Out-of-Service Procedure".

3.12 OUT-OF-SERVICE PROCEDURE

3.12.1 REMOVAL FROM SERVICE 

Prepare the generator for storage as follows:

1. Start the engine and let it run until it is thoroughly

warmed up (at least five minutes), then shut off the engine.

2. While the engine is still warm from running, drain

the oil completely (see "Changing the Engine Oil and/or Filter"). Refill the crankcase with the recommended oil (see "Engine Oil Requirements").

3. Attach a tag to the engine, indicating the viscosity

and classification of the oil in the crankcase.

4. 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.

5. Clean and wipe the entire generator.

3.12.2 RETURN TO SERVICE 

To return the unit to service after storage, proceed as follows:

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

sification. 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.

Section 3 – Maintenance

Recreational Vehicle Generator

Section 3 – Maintenance

Recreational Vehicle Generator

3.13 SERVICE SCHEDULE

ATTENTION: It is recommended that all service work

be performed by the nearest Authorized Service Dealer.

SYSTEM/COMPONENT PROCEDURE FREQUENCY

X = Action Inspect Change Clean D = Daily W = Weekly R = Replace/Adjust as Needed M = Monthly Y = Yearly * = To Be Completed by an H = Hours

Authorized Service Dealer.

FUEL

Fuel level X AFTER 25-H, D / BEFORE USE

Fuel lines and connections* X AFTER 25-H, EVERY 250 H / 6 M

Fuel Filter* X EVERY 250 H / 6 M

LUBRICATION

Oil level X EVERY 8 H / D Oil X AFTER 25-H,

EVERY 250 H / 6 M Oil Filter X AFTER 25-H,

EVERY 250 H / 6 M Oil line leakage* X EVERY 100 H

COOLING

Engine cooling system* X AFTER 25-H, EVERY 100 H / M

Coolant level X AFTER 25-H, D / BEFORE USE

Coolant* X EVERY 500 H / Y Enclosure louvers X X EVERY 250 H / 6 M

EXHAUST

Exhaust system X EVERY 100 H / M Retorque Exhaust Manifold* X EVERY 750 H Clean out Muffler/Spark Arrestor X EVERY 150 H/Y

BATTERY

Electrolyte fluid level X AFTER 25-H, W Charge and condition X R X W, EVERY 250 H / 6 M FAN/ALTERNATOR BELTS Tension and condition* X R EVERY 750 H

ENGINE

Retorque cylinder head* X EVERY 750 H Retorque intake manifold* X EVERY 750 H Starter motor* X EVERY 750 H Air filter X R EVERY 500 H Compression* X EVERY 750 H Valve clearance* X R EVERY 750 H Governor* X R EVERY 750 H Safety devices* X R EVERY 750 H Injection system* X R EVERY 750 H

GENERAL

Overall condition X X AFTER 25-H, W Exercise system W COMPLETE TUNE-UP* X X X Y

PART II –

INSTALLATION

INSTRUCTIONS

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!

DANGER

Safety Rules

Recreational Vehicle Generator

DANGER: For fire safety, installation of a generator into a recreational vehicle must comply

strictly with NFPA 70 (latest edition), “National Electrical Code”, Article 551, and NFPA 1192



(latest edition), “Standard for Recreational Vehicles”. In addition, installation must comply with the manufacturer’s instructions and recommendations.



NOTICE TO INSTALLER

These Installation Instructions have been published by The manufacturer to aid in the installation of the products described in this manual. The manufacturer assumes that installation personnel are familiar with the procedures for installing such products, or similar products manufactured. The manufacturer also assumes that personnel have been trained in the recommended installation procedures for these products and that such training includes (a) use of common hand tools, (b) use of special tools, and (c) use of any tools and/or equipment from other suppliers.

The manufacturer cannot possibly know of, nor 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 are 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 are both accurate and current. However, the manufacturer reserves the right to change, alter, or otherwise improve this product at any time, without prior notice.

DANGER

Despite the safe design of this generator,



Parts of the generator are rotating and/or hot



during operation. Exercise care near running generators.

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.

GENERAL HAZARDS



• For safety reasons, the manufacturer recommends that the installation, initial startup, and maintenance of this equipment is carried out by an Authorized Service Dealer.

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

• Keep hands, feet, clothing, etc., away from drive belts, fans, and other moving or hot parts. Never remove any drive belt or fan guard while the unit is operating.

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

• When working on this equipment, remain alert at all times. Never work on the equipment when physically or mentally fatigued.

• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts, and may result in dangerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

• Never insert any tool or other object through openings in the generator interior, even if the unit is not running. Serious injury or damage to the equipment could be done.



