Generac Welding System 005411 0 User Manual

Models:

005411-0, 005413-0, 005415-0, 005751-0,

005752-0, 005753-0, 005855-0, 005856-0,

005857-0

Owner's Manual

Air-cooled Recreational

Vehicle Generators

RV 45, 55 and 65

www.generac.com or 1-888-GENERAC

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Introduction

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.

INTRODUCTION

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the near-

est 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 care-

lessly. Observe them carefully. Their definitions are as follows:

CONTENTS

This manual contains pertinent owner’s information, including

warranty, electrical diagrams, exploded views and lists of repair

parts. In addition, the latter portion of this manual contains infor-

mation necessary for the proper installation of these generators.

After this heading, read instructions that, if not

strictly complied with, will result in personal

injury, including death, and property damage.

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 workman-

ship within the terms of the warranty. Individual operating habits

and usage contribute to the need for maintenance service.

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.

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 acces-

sories.

NOTE:

After this heading, read explanatory statements that require

special emphasis.

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.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliance with the special

instructions while performing the service are essential to prevent-

ing accidents.

When contacting an Authorized Service Dealer about parts and

service, always supply the complete model number and serial

number of the unit as given on its data decal, which is located on

the generator.

Four commonly used safety symbols accompany the Danger,

Warning and Caution blocks. The type of information each indi-

cates follows:

n^{This symbol points out important safety}

information that, if not followed, could

endanger personal safety and/or property of

others.

Model No. _________________ Serial No.______________

This symbol points out potential explosion

hazard.

^

Authorized SERVICE

DEALER LOCATION

To locate the nearest AUTHORIZED SERVICE

DEALER, please call this number:

^{This symbol points out potential fire hazard.}

^{This symbol points out potential electrical}

shock hazard.

1-800-333-1322

ONLY DEALER LOCATION INFORMATION

CAN BE OBTAINED AT THIS NUMBER.

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Safety Rules

n^{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 reli-

ably only if it is properly installed, operated and maintained. Many

accidents are caused by failing to follow simple and fundamental

rules or precautions.

GENERAL HAZARDS

• For safety reasons, the manufacturer recommends that the

installation, initial start-up and maintenance of this equipment

is carried out by an Authorized Service Dealer.

• The generator engine releases DEADLY carbon monoxide gas

through its exhaust system. This dangerous gas, if breathed

in sufficient concentrations, can cause unconsciousness or

even death. Never operate the generator set with the vehicle

inside any garage or other enclosed area. Shut down the

generator and do not operate it until it has been inspected

and repaired.

The manufacturer cannot anticipate every possible circumstance

that might involve a hazard. The warnings in this manual, and on

tags and decals affixed to the unit, are, therefore, not all-inclusive.

If using a procedure, work method or operating technique the

manufacturer does not specifically recommend, ensure that it is

safe for others. Also make sure the procedure, work method or

operating technique that chosen does not render the generator

unsafe.

• 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) dizzi-

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

EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO

FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET

MEDICAL HELP.

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

the vehicle has a working carbon monoxide detector. The

exhaust system must be installed in accordance with the

genset installation manual. Make sure there is ample fresh

air when operating the genset in a confined area.

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

and other moving or hot parts. Never remove any drive belt or

fan guard while the unit is operating.

• Adequate, unobstructed flow of cooling and ventilating air is

critical to correct generator operation and is required to expel

toxic fumes and fuel vapors from the generator compartment.

Without sufficient cooling airflow, the engine/generator quickly

overheats, which causes serious damage to the generator. Do

not alter the installation or permit even partial blockage of ven-

tilation provisions, as this can seriously affect safe operation of

the generator.

n^{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 respon-

sible 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.

n^{Parts of the generator are rotating and/or hot}

during operation. Exercise care near running

generators.

• 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.

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.

• 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 dan-

gerous operating conditions from leaking exhaust gases, fuel

leakage, oil leakage, etc.

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.

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Safety Rules

ELECTRICAL HAZARDS

FIRE 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 bar-

riers 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 conduc-

tor. 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 mainte-

nance. If the grounding conductor must be replaced, use only a

flexible conductor that is of No. 8 American Wire Gauge (AWG)

copper wire minimum.

• 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 noth-

ing 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 elec-

trical 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.

• In case of accident caused by electric shock, immediately

shut down the source of electrical power. If this is not pos-

sible, 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.

EXPLOSION HAZARDS

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

spills immediately. Ensure that no combustible materials are left

in the generator compartment, or on or near the generator, as

FIRE or EXPLOSION may result. Keep the area surrounding the

generator clean and free from debris.

• Gasoline is extremely FLAMMABLE and its vapors are

EXPLOSIVE. Do not permit smoking, open flame, sparks or any

source of heat in the vicinity while handling gasoline. Comply

with all laws governing the storage and handling of gasoline.

• This generator may use liquid propane (LP) gas as a fuel. LP

gas is highly EXPLOSIVE. The gas is heavier than air and tends

to settle in low areas where even the slightest spark can ignite

the gas and cause an explosion.

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General Information

1.1 GENERATOR IDENTIFICATION

Please record the following information from the generator DATA DECAL or information decal.

1. Model Number ____________________

3. kW Rating _________________________

5. Phase _____________________________

2. Serial Number _________________

4. Rated Voltage _________________

6. Hertz __________________________

10, 17 3 4 5

12 11

9, 17

REFERENCE NUMBER IDENTIFICATION

1. Generator Air Intake

2. Data Plate

3. Engine Start/Stop Switch

4. 7.5 amp Fuse

10. Fuel Pump

11. Oil Filter

12. Oil Drain Plug

13. Oil Dipstick and Filler Tube

14. Air Filter (Behind access panel.)

15. Spark Plugs

16. Exhaust Outlet

17. Fuel Filter

18. Evaporative Port

5. Circuit Breaker

6. Optional Remote Panel Receptacle

7. Generator AC Output Leads

8. Starter Contactor

9. Fuel Inlet

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General Information

1.2 GENERATOR APPLICABILITY

These generators have been designed and manufactured for sup-

plying electrical power for recreational vehicles. DO NOT modify

the generator or use it for any application other than for what it

was designed. If there are any questions pertaining to its applica-

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

competent authority.

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 recommenda-

tions for installing the unit into an industrial vehicle. After installa-

tion, installers should forward the Installation Manual to Owners/

Operators for their information.

^{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.

Owners/Operators have the responsibility to make sure that noth-

ing is done that might render the installation unsafe or in non-

compliance 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 manu-

facturer suggests copying and posting the GENERAL SAFETY

RULES to potential operators of this equipment.

Use the generator set to supply electrical power for operating one

of the following electrical loads:

• RV 45 G: 120 and/or 240 volts, single phase, 60 Hz electrical

loads. These loads can require up to 4500 watts (4.5 kW) of

total power, but cannot exceed 37.5 AC amperes of current at

120 volts (breaker is limited to 30 Amps).

• RV 55 G: 120 and/or 240 volts, single phase, 60 Hz electrical

loads. These loads can require up to 5500 watts (5.5 kW) of

total power, but cannot exceed 45.8 AC amperes of current at

120 volts or exceed 22.9 AC amperes at 240 volts.

• RV 65 G: 120 and/or 240 volts, single phase, 60 Hz electrical

loads. These loads can require up to 6500 watts (6.5 kW) of

total power, but cannot exceed 54.1 AC amperes of current at

120 volts or exceed 27 AC amperes at 240 volts.

1.5 GENERATOR AC CONNECTION

SYSTEM

These air-cooled generator sets are equipped with dual stator

AC power windings. These two stator windings supply electrical

power to customer electrical loads by means of a dual 2-wire

connection system.

Generators may be installed to provide the following outputs:

1. 120 VAC loads only — two loads, each with a maximum

total wattage requirement equal to half of the generator’s

rated power output (in watts), and 120V across the generator

output terminals. Figure 1.1 shows the generator lead wire

connections for 120VAC ONLY.

Do not overload the generator. Some instal-

lations may require that electrical loads be

nꢀ

Figure 1.1 – Connection for 120 Volts Only

alternated to avoid overloading. Applying

excessively high electrical loads may dam-

age 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 watt-

age capacity of the generator. If an electri-

cal device nameplate gives only volts and

amps, multiply volts times amps to obtain

watts (volts x amps = watts). Some elec-

tric motors require more watts of power (or

amps of current) for starting than for con-

tinuous operation.

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General Information

2. 120/240 VAC loads — one load with a maximum total watt-

age requirement equal to the generator’s rated power output,

and 240V across the generator output terminals; or two sepa-

rate 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.

NOTE

Some installations using a “shared” fuel tank may have a gen-

erator 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.

This procedure should be done by an Authorized Service Dealer or

other qualified installer.

NOTE:

Using unleaded gasoline contributes to longer engine valve life by

reducing lead and carbon deposits.

Figure 1.2 - Connection for 120/240 Volts

RED

CB1

n^{The manufacturer does not recommend}

using any gasoline containing alcohol (such

as “gasohol”). If using any gasoline contain-

ing alcohol, it must not contain more than

10 percent ethanol (Do not use E85), and it

must be removed from the generator during

storage. Do NOT use any gasoline contain-

ing methanol. If using gasoline with alcohol,

inspect more frequently for fuel leaks and

other abnormalities.

WHITE

1.6.2 ENGINE OIL REQUIREMENTS

All oil should meet minimum American Petroleum Institute (API)

Service Class SJ, SL or better. Use no special additives. Select the

oil's viscosity grade according to the expected operating tempera-

ture (also see chart).

CB2

BLACK

GROUNDED NEUTRAL

STATOR POWER

WINDINGS

• SAE 30 Î Above 32° F

• 10W-30 Î Between 40° F and -10° F

• Synthetic 5W-30 Î 10° F and below

1.6 SPECIFICATIONS

1.6.1 FUEL REQUIREMENTS (GASOLINE)

SAE 30

This generator is equipped with a gasoline fuel system as standard

equipment. Specific installations may provide either a separate fuel

tank for the generator, or the generator may “share” the vehicle

engine’s fuel tank.

10W-30

Syntthetiic 5W-30

1.6.1.1 Fuel Consumption (gph)

Model

RV45G

RV55G

RV65G

10% Load

50% Load

100% Load

.33

.35

.37

.45

.55

.65

.73

.89

.97

Crankcase and oil filter capacity is approximately 1.4 L or 1.5 U.S.

quarts. DO NOT use special additives. See sections "Checking the

Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter" for

oil level check and filling procedures.

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General Information

1.6.3 GENERATOR SPECIFICATIONS

SERIES

RV45G

3600

RV55G

3600

RV65G

3600

Rotor RPM

Rotor Poles

Engine RPM

2571

Rated Max. Continuous AC Output Watts*

4500

5500

6500

Voltage*

120

Rated Max. Continuous Current Amps (240V)

37.5 (18.7)

45.8 (22.9)

54.1 (27)

Phase

Frequency

Weight

Length

Width

60 Hertz

278 lbs.

33.7 in.

21.5 in.

16.8 in.

60 Hertz

285 lbs.

33.7 in.

21.5 in.

16.8 in.

60 Hertz

293 lbs.

33.7 in.

21.5 in.

16.8 in.

Height

All units are re-connectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output

** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambient temperature, altitude, engine condition, etc.. Maximum power

decreases about 3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16° C (60° F) ambient temperature.

• 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)

1.6.4 ENGINE SPECIFICATIONS

Type of Engine........................................................................GT-530

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

Rated Horsepower ...................................................18 at 3600 rpm

Displacement........................................................................... 530cc

Compression Ratio................................................................8.5 to 1

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

Type of Governor.......................................Electronic, Fixed Speed

Engine Governor Speed................................................... 2571 rpm

Air Cleaner................................................................. Paper Element

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

Ignition System ............................ Solid-state w/Flywheel Magneto

Recommended Spark Plug

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 com-

pliance period for this generator. The displacement of the engine is

listed on the Emissions Compliance Label.

NGK....................................................................................BPR6HS

Spark Plug Gap ............................................. 0.030 inch (0.76 mm)

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

Class II Emission Certified

Displacement

Category

Compliance Period

500 Hours

1.7 EXHAUST EMISSIONS

INFORMATION (GASOLINE)

> 66 cc - < 225 cc

250 Hours

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 mainte-

nance 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:

125 HOurs

1000 Hours

500 Hours

≥ 225 cc

250 Hours

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Operation

Figure 2.1 – Typical Control Panel

1.8 EVAPORATIVE EMISSIONS

INFORMATION

This generator is subject to evaporative emission standards which

have been implemented by the California Air Resource Board

(CARB) and the Environmental Protection Agency (EPA). If this

generator is offered for sale in the state of California, it must be

covered by a CARB evaporative Executive Order. If this generator

is offered for sale to the final consumer in any other state, certified

low-permeation fuel line must be used to supply fuel to the genera-

tor 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 repu-

table fuel system manufacturer to purchase a complete fuel sys-

tem 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.

The switch center position is the RUN position.

To stop a running engine, press momentarily the bottom half of the

switch to kill the ignition.

2.1.2 7.5 AMP FUSE

The fuse protects the engine’s DC control circuit against electrical

overload. If the fuse element has melted open due to overloading,

the engine cannot be cranked. If the fuse must be replaced, use

only an identical 7.5 amp replacement fuse.

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-per-

meation 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.

2.1.3 LINE BREAKERS

Protects generator’s AC output circuit against overload, i.e., pre-

vents unit from exceeding wattage/amperage capacity. The circuit

breaker ratings are as follows:

2.1 GENERATOR CONTROL PANEL

The following features are mounted on the generator control panel

(Figure 2.1):

Model

RV45

RV55

RV65

Cir. Breaker 1

Cir. Breaker 2

240 Volt

N/A

30A

20A

30A

N/A

30A

25A 2P

30A 2P

2.1.1 START/STOP SWITCH

This generator is started with a "One Touch" starting sequence.

Push up on the top half of the momentary switch. Hold for one

(1) second and release. Note flashing indicator light on the switch.

Fuel pump engages automatically for a three (3) to five (5) second

delay before starter motor cranks the engine for 16 seconds or

until the engine starts. If the engine does not start, the starter

will cool for seven (7) seconds and crank the engine again for 16

seconds. If the engine does not start, the starter will cool for seven

(7) seconds before cranking for seven (7) seconds to a maximum

cycle total of 90 seconds. Once started, the light on the switch

stays on continuously. If the generator does not start at the end

of the start sequence, a fault code will flash on the switch (see

Diagnostics).

NOTE:

If this generator has been reconnected for dual voltage AC out-

put (120/240 volts), install line breakers having an amperage

rating equal to that stated in the preceding chart. The replace-

ment 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 recon-

nected for dual voltage, it is no longer RVIA listed.

The switch center position is the RUN position.

To stop a running engine, press momentarily the bottom half of the

switch to kill the ignition.

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Operation

2.1.4 DIAGNOSTICS

2.3.2 PRECHOKE

If the generator shuts down due to a fault, the indicator will flash a

code to identify the problem.

The choke system also has a temperature-sensitive metal strip that

adjusts choke valve angle according to ambient temperatures (i.e.,

in cold ambient temperatures, choke valve closes more). Once the

engine starts, an element heats the temperature-sensitive strip to

a normal operating condition, opening the choke valve. This may

take about three minutes in cooler weather (Gasoline only.).

• 2 Flashes = Low Battery (Voltage falls below 11.0 VDC for one

minute)

NOTE:

Alarm will clear automatically if voltage rises over 11.0 VDC.

Battery voltage is not monitored during crank cycle.

2.4 BEFORE STARTING THE

• 3 Flashes = Overcrank (Unit does not start through entire start

ENGINE

cycle)

NOTE:

• 4 Flashes = Overspeed (Alternator spins at 4200 rpm/72 Hz

or greater)

Instructions and information in this manual assume the genera-

tor has been properly installed, connected, serviced, tested and

adjusted by a qualified installation technician or installation

contractor.

• 5 Flashes = Low Oil Pressure (Drops below the 5 psi threshold

of the switch)

NOTE:

There is a five second delay of the alarm when the engine is

first started up.

2.4.1 INSTALLATION

Generator installation must have been properly completed so it

complies with all applicable codes, standards and regulations

and with the manufacturer's recommendations. (See Part II -

Installation Instructions.)

• 6 Flashes = High Oil Temperature (Unit shuts down when tem-

perature switch limit is reached)

NOTE:

2.4.2 ENGINE LUBRICATION

As the unit cools down it will attempt to restart automatically

when the temperature switch opens again.

Have the engine crankcase properly serviced with the recommend-

ed 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.

• 7 Flashes = Underspeed (Alternator spins less than 3240

rpm/54 Hz for three (3) seconds)

NOTE:

After a fault is indicated, press stop momentarily to clear the

alarm once the problem is fixed.

n^{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.

2.2 OPTIONAL REMOTE

START/STOP PANEL

A remote mounted Start/Stop Panel is available that allows start-

ing and stopping the generator engine conveniently from inside the

vehicle. The remote panel includes a Start/Stop switch, hourmeter,

generator run lamp, and a wire harness.

2.4.3 FUEL SUPPLY

The engine must have an adequate supply of proper fuel to oper-

ate. 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.

2.3 AUTOMATIC CHOKE

This engine is equipped with an automatic choke that consists of

two main components: a choke solenoid and prechoke (Gasoline

only.).

2.4.4 COOLING AND VENTILATING AIR

2.3.1 CHOKE SOLENOID

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.

During engine cranking (Start/Stop switch at START), a solid-state

choke module signals the choke solenoid to activate and cycle

(choke on/choke off) until the engine starts. The choke solenoid

thus opens and closes the carburetor choke valve only when

the engine is cranking. When the engine starts, the choke stops

cycling (Gasoline only.).

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Operation

NOTE:

2.4.5 ENGINE EXHAUST GAS

If starting from the generator control panel, turn OFF loads

by setting the generator’s main circuit breaker to the OFF (or

open) position. If starting from a remote panel, turn OFF loads

using the means provided in the vehicle (such as a main circuit

breaker). Electrical load circuits should be turned ON after the

generator has started, stabilized and warmed up.

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.

2. To crank and start the engine, push up on the Start/Stop

switch momentarily and release. There is a delay as the fuel

pump primes and the generator automatically begins the start

sequence (Note the flashing light on the switch.).

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

warm up.

The generator engine releases DEADLY

carbon monoxide gas through its exhaust

system. This dangerous gas, if breathed in

sufficient concentrations, can cause uncon-

sciousness 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

4. Turn ON electrical loads using the means provided (such as a

main circuit breaker or transfer switch).

DAMAGED. Shut down the generator and

do not operate it until it has been inspected

and repaired. SYMPTOMS OF CARBON

MONOXIDE POISONING ARE (a) inability to

think coherently, (b) nausea, (c) vomiting, (d)

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

dizziness, (g) headaches, (h) weakness, and

(i) sleepiness. IF EXPERIENCING ANY OF

THESE SYMPTOMS, MOVE INTO FRESH AIR

IMMEDIATELY. IF SYMPTOMS PERSIST, GET

MEDICAL HELP.

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:

n^{Never sleep in the vehicle while the genset}

is running unless the vehicle has a working

• Before applying electrical loads, let the generator stabilize and

warm up for a minute or two.

• DO NOT overload the generator.

carbon monoxide detector. The exhaust sys-

tem 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.

2.7.1 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 appli-

ances.

2.5 STARTING THE GENERATOR

NOTE:

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.

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.

2.7.2 DO NOT OVERLOAD THE GENERATOR

Read the rated wattage/amperage capacity of the generator on the

generator data label (See the "Generator Identification" section.).

To crank and start the generator engine, proceed as follows:

Applying electrical loads in excess of the unit’s rated capacity will

cause the engine/generator to automatically shut down.

1. Turn OFF electrical loads using the means provided in the

vehicle (such as a main line circuit breaker or transfer

switch).

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.

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Operation

• Most lighting, appliance, tool and motor loads indicate their

required watts on their nameplate or data plate. For light bulbs,

simply note the wattage rating of the bulb.

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 compo-

nents are part of a “field boost” circuit (Figure 2.3). During engine

cranking only, a positive DC (battery) voltage is delivered through

a diode, resistor, brushes, slip rings, and the generator rotor.

Application of this voltage to the rotor “flashes the field” whenever

it is started. Flashing of the field each time the generator starts

makes sure that a sufficiently strong magnetic field is available to

produce “pickup” voltage in the stator windings.

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

rated VOLTS times AMPS to obtain WATTS.

• Induction type motors (such as those that run the vehicle’s

furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2

times more watts of power for starting than for running (for a

few seconds during motor starting). Be sure to allow for this

when connecting electrical loads to the generator. First, figure

the watts needed to start electric motors in the system. To that

figure, add the running wattages of other items that will be oper-

ated by the generator.

Figure 2.3 – Field Boost Circuit

• Do not apply heavy electrical loads for the first two or three

hours of operation.

2.8 PROTECTION SYSTEMS

2.8.1 LOW OIL PRESSURE SWITCH

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

are held open by engine oil pressure during cranking and operat-

ing. Should oil pressure drop below a preset level, switch contacts

close, and the engine automatically shuts down. The unit should

not be restarted until oil is added.

2.8.2 HIGH TEMPERATURE SWITCH

This switch (Figure 2.2), which has normally open (N.O.) contacts,

is mounted near the oil filter. The contacts close if the temperature

should exceed approximately 270º F (132º C) for gasoline mod-

els.

2.8.4 OVERVOLTAGE PROTECTION

A solid-state voltage regulator (Figure 2.4) controls the generator’s

AC output voltage. This regulator supplies an excitation current to

the rotor. By regulating the rotor’s excitation current, the strength

of its magnetic field is regulated and, in turn, the voltage delivered

to connected electrical loads is controlled. When the AC frequency

is 60 Hertz, voltage is regulated at 125 to 120 volts.

Figure 2.2 – Low Oil Pressure and

High Temperature Switches

Figure 2.4 – Solid State Voltage Regulator

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Maintenance

2.8.5 OPERATION IN HIGH GRASS OR BRUSH

3.2 CHANGING THE ENGINE OIL

AND/OR OIL FILTER

^{Never operate the generator while the vehicle}

is parked over high grass, weeds, brush,

n^{Hot oil may cause burns. Allow engine to}

cool before draining oil. Avoid prolonged

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 dur-

ing operation and remains hot for a long time

after it has shut down.

or repeated skin exposure with used oil.

Thoroughly wash exposed areas with soap.

Oil Change Intervals – see Section “RV Generator Service

Interval”.

To change the oil and oil filter, proceed as follows:

3.1 CHECKING THE ENGINE OIL

1. Run the engine until it is thoroughly warmed up (at least five

minutes) then shut off the engine.

2. With the engine still warm from running, remove the round

access grommet from underneath the front of the generator.

Place a suitable container underneath to catch all the drain

oil.

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.

3. Use the 0G4818 tool (supplied with the generator) to turn the

old filter counter-clockwise and remove. Let oil drain into the

container located directly below.

4. Locate the oil drain hose inside and pull the yellow drain plug

out of the access hole (Figure 3.1).

5. Turn the yellow cap counter-clockwise to remove and finish

draining the old oil.

6. After the oil has been drained, replace the oil drain plug by

tightening it clockwise and return.

7. Clean off the oil filter bracket and any old oil that may have

spilled while draining.

n^{Never operate the engine with the oil level}

below the “Add” mark on the dipstick. Doing

8. Apply a light coating of clean engine oil the gasket of the new

oil filter (Figure 3.2).

this could damage the engine.

9. Screw the new oil filter on by hand until its gasket lightly con-

tacts the oil filter adapter. Then, tighten the filter an additional

¾ to one turn. Replace and secure the round access grom-

met.

5. Install and tighten the oil fill cap and the dipstick before oper-

ating the engine.

Figure 3.1 — Oil Dipstick/Fill Tube and

Location of Oil Drain Plug

Figure 3.2 — Engine Oil Filter

Engine

Oil Filter

Oil Fill

Oil Drain Hose

Oil Dipstick

Twist Counter-clockwise to Loosen

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Maintenance

10. Remove the dipstick, valve cover plug and add new oil (see

3.4 CHECKING THE ENGINE

“Engine Oil Requirements”) to engine. DO NOT FILL ABOVE

SPARK PLUG

THE “FULL” MARK.

Reset the spark plug gap or replace the spark plugs as necessary.

See the Service Schedule section for maintenance requirements.

11. Install and tighten plug and dipstick before starting the

engine.

12. Start engine and check for leaks.

1. Clean the area around the base of the spark plugs to keep dirt

and debris out of the engine.

NOTE:

2. Remove the spark plugs and check the condition. Replace the

spark plugs if worn or if reuse is questionable. See the Service

Schedule section for recommended interval. Clean by scrap-

ing or washing using a wire brush and commercial solvent.

Do not blast the spark plugs to clean.

3. Check the spark plug gap using a wire feeler gauge. Adjust the

gap to 0.76mm (0.030 inch) by carefully bending the ground

electrode if necessary (Figure 3.4).

Check the oil level and fill to the “FULL” mark after checking for

leaks. The filter will retain some oil.

3.3 MAINTAINING THE ENGINE

AIR CLEANER

Replace the paper air filter element after every 200 hours of opera-

tion. (Perform more often when operating in dusty conditions)

1. At the Air Cleaner Cover, turn the yellow plastic knob ¼ turn

counter-clockwise.

Figure 3.4 – Setting the Spark Plug Gap

2. Pull the top of the Cover out as it hinges on the bottom of the

Air Cleaner Base.

3. Separate the Cover by lifting up and out from the Base.

4. Pull the old filter out and discard safely.

5. Install the new filter in place on the Air Cleaner Base (Figure

3.3).

6. Interlock the Air Cleaner Cover to hinge with the Air Cleaner

Base.

7. Align the Cover and gently push the top closed.

8. Engage the yellow plastic knob and turn ¼ turn clockwise to

secure.

n^{Sparking can occur if the wire terminal does}

not fit firmly on the spark plug terminal end.

If necessary, re-form the wire terminal to

obtain a tight fit.

Figure 3.3 – Engine Air Cleaner

Air Cleaner Base

3.5 FUEL FILTER (GASOLINE ONLY)

Remove and replace the fuel filter (Figure 3.5) every 400 hours of

operation.

Air Cleaner

Figure 3.5 – Fuel Filter

Knob

FUEL FILTER

TO FUEL PUMP

Air Cleaner Cover

CUSTOMER FUEL CONNECTION

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Maintenance

3.6 CLEAN SPARK ARRESTOR

The engine exhaust muffler has a spark arrestor screen. Inspect and

clean the screen every 200 hours of operation or once each year,

whichever comes first.

n^{Do NOT use a forceful spray of water to}

clean the generator. Water will enter the gen-

erator interior and cause problems, and may

also contaminate the generator fuel system.

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 condi-

tion by the owner/operator.

3.8 BATTERY MAINTENANCE

NOTE:

This generator is not equipped with an internal battery charger.

It is intended for use in systems where an external battery char-

ger is installed by the RV O.E.M. or an aftermarket installer.

Clean and inspect the spark arrestor as follows:

• Remove the screen by removing the screw.

• Slide the spark arrestor screen out from the tail pipe.

• Inspect screen and replace if torn, perforated or otherwise

damaged. DO NOT USE a defective screen. If screen is not

damaged, clean it with commercial solvent.

All lead-acid batteries will discharge when not in use. The generator

battery should be inspected as follows:

3.8.1 WEEKLY

• Replace the screen and the screw.

• Inspect the battery posts and cables for tightness and corro-

sion. Tighten and clean as necessary.

Figure 3.6 - Spark Arrestor

• 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.

TAILPIPE

P/N 0G5857

NOTE:

Servicing of the battery is to be performed or supervised by

personnel knowledgeable of batteries and the required precau-

tions. Keep unauthorized personnel away from batteries.

SPARK ARRRESTOR

SCREEN P/N 089680

Damage will result if the battery connections are made in

reverse.

RETAINING

SCREW P/N 056892

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

battery is capable of exploding. Storage bat-

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.

teries 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.

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.

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Maintenance

^{A battery presents a risk of electrical shock}

and high short circuit current. The following

precautions are to be observed when work-

ing on batteries:

• 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.

• 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;

To adjust valve clearance (if necessary):

• 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.

• 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).

Do not open or mutilate the battery.

Released electrolyte has been known to

nꢀ

be harmful to the skin and eyes, and to be

toxic.

Figure 3.7 - Valve Clearance Adjustment

The electrolyte is a dilute sulfuric acid that

is harmful to the skin and eyes. It is electri-

nꢀ

Rocker

Arm

cally conductive and corrosive. The follow-

ing procedures are to be observed:

Pivot Ball

Stud

Jam Nut

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

Valve

Stem

• 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 (foam-

ing) has ceased. The resulting liquid is to be

flushed with water and the area dried.

NOTE:

3.9 ADJUSTING VALVE CLEARANCE

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

turned.

After the first 50 hours of operation, check the valve clearance

in the engine, adjust if necessary.

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.

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.

• Install new valve cover gasket.

• Re-attach the valve cover.

NOTE:

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.

Start all four screws before tightening or it will not be possible

to get all the screws in place. Make sure the valve cover gasket

is in place.

• Install spark plugs.

• Re-attach the spark plug wire to the spark plug.

• On the GT-530, repeat the process for the other cylinder.

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Maintenance

3.13.2 RETURN TO SERVICE

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

3.10 MAJOR SERVICE MANUAL

To obtain a service manual for the generator, contact the near-

est Authorized Service Dealer. Make sure to identify the MODEL

NUMBER and SERIES.

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 batter-

ies 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.

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.

4. Reconnect the battery. Observe battery polarity. Damage may

3.12 EXERCISING THE GENERATOR

The manufacturer recommends starting and operating the genera-

tor at least once every seven days. Let the unit run for at least 30

minutes to “exercise” the engine.

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

3.13 OUT OF SERVICE PROCEDURE

wattage capacity.

8. When the engine is thoroughly warmed up, shut it down.

9. The generator is now ready for service.

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:

3.14 RV GENERATOR SERVICE

INTERVAL

1. Start the engine and let it warm up.

1st 8 Hours,

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

then every 200 Hours......................... Change Engine Oil/Filter

1st 50 Hours,

the unit to shut down.

3. While the engine is still warm from running, drain the oil

completely. Refill the crankcase with SAE 5W-30 oil having

API classification “For Service SJ/SL.”

then every 500 Hours.................................. Adjust Valve Lash

200 Hours ..................................................Clean Spark Arrestor

200 Hours .................................Replace Paper Air Filter Element

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

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

4. Attach a tag to the engine indicating the viscosity and clas-

sification of the oil in the crankcase.

5. Remove the spark plug and pour two or three tablespoons of

clean, fresh engine oil into the spark plug threaded openings.

Reinstall and tighten the spark plug.

6. Remove the battery and store it in a cool, dry room on a

wooden board. Never store the battery on any concrete or

earthen floor.

7. Clean and wipe the entire generator.

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Part II - Installation Instructions

Part II –

Installation

Instructions

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!

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Safety Rules

n^{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 man-

ufacturer’s instructions and recommendations.

NOTICE TO INSTALLER

GENERAL HAZARDS

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.

• For safety reasons, the manufacturer recommends that the

installation, initial start-up and maintenance of this equipment

is carried out by an Authorized Service Dealer.

• The generator engine releases DEADLY carbon monoxide gas

through its exhaust system. This dangerous gas, if breathed

in sufficient concentrations, can cause unconsciousness or

even death. Never operate the generator set with the vehicle

inside any garage or other enclosed area. Shut down the

generator and do not operate it until it has been inspected

and repaired.

The manufacturer cannot possibly know of and advise the rec-

reational vehicle trade of all conceivable methods, procedures or

techniques by which to perform an installation. Nor can the manu-

facturer anticipate every possible hazard that might result from

each installation method, procedure or technique. The manufactur-

er 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, proce-

dure or technique selected.

• 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) dizzi-

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

EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO

FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET

MEDICAL HELP.

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

the vehicle has a working carbon monoxide detector. The

exhaust system must be installed in accordance with the

genset installation manual. Make sure there is ample fresh

air when operating the genset in a confined area.

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

and other moving or hot parts. Never remove any drive belt or

fan guard while the unit is operating.

Information, illustrations, specifications, etc., contained in these

Installation Instructions are based on the latest information avail-

able 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.

• 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 ven-

tilation provisions, as this can seriously affect safe operation of

the generator.

• When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally

fatigued.

• Before performing any maintenance on the generator, discon-

nect its battery cables to prevent accidental start up. Disconnect

the cable from the battery post indicated by a NEGATIVE, NEG

or (–) first. Reconnect that cable last.

n^{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.

n^{Parts of the generator are rotating and/or hot}

during operation. Exercise care near running

generators.

• 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 dan-

gerous 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.

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Safety Rules

ELECTRICAL HAZARDS

FIRE 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 bar-

riers are in place before operating the generator. If work must

be done around an operating unit, stand on an insulated, dry

surface to reduce shock hazard.

• Do not handle any kind of electrical device while stand-

ing in water, while barefoot, or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• During installation onto the vehicle, properly ground (bond) the

generator either by solid mounting to the vehicle frame or chas-

sis, 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.

• 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 noth-

ing 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 extin-

guishers, consult the local fire department.

• 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 conduc-

tor. If the victim is unconscious, apply first aid and get immediate

medical help.

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.

• GasolineisextremelyFLAMMABLEanditsvaporsareEXPLOSIVE.

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.

• 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.

• 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.

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General Information

1.1 PURPOSE AND SCOPE OF THE

1.4 EQUIPMENT DESCRIPTION

Instructions and information in this section pertain to air-cooled

generators. These generators are designed specifically for install-

ing in recreational vehicles. They operate 120-volt, single-phase,

60-Hertz, AC electrical loads.

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 seri-

ous consideration to all information and instructions in the manual,

both for safety and for continued reliable operation of the equip-

ment.

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 oper-

ating at 3,600 rpm. The drive belt arrangement allows the engine to

operate at a lower speed than the rotor.

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.

1.6 GENERATOR AC

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.

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:

1.2 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. 120 VAC loads only — two loads each, with a maximum total

wattage requirement equal to half of the generator’s rated

power output (in watts), and 120V across the generator out-

put terminals (see Fig. 1.1).

2. 120/240 VAC loads — one load with a maximum total wattage

requirement equal to the generator’s rated power output, and

240V across the generator output terminals; or two separate

loads, each with a maximum total wattage requirement equal

to half of the generator’s rated power output (in watts), and

120V across the generator output terminals (see Fig. 1.3).

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 revi-

sion) are available from the sources indicated:

Figure 1.1 – Connection for 120 Volts Only

1. NFPA Standard 501C, “Standard for Recreational Vehicles,”

available from the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

2. NFPA 70, “NFPA Handbook of the National Electric Code,”

available same as Item 1.

3. ANSI C1-1975 and ANSI 119.2-1975, available from the

American National Standards Institute, 1430 Broadway, New

York, NY 10018.

4. ANSI A119.2/RVIA EGS-1, available from the Recreational

Vehicle Association, 1896 Preston White Drive, Reston, VA

22090.

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

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

Highlands, CA 95660.

6. CSA Electrical Bulletin 946, available from the Canadian

Standards Association, Housing and Constructions Materials

Section, 178 Rexdale Boulevard, Rexdale, Ontario, Canada,

M9W 1R3.

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Installation

Figure 1.2 - Major Features and Dimensions (Drawing No. 0G5519-D)

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Installation

• The location must provide sufficient room to allow minimum

clearances as outlined in "Generator Compartments". If sound

insulation is to be used on the compartment walls and ceiling,

the minimum recommended applies to the space between the

generator and such insulation.

Figure 1.3 - Connection for 120/240 Volts

RED

CB1

• 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.

WHITE

2.1.2 GENERATOR SUPPORT

CB2

BLACK

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.

GROUNDED NEUTRAL

STATOR POWER

WINDINGS

• The AC connection system on air-cooled generators uses a

GROUNDED neutral.

• A separate green ground wire is connected to the recreational

vehicle’s junction box.

• Total load connected across T1 (Red) to T2 (White), and T3

(Black) to T2 (White), must not exceed rating for the specific

generator (see "Generator Specifications").

NOTE:

Figure 2.1 – Typical Horizontal Support Frame

Do NOT connect loads in excess of circuit breaker ratings.

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.

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 fol-

lowing general rules apply:

Many recreational vehicles have been factory equipped with an

area for the generator set. Some vehicles may even have a genera-

tor compartment provided by the vehicle manufacturer.

• 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.

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.

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Installation

2.1.3 SUSPENDED MOUNTING

2.2 GENERATOR COMPARTMENTS

Whether the generator set is being installed inside a compartment

specifically manufactured to house a generator or inside a compart-

ment that the installer constructs, the compartment MUST meet

certain specifications as outlined in the following sections:

If planning to suspend the generator below the horizontal sup-

port 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, keep-

ing the following general rules in mind:

2.2.1

COMPARTMENT SIZE

Plan the compartment size carefully. Provide a minimum clearance

of 1/2 inch (13 mm) on the front top, sides, and from the back for

air circulation AFTER the compartment has been lined with metal

and sound insulation (Figure 2.4).

• 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.

NOTE:

Refer to “Figure 1.2 – Major Features and Dimensions”.

Figure 2.2 – Typical Suspended Mounting System

Figure 2.4 – Clearances

Plywood

Compartment

1/2" Clearance on Top

1/2" Clearance

in Back

1/2" Each Side

• The installer must make certain that the selected location will

permit adequate cooling and ventilating airflow to be supplied.

1/2"

Insulation

in Front

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 support-

ing framework (Figure 2.3). All bolts must be long enough so that

when tight, at least three threads are visible past the retaining lock

nuts. Refer to "Generator Compartments" for the location of the

generator mounting holes. Torque Bolts to 31 ft./lbs..

2.2.2 COMPARTMENT CONSTRUCTION

• The generator compartment should be either constructed of, or

lined with, 26-gauge galvanized steel.

NOTE:

Figure 2.3 – Typical Generator Restraint

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 poison-

ous, flammable or explosive vapors from entering the vehicle

interior.

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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 struc-

ture, may be sufficient to ignite, char or dis-

color seat cushions, fiberboard and other

flammable materials. Use approved nonflam-

mable insulating materials in high tempera-

ture areas.

2.2.3 SOUND INSULATING MATERIALS

NOTE:

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.

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 rub-

ber base sealant is recommended.

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.

• 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.

^{Do not install sound insulation or any absor-}

bent material on the compartment floor inte-

NOTE:

rior. Such materials will become soaked with

combustible or explosive vapors and liquids

and will become a fire hazard.

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.

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.

• 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".

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Installation

2.2.4 ACOUSTICS

2.2.5 COMPARTMENT FLOOR CUTOUTS

For additional noise abatement, the installer may wish to consider

the following:

Provide openings in the generator compartment for the following

items (Figure 2.9):

• Using special sound insulating materials.

• Construction of a special noise abatement compartment.

NOTE:

• Engine exhaust and cooling air outlets

• Generator cooling air inlet

• Four holes for passage of generator mounting bolts. See

"Generator Restraint".

Any method used to reduce noise must not adversely affect the

flow of cooling and ventilating air into or out of the compart-

ment.

n^{Fuel lines and exhaust piping must not pen-}

etrate into the vehicle living area.

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):

2.3 COOLING AND VENTILATING

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

ment.

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, ventilat-

ing and combustion. The installer also must provide for a path for

exhausting the cooling air to the exterior of a compartment, if so

equipped.

• 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".

^{To prevent fire or explosion, do not install}

any insulation or other absorbent materials

^{Never use discharged cooling air for heating}

or permit such air to enter the vehicle inte-

rior. This air contains deadly carbon monox-



ment floor.

ide gas and other poisonous, flammable or

explosive gases.

• Seal all compartment door edges to prevent noise leakage

around the door perimeter.

2.3.1 GENERATOR AIRFLOW

Figure 2.7 – Typical Noise Abatement

Engine operation drives cooling fans for the two-stage cooling

air system. A pressure fan draws cooling air into the top of the

generator (Figure 2.8). This airflow cools the engine/generator and

electronic components. The second part of the cooling system, a

suction fan, draws air that is heated from a hot engine into a col-

lector pan at the base of the unit. This heated air (although cooler

than exhaust muffler) is then deflected out the bottom toward the

ground.

Figure 2.8 – Airflow Through Engine/Generator

COOLING AIR IN

ENGINE AIR IN

COOLING

AIR OUT

• 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).

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Installation

Figure 2.9 — Compartment Floor Cutout (Drawing 0G4432-A)

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Installation

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.

6.3.2 TESTING THE INSTALLATION

The manufacturer recommends testing the installation to be sure

adequate cooling airflow is available to the unit before placing the

unit into service. If the unit shows signs of overheating, enlarge the

air openings. Never place a unit into service until absolutely certain

that cooling and ventilation is adequate.

Gasoline generators are equipped with an Evaporative Emissions

Port that may be used in conjunction with a certified fuel system

where required by law.

NOTE:

The installation must be tested, especially if bringing in air from

below the generator set.

n^{Do NOT tee the generator fuel supply line}

into the vehicle engine fuel supply line. If

2.4 GASOLINE FUEL SYSTEM

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 dif-

ficult to start the vehicle engine.

^{Gasoline is highly flammable, and its vapors}

are explosive. Comply with all codes, stan-

dards and regulations pertaining to gasoline



fuel systems used in recreational vehicle

generators. Properly install and maintain

the fuel system and keep it entirely free of

leaks. Gasoline vapors must not enter the

vehicle interior.

2.4.2 GENERATOR FUEL SUPPLY LINE

2.4.2.1 Rigid Fuel Lines

Those lines used to supply fuel from a tank to the generator must

comply with applicable codes, standards and regulations. The fol-

lowing general rules apply to rigid fuel lines:

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.

• Rigid lines should be of annealed, seamless, drawn aluminum

or steel.

Figure 2.10 – Generator Fuel System

• 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.

2.4.2.2 Flexible Fuel Line

a, b

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:

Factory installed generator fuel system components include (a)

fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and

(d) interconnecting lines and fittings, (e) evaporative port. Connect

a fuel supply line to the fuel filter inlet. Use a flexible length of

approved fuel hose between the fuel filter inlet connection and

rigid fuel lines.

• 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.

2.4.1 FUEL TANK

Either the generator must share the vehicle engine's fuel tank, or a

separate fuel tank for the generator set must be installed. All fuel

tanks installed on the vehicle must be constructed, installed and

restrained so they comply with applicable codes, standards and

regulations. The generator has an evaporative emissions port to

evacuate accumulated gasoline vapors when necessary.

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Installation

Figure 2.11 - Spark Arrestor

2.5 EXHAUST SYSTEM

The generator exhaust system must be safely and properly

installed. Only approved mufflers and other exhaust system parts

must be used. A properly installed exhaust system must be vapor

tight, quiet and completely safe.

TAILPIPE

P/N 0E0683

n^{The generator engine gives off DEADLY}

carbon monoxide gas through its exhaust

system. This dangerous gas, if breathed in

sufficient concentrations, can cause uncon-

sciousness or even death. Never operate

the generator set with the vehicle inside

any garage or other enclosed area. DO

NOT OPERATE THE GENERATOR IF THE

EXHAUST SYSTEM IS LEAKING OR HAS

BEEN DAMAGED. SYMPTOMS OF CARBON

MONOXIDE POISONING ARE (a) inability to

think coherently; (b) vomiting; (c) twitch-

ing muscles; (d) throbbing temples; (e)

dizziness; (f) headaches; (g) weakness;

and (h) sleepiness. IF FEELING ANY OF

THESE SYMPTOMS, MOVE INTO FRESH AIR

IMMEDIATELY. IF SYMPTOMS PERSIST, GET

MEDICAL HELP. Do not operate the generator

until its exhaust system has been inspected

and properly repaired.

SPARK ARRRESTOR

SCREEN P/N 089680

RETAINING

SCREW P/N 056892

Figure 2.12 — Spark Arrestor Installation

n^{Never tee the generator engine exhaust pipe}

into the vehicle engine exhaust piping. This

causes excessive back pressure on the gen-

erator engine. Also, water from one engine

can damage the other engine.

2.5.2 EXHAUST SYSTEM SAFETY

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

exhaust system parts and any combustible material (such as

wood, felt, cotton, organic fibers or other like material). If the

3-inch (76 mm) clearance cannot be maintained, locate, insu-

late 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.

2.5.1 MUFFLERS AND SPARK ARRESTORS

This muffler meets code and standard requirements of the U.S.

Forest Service. Use only mufflers and parts approved by the

manufacturer. Any person(s) installing an unapproved muffler,

or an unapproved exhaust system part, or modifying an exhaust

system in any way that might cause a hazard, is liable for any

damage, injury or warranty expense that might be caused by such

unapproved installation or modification.

• Terminate the exhaust tailpipe such that exhaust gases will not

be drawn back into the generator compartment and recircu-

lated.

• If there is any possibility of the tailpipe or muffler being dam-

aged, protect these damage-prone areas by means of a protec-

tive device (such as a skid bar).

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.

• 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 unauthor-

ized parts.

When installing/replacing the tailpipe or spark arrestor compo-

nents, verify that the tailpipe has a hole to securely fasten the

spark arrestor components (see Figures 2.11 and 2.12). Use only

manufacturer supplied hardware. Substitution of parts may cause

damage to the screen or a loose fit to the tailpipe.

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Installation

• Do not terminate the exhaust system under any opening, win-

dow or vent that can be opened or is not permanently sealed

from the vehicle interior.

• 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).

• 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.

• Conductors must be rated 221° F (105° C) or must be of a

larger conductor size.

• Plan exhaust system installation carefully. Comply with all appli-

2.6.3 GENERATOR AC CONNECTIONS

cable codes, standards and regulations.

Generator AC output leads T1 (red), T2 (white) and T3 (black)

come out of the generator as shown in Figure 2.13. Leads T1 (red)

and T3 (black) are “hot,” while T2 (white) is the grounded neutral

lead. There is also a green lead that connects to ground in the

junction box of the recreational vehicle.

2.6 ELECTRICAL CONNECTIONS

The following general rules apply to electrical connections in a

recreational vehicle:

• Qualified electricians who are familiar with applicable codes,

standards and regulations should install electrical wiring.

• The wiring should comply with codes, standards and regula-

tions. The National Electrical Code (NFPA 70), and state and

local codes apply.

Figure 2.13 – Generator AC Output Leads

• 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.

2.6.1 ELECTRICAL JUNCTION BOX

Install an approved, square electrical junction box with a blank

cover on the interior or exterior wall of the area planned for installa-

tion 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.

AC Output Leads

Green

2.6.2 WIRING

(Ground)

• 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.

4500 Watts

Line T1 (black) to T2 (white) is protected by circuit breaker a

(CB1). Use this line to neutral connection to operate 120 volt,

single-phase, 60 Hz, AC loads.

5500 and 6500 Watts

Line T1 (red) to T2 (white) is protected against overload by a cir-

cuit 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.

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Installation

2.7.1 RECOMMENDED BATTERY

Install a battery that meets the following requirements:

^{Do NOT connect electrical loads in excess}

of any circuit breaker rating or problems will

• The battery must be a 12-volt, automotive type storage bat-

tery.

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

a battery rated 70 amp-hours and capable of delivering 400

cold-cranking amperes.

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

a battery rated 95 amp-hours and capable of delivering 400

cold-cranking amperes.

develop with circuit breaker tripping, which

causes a loss of AC output. Also, do NOT

exceed the generator's rated wattage capac-

ity. 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.

NOTE:

If the battery is to be used to power other vehicle accessories,

as well as start the generator, a battery with a larger capacity

may be needed.

2.6.4 CONDUIT

Route the connections between the generator and the junction box

through approved, flexible conduit. The following general rules

apply:

2.7.2 BATTERY CABLES

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

tion box connections.

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.

• Carefully prepare conduit ends to prevent sharp edges from

cutting through wiring insulation.

• Route conduit so it does not interfere with generator move-

ment.

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

where it enters the junction box. Do this because flexible metal-

lic conduit is not vapor proof along its entire length.

These generators are rated at about 100 DC amperes of cranking

current.

Select battery cables based on (a) cable length and (b) prevail-

ing ambient temperatures. Generally, the longer the cable and the

colder the weather, the larger the cable size must be, as shown in

the chart.

2.6.5 ISOLATING DIFFERENT POWER SOURCES

Connections from the junction box must terminate in a double-

pole, double-throw transfer switch (Figure 2.14). An alternate

method for isolating different power sources is by using an isolat-

ing receptacle (Figure 2.15). Whichever method is used, be certain

that both power sources are NOT connected at the same time.

CABLE LENGTH in Feet (meters)

0 to 10 (0 to 3)

CABLE SIZE

11 to 15 (3.4 to 4.5)

16 to 20 (4.5 to 6)

000

2.6.6 POWER SUPPLY CORD

The power supply cord must comply with all applicable codes,

standards and regulations. It must be large enough to handle the

full amperage to which it will be subjected.

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

NOTE:

Where a minimum of 1025 CCA (cold cranking amps) battery

current is available, up to 30 feet of AWG #2 battery cable is

permitted.

2.6.7 GROUND FAULT CIRCUIT

INTERRUPTERS

The National Electrical Code (NFPA 70, article 551) requires that

ground fault circuit interrupters (GFCIs) on all external and some

internal electrical receptacles be installed. Contact the manufac-

turer or dealer for recommendations.

2.7.3 BATTERY CABLE CONNECTIONS

1. Connect the battery cable from the battery post or terminal

indicated by a POSITIVE, POS or (+) to the lug on the starter

contactor (Figure 2.16).

NOTE:

2.7 BATTERY INSTALLATION

Check to be sure the battery cable boot for the starter cable has

been installed.

NOTE:

2. Connect the battery cable from the battery post indicated by a

NEGATIVE, NEG or (-) to the frame ground connection (Figure

2.16).

This generator is not equipped with an internal battery charger.

It is intended for use in systems where an external battery char-

ger is installed by the RV O.E.M. or an aftermarket installer.

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

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Installation

Figure 2.14 — Typical Transfer Switch Isolation Method

Figure 2.15 — Typical Installation With Isolation Receptacle

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Installation

Figure 2.16 – Connecting Battery Cables

Figure 2.17 – Remote Panel Plug-in Receptacle

Positive Cable

—

Battery

Chasis Ground

Negative Cable

2.7.4 BATTERY COMPARTMENT

Install the generator battery in its own, vented compartment. Place

the battery compartment away from any source of heat, sparks

or flame.

Provide ventilation openings in the battery compartment. The

minimum size of openings should be two (2) square inches at

the top of the compartment. Mount the battery on a strong, rigid

supporting structure, where leaks and spills of battery fluid will not

cause damage.

2.8 OPTIONAL ACCESSORIES

A plug-in receptacle (Figure 2.17) is provided on the generator set.

Use this receptacle to connect an optional remote-mounted start/

stop panel to the generator. Installation of such a panel will permit

starting and stopping the generator engine from any convenient

location inside the vehicle.

2.8.1 REMOTE PANEL MODELS

The remote panels mount a rocker type start/stop switch, a

“Generator Run” advisory lamp and an hourmeter. The hourmeter

should be used in conjunction with the maintenance operations

found in Part I of this manual.

WIRE NO.

WIRE COLOR

Black

FUNCTION

Ground

Blue

Engine Run Signal

12 VDC

712

Blue

Brown/White

Brown/Black

Start

Stop

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Post Installation

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 min-

utes 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.

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.

n^{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.

NOTE:

The generator set was thoroughly tested and adjusted at the fac-

tory before shipping. No additional adjustment should be neces-

sary. Only qualified service technicians who have been trained

should perform adjustments outlined in this manual.

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 rec-

ommended oil. Do not fill above the FULL mark.

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

purged and leak tested in accordance with applicable fuel

codes. All fuel shutoff valves in the fuel supply lines must be

open.

3.4 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.

3.3 INITIAL START

NOTE:

When certain that the unit has been properly installed and prepared

for use, start the engine as follows:

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.

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

main circuit breakers to their “OFF” (or open) position.

2. Refer to Part I, “Starting the Generator”, for cranking and

starting instructions. The engine may require more cranking

for initial starting since the fuel lines have to be primed (use

of the primer switch will shorten this time).

THE MANUFACTURER RECOMMENDS THAT THE GENERATOR BE

TESTED FOR ADEQUATE COOLING.

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.

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Post Installation

ELECTRICAL CONNECTIONS

3.5 INSTALLATION CHECKLIST

LOCATION AND SUPPORT

❑ Connections comply with local code requirements

and all National Electrical Codes.

❑ Generator is properly located.

❑ Generator is properly supported.

❑ Generator is properly restrained.

❑ Junction box is properly installed.

❑ Wiring meets all standards.

❑ All connections are correct.

❑ Conduit is properly installed and sealed.

❑ Generator is properly bonded to the vehicle.

GENERATOR COMPARTMENT

❑ Compartment construction is proper.

❑ Holes/Openings are vapor-sealed.

❑ Compartment size is correct.

❑ Compartment is vapor-sealed.

❑ Sound insulation is correct.

❑ Generator is always isolated from other power

sources.

BATTERY INSTALLATION

❑ Recommended battery is installed.

❑ Recommended cables are installed.

❑ Cables are clean and tight.

❑ Cables are connected properly.

❑ Proper ventilation is provided.

❑ 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.

❑ Terminals are coated with anti-corrosion grease, and

terminal covers are positioned.

OPTIONAL ACCESSORIES

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

GASOLINE FUEL SYSTEM

❑ Fuel tank complies with all applicable codes.

installed properly.

❑ Check that hourmeter kit (if used) is installed

❑ Fuel system is properly installed and checked for

properly.

leaks.

❑ Check that any other options and accessories (if

used) are installed properly.

EXHAUST SYSTEM

❑ Exhaust system complies with all applicable codes.

POST INSTALLATION TESTS

❑ Check that all tests are completed properly.

❑ Exhaust system is properly and safely installed.

DATE OF INSTALLATION_________________________________________________

NAME OF INSTALLER ____________________________________________________

SIGNATURE OF INSTALLER _____________________________________________

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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

battery cable(s).

2. Tighten, clean or replace,

as necessary.

3. Battery is discharged or defective.

4. Defective Start/Stop switch.

5. Defective starter contactor.

6. Defective starter motor.

7. Defective Engine Control Board

3. Recharge or replace battery.

4. Replace switch.

5. Replace starter contactor.

6. Replace starter motor.

7. Contact an authorized service dealer.

Engine cranks, won't start.

1. Out of fuel.

1. Refill fuel tank.

2. Fuel pump not operating.

3. Automatic choke not operating properly.

4. Engine is flooded.

5. Fuel filter is clogged.

6. Engine spark plugs defective.

7. Bad ignition magneto on engine.

8. Bad carburetor.

2. Repair or replace pump.

3. Repair, replace or adjust.

4. Wait 5-10 minutes; try again.

5. Replace filter if clogged.

6. Clean, regap or replace as needed.

7. Replace if defective.

8. Adjust, repair or replace.

9. Clean or replace as needed.

9. Dirty air cleaner.

Engine starts hard, runs rough.

Engine starts, then shuts down.

1. Dirty engine air cleaner.

2. Automatic choke is sticking.

3. Defective spark plugs.

1. Clean or replace as needed.

2. Free choke linkage as needed.

3. Clean, regap or replace.

4. Replace it if defective.

4. Defective ignition magneto.

1. Engine oil level is low.

2. Bad low oil pressure switch.

3. Defective high temp switch.

4. Water in fuel.

1. Add oil as needed.

2. Replace, if bad.

3. Replace, if bad.

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.

2. Transfer switch (if so equipped) is

set to wrong position.

1. Close main breaker(s).

2. Reset transfer switch.

3. Failure in vehicle electrical system.

4. Generator component failure.

3. See vehicle manual.

4. Contact an authorized service facility.

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Electrical Data

Wiring Diagram Drawing No. 0G4221-C

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Wiring Diagram Drawing No. 0G4221-C

Electrical Data

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Electrical Data

Wiring Diagram Drawing No. 0H3633-A

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Wiring Diagram Drawing No. 0H3633-A

Electrical Data

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Exploded Views & Parts Lists

Enclosure Drawing No. 0G3881-F

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Enclosure Drawing No. 0G3881-F

Exploded Views & Parts Lists

ITEM

PART NO.

QTY.

DESCRIPTION

0G3396

0C5644

0G5236

0D3700

0G3401

0G4077

0G4433

0G3377

0G3431

0F9199

0G3430

0G3402

090388

0G3422

0G5237

0G3399

0D3472

0G4933

0G5238

0G3397

0G4391

0G5239

0G3392

0G3754

0G3398

0G3912

0G3400

0G5240

0G5242

0G5241

045756

0G5755

0G5761

022473

022097

022287

0G3429

ENCLOSURE DOOR

SLIDE LATCH, FLUSH

FOAM ENCLOSURE DOOR

NUT FLANGE M6-1.0 NYLOK

DUCT, AIR IN DOOR

GROMMET, OIL FILTER

U CHANNEL 1/8”

TRAY, 530 RV

GASKET AIR IN BOTTOM DUCT

PLUG PLASTIC 1.093-1.125

GASKET AIR IN TOP DUCT

DUCT AIR IN ROOF

SCREW HHTT M6-1.0X12 ZINC

TOP DIVIDER PANEL

FOAM, SIDE ENCLOSURE

ENCLOSURE SIDE / BACK

GROMMET OVAL 31.75X50.8

SCREW SWT 1/4-20X5/8 W/W

FOAM BACK ENCLOSURE ALT SIDE

ENCLOSURE ROOF

ENCLOSURE, BACK PANEL 530 RV

FOAM BACK PANEL ENCLOSURE

UPPER BLOWER HOUSING

UPPER BLOWER HOUSING GASKET

EXHAUST DIVIDER PANEL

MUFFLER HOLD DOWN BRACKET

ENCLOSURE EXHAUST SIDE PANEL

FBR GLASS, ENCLOSURE MFLR BACK

FOAM EXHAUST END ENCL FRONT

FBR GLASS, ENCLOSURE MFLR SIDE

SCREW HHTT M6-1.0X10 ZYC

BUMPER

STAND OFF

WASHER, FLAT 1/4”

WASHER, LOCK 1/4”

SCREW HHC 1/4-20 X 3/4” G5

GASKET, SCROLL DUCT

SHEET METAL PAINT/MATERIAL CODE LEGEND

The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the

correct color and material information must be included as a suffix at the end of the part number as shown below.

Material

S = Steel

Color

G = Gray

B = Black

Example:

Desc.

Roof

Upper Blower Hsg.

Part No.

0G3397

0G3392

Material

S = Steel

Color

G = Gray

B = Black

Order As"

0G33970ST08

0G33920ST03

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Exploded Views & Parts Lists

Control Panel Drawing No. 0H3635-C

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Control Panel Drawing No. 0H3635-C

Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

045757

0F5458

023484S

0G9081*

049813

022473

0A1658

0G3380

0F9176

0G3662A

028414

0D3700

0G5225

028916

087769

025965

022097

0G5318

0H3634

0G4602

0C7968

022237

0A4456

0C7423

022259

022129

022145

0E0593

0D8502

0G5233

0G3825

0G3689

092036

0A9611

032300

0G4215

SCREW HHC M6-1.0 X 25 G8.8

SCREW PLASTITE HI-LOW #10X3/8

BUSHING SNAP SB-1093-937

WIRE HARNESS C/PNL FRAME

NUT HEX M6 X 1.0 G8 YEL CHR

WASHER FLAT 1/4-M6 ZINC

082025

0F9719

0G3977

0G3530

075476

090987

0C2174

031879

0D9784

075235

074908

075210A

0E6480

090144 (5500W)

090145 (6500W)

090145

NUT HEX LOCK M5-0.8 NYINS ZINC

ASSY PCB VREG AIR COOLED 2006

ASSY PCB RV CONTROLLER

C/PNL FRAME RV

SCREW PPHM M4-0.7 X 16

SCREW PPHM M3-0.5 X 12

RELAY 12V 25A SPST

WASHER LOCK SPECIAL 1/4"

FUEL PUMP MOUNTING BRACKET

WASHER FLAT #4 ZINC

28.75” HOSE,1/4" SAE30R7

NUT HEX LOCK M3-0.5 NY INS

SCREW HHC M5-0.8 X 30 G8.8

SCREW HHTT M5-0.8 X 10 BP

BLOCK 1 POSITION, 4 TAB

NUT HEX LOCK M4-0.7 NY INS

CIRCT BRK 20X1 MAG 10-32 CARL

CIRCT BRK 30X1 MAG 10-32 CARL

(4500W, 5500W, 6500W)

EARTH STRAP

NYLON SPACER .26 X 1.00 X 1.73

PLUG, PLASTIC .75 (5410-1/5412-

1/5414-1 ONLY)

BARBED EL 90 ¼ NPT X 5/16

(5751/5752/5753 ONLY)

BULKHEAD ADAPTER

(5751/5752/5753 ONLY)

BUSHING REDUCER HEX ¼ TO 1/8 NPT

(5751/5752/5753 ONLY)

NIPPLE PIPE 1/8 NPT X 1 ½

(5751/5752/5753 ONLY)

SOLENOID 12 VDC (5751/5752/5753

ONLY)

BARBED EL 90 1/8 NPT X ¼

(5751/5752/5753 ONLY)

CLAMP HOSE BAND .50

BARBED STR 1/8NPT X 1/4

NUT FLANGE M6-1.0 NYLOK

FUEL PUMP

ELBOW 90D STREET 1/8 BRASS

FILTER FUEL 1/8P-1/4H

SCREW HHC 1/4-20 X 2-1/4” G5

WASHER LOCK M6-1/4

AC HARNESS 530RV (5500 + 6500W)

AC HARNESS 530RV EVAP (4500W)

GROMMET, DOUBLE SLIT

NUT HEX JAM 3/8-16 BRASS

WASHER LOCK 3/8

WASHER LOCK SPECIAL 3/8

STUD 3/8-16 X 2-1/4 BRASS

NUT HEX 5/16-18 STEEL

WASHER LOCK M8-5/16

WASHER FLAT 5/16-M8 ZINC

STUD, 1/4-20 TO 5/16-18

NEUTRAL CONNECTOR UL

SCREW PPHTF #8-18 X 1/2 AB

CONTROL PANEL COVER

C/PNL FACE

0C2417A

0G5986

061669

059502

069598

035579

035483

0G0247

028740

SCREW PPHM #6-32 X 1/4 SEMS

FUSE 7.5AXBK/AGC7.5NX

HOLDER FUSE

*HARNESS NOT SHOWN

SWITCH RKRSPDT(ON)OFF(ON)ILLUM

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Exploded Views & Parts Lists

Base & Pulley Drawing No. 0G7720-B

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Base & Pulley Drawing No. 0G7720-B

Exploded Views & Parts Lists

ITEM

PART NO.

QTY.

DESCRIPTION

0G3377

081105

022259

022129

022145

0G5217

0G3748

046526

022131

0G3384

0C7758A

0C1751

0C2824

022473

022097

043116

0G3383

0G4350

0G3379

0C3062

0G4429

0G3391

0G3742

0G7670

0E0588

0G4702

029451

0G3426

0G5676

0G5676A

0G4692

022473

0A2110

0G3410

0G3393

0G7887

025145

0C8565

056892

089680

094670

0G3394

0G3395

056893

023897

0G4260

0E9369

1.5ft

TRAY, 530 RV

NUT FLANGE 5/16-18 LOCK

NUT HEX 5/16-18 STEEL

WASHER LOCK M8-5/16

WASHER FLAT 5/16-M8 ZINC

SCREW HHC 3/8-24 X 1-1/2 G8

BELT V-RIBBED 4L X 43.75" LG

WASHER LOCK M10

WASHER FLAT 3/8-M10 ZINC

ALTERNATOR PULLEY

VIB MNT 1.5X1.38X5/16-18 DR 45

FAN 7" DIA (NYLON)

SCREW HHTR #10-32 X 9/16

WASHER FLAT 1/4-M6 ZINC

WASHER LOCK M6-1/4

SCREW HHC M6-1.0 X 12 G8.8

ENGINE PULLEY

FAN ENGINE PULLEY RV

BRACKET MUFFLER SUPPORT

BOLT CARR 5/16-18 X 1

EDGE TRIM W/ 3/4" HOLLOW CYL.

BLOWER HOUSING WALL

GASKET, LOWER BLOWER HOUSING

FRAME GT530 RV MOUNTING

SPACER, SAFETY BOLT .375 I.D.

SCREW HHC 5/16-18 X 3 SPC

TAPE ELEC UL FOAM 1/8 X 1/2

DUCT AIR OUT

GASKET,AIR OUT DUCT

GASKET, AIR OUT DUCT OPPOSITE SIDE

SCREEN, BOTTOM AIR OUT

WASHER FLAT 1/4-M6 ZINC

SCREW SWAGE 1/4-20 X 1/2 ZYC

ISOLATION SPRING

MUFFLER, 530 RV

MUFFLER. 530 RV (MODELS: 5410-1 / 5412-1 / 5414-1 ONLY)

BOLT U 5/16-18 X 1.25 W/SADDLE

SCREW SHC M8-1.25 X 18 G8.8

SCREW CRIMPTITE 10-24 X 3/8

SCREEN SPARK ARRESTOR

CLAMP EXHAUST

EXHAUST FLEX

EXHAUST MANIFOLD

SCREW CRIMPTITE 10-24 X 1/2

WASHER FLAT #10 ZINC

GASKET, EXH BASE, 530 RV

GASKET, EXHAUST GT530

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Exploded Views & Parts Lists

Engine Accessories Drawing No. 0G7718-K

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Engine Accessories Drawing No. 0G7718-K

Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

0G7670

0G3404

0E9507

023484S

056893

0G4129

0C8563

0G3405

0G4985A

0E9525A

0E4997

067198N

067890

0G3911

0G4130

082774

0G3454

022131

0G5221A

0G5221B

0G6432

0E9319

0E9333

040976

0E9471

0E9383D

0G9640

0G3890

0G4378

040173

0G3406

0G3455

0G3413

078601

0G5057

0E9511B

0G3414

0G3408

045756

FRAME

0G3386

0A2311

070185B

0D9235

0G4793

043182

0C1085

0G4576

0A2110

0G3407

0G3915

0G3840

0G3839

0E9368

0G7671

0G3389

0A7094

0D8590

0D8591

0G3984

043146

022097

0D6342

0D9784

0G4016

043116

0F1177

077091

075763A

0742600173

022473

061906

049813

056892

0E9323

022129

0A4456

022746

055934M

0G6725

0G6729

078643C

096290A

046526

0G9148

0G7757A

OIL FILTER SUPPORT

SCREW SWAGE 1/4-20 X 1

OIL FILTER

OIL PRESSURE SWITCH 5 PSI

SWITCH, THERMAL 270F

WASHER, LOCK M3

SCREW PPHM M3-0.5 X 8

BRACKET, OIL CHECK TUBE

SCREW SWAGE 1/4-20 X 1/2

WRAPPER ENGINE VALLEY

WRAPPER UPPER VALLEY

WRAPPER INNER CYLINDER #2

WRAPPER INNER CYLINDER #1

SPARKPLUG

ENGINE WRAPPER, STARTER SIDE

SCREW HHFC M8-1.25 X 14

SNAP BUSHING

SCREW CRIMPTITE 10-24 X 1/2

SHIELD WRAPPER, CYLINDER #1

SCREW HHFC M6-1.0 X 12 G8.8

ENGINE WRAPPER, BACK

BACKPLATE

ASSY, FLYWHEEL & RING GEAR 29D

ASSY, GROUND WIRE CONNECTOR

WASHER,BELV-20 X 2.2

NUT HEX M20-1.5 G8

BLOWER HOUSING

SHIELD WRAPPER, CYLINDER #2

KEY, WOODRUFF 4 X 19D

BREATHER HOSE

WASHER FLAT 3/8 – M10 ZINC

IGNITION COIL CYLINDER #1

IGNITION COIL CYLINDER #2

SCREW HHFC M6-1.0 X 25 SEMS

GASKET, INTAKE

OIL LINE OUT

OIL LINE IN

SCREW PPHM #4-40 X 1/4

ASSEMBLY, BI-METAL/HEATER

CHOKE SOLENOID

CONTROLLER ASSEMBLY

SCREW HHC M6-1.0 X 10 G8.8

WASHER LOCK M6-1/4

BALL STUD, 10 MM

NUT HEX LOCK M3-0.5

BRACKET, CONTROLLER SUPPORT

SCREW HHC M6-1.0 X 12 G8.8

ASSY, GROUNDING WIRE W/O DIODES

COTTER PIN

INTAKE MANIFOLD

SCREW SHC M8-1.25 X 20 G12.9

GASKET, MANIFOLD TO CARB/MIXER

CARBURETOR

ROD, CHOKE CONTROL

ASSY GOVERNOR ROD

GASKET, AIRBOX/CARB

CLAMP, HOSE WORM GEAR

WRAPPER, ENGINE OIL ADAPTOR

SNORKEL, AIR BOX

AIRBOX BASE

AIR FILTER

AIRBOX SEAL

AIRBOX QUARTER KNOB

AIRBOX COVER

OIL DRAIN LINE

SCREW HHTT M6-1.0 X 10 YELLOW

CHROME

CLAMP, VINYL 9.5 O.D.

3/4 NPT TO 3/8 O.D. FLARE

ASSY, CAP AND DIPSTICK

OIL DRAIN/DIPSTICK TUBE

90 DEGREE ELBOW 3/8 NPT X 3/8

BARBED

BOOT, BATT. CABLE

WIRE ASSY. BATT. POS.

WASHER, FLAT 1/4-M6

SCREW HHC M8-1.25 X 85

NUT M6-1.0

SCREW CRIMPTITE 10-24 X 3/8

START MOTOR

WASHER, LOCK M8-5/16

WASHER, LOCK SPECIAL 3/8

SCREW HHC 3/8-16 X 1-3/4 G5

CLAMP VINYL .75 X .343

INSULATOR

GASKET, MANIFOLD TO CARB/MIXER

BOLT,CARB MOUNT M6-1.0 X 95

STUD M6-1.0 X 100

0E0998

0G3432

0E0393A

0E0361B

043790

WASHER LOCK M10

PLUG, RUBBER (4703, 5, 6 & 7)

HOSE MOLDED EVAP. PORT (05751,

05752 & 05753)

SCREW, BHSC M6-1 X 8

SCREW BHSC M6-1 X 8MM BLACK

0G3662B

0F0452B

0G4426

8”

HOSE OETIKER CLAMP

HOSE, 3/8” I.D.

ASSY, OIL DRAIN FITTING

100

0H4269

0G9062

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Exploded Views & Parts Lists

530 RV Engine Drawing No. 0G7719-B

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530 RV Engine Drawing No. 0G7719-B