Safety Rules

Recreational Vehicle Generator

ELECTRICAL HAZARDS



• The generator covered by this manual produces dangerous electrical voltages that can cause fatal electrical shock. Avoid contact with bare wires, terminals, connections, etc., while the unit is running. Ensure all appropriate covers, guards, and barriers are in place before operating the generator. If work must be done around an operating unit, stand on an insulated, dry surface to reduce shock hazard.

• Do not handle any kind of electrical device while standing in water, while barefoot, or while hands or feet are wet. DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• During installation onto the vehicle, properly ground (bond) the generator either by solid mounting to the vehicle frame or chassis, or by means of an approved bonding conductor. DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 American Wire Gauge (AWG) copper wire minimum.

• If the vehicle electrical circuits can be powered by any other source of electricity (such as, a “dockside” power receptacle), there must be no possibility of connecting the different power sources to the vehicle’s circuits at the same time. The dockside (utility) power source must be positively isolated from the vehicle’s circuits whenever the generator is operating. Failure to isolate the vehicle’s circuits from the dockside power supply when the generator is running may result in damage to the generator or in serious injury or death to dockside (utility) power workers due to backfeed of electrical energy.

• In case of an 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.

• All fuel types are potentially FLAMMABLE and/or EXPLOSIVE and should be handled with care. Comply with all laws regulating the storage and handling of fuels.

• Fuel supply lines must be properly installed, purged and leak-tested according to applicable fuel-gas codes, before placing this equipment into service. There must be no possibility of fuel vapors entering the vehicle interior.

• It is required that an approved, flexible, nonconductive fuel line between the generator fuel connection point and the rigid fuel lines be installed.





Section 1 – General Information

Recreational Vehicle Generator

1.1 PURPOSE AND SCOPE OF THE MANUAL

These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to all information and instructions in the manual, both for safety and for continued reliable operation of the equipment.

Because of the different recreational vehicle models and the variations between the models, it would be extremely difficult, if not impractical, to provide detailed instructions for every possible installation. For that reason, instructions and illustrations in this manual are general in nature. Illustrations are not intended to serve as detailed installation blueprints.

The installation should comply strictly with all applicable codes, standards, and regulations pertaining to the installation and use of this product. If any portion of this manual appears to be in conflict with such codes, standards, or regulations, the applicable codes, standards, or regulations must take precedence over the manual.

1.2 SAFETY

Before handling, installing, operating, or servicing this equipment, carefully read the “Notice to Installer” and “Safety Rules” on pages 18 and 19. Comply with all safety rules to prevent death, personal injury, or damage to equipment and/or property. Stress safety to all installers, operators, and service technicians who work on this equipment.

5. CSA Electrical Bulletin 946, available from the Canadian Standards Association, Housing and Constructions Materials Section, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3.

1.4 EQUIPMENT DESCRIPTION

Instructions and information in this section pertain to liquid-cooled generators, designed specifically for installing in recreational vehicles. This unit operates 120/240-volt, single-phase, 60-Hertz, AC electrical loads that require up to 70.8 amps at 120 volts or 35.4 amps at 240 volts.

1.5 GENERATOR ENGINE

OPERATING SPEED

The generator’s two-pole revolving field (rotor) is driven by a three-cylinder, 1.1-liter diesel engine. The generator supplies 120/240 volts AC at 60 Hertz, when the rotor is operating at 3,600 rpm. Engine speed is held nearly constant by a mechanical, fixed speed governor at 1,950 rpm.

1.6 GENERATOR AC

CONNECTION SYSTEM

The generator is equipped with dual stator power windings, as shown in Figure 1.1.

Figure 1.1 – Connections for 120 Volts Only —

Dual Circuits

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 1192, “Standard for Recreational Vehicles” (replaces ANSI A119.2/NFPA 501C), 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/RVIA EGS-1, “Engine Generator Sets for Recreational Vehicle Safety Requirements”, available from the Recreational Vehicle Industry Association, 1896 Preston White Drive, Reston, VA 22090.

4. California Administrative Code, Title 25, available from the State of California, Documents Section, P.O. Box 1015, North Highlands, CA 95660.

• The AC connection system uses a GROUNDED neutral. A separate green ground wire is connected to the recreational vehicle’s junction box.

• For this unit, each stator winding can support 120volt, 60-Hertz, AC electrical output (3,600 rpm). When the two stator windings are connected in series, the unit can generate an output of 240 volts AC.

NOTE:

Do NOT connect loads in excess of circuit breaker ratings.

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Guardian QUIETPACT 85D Owner's Manual And Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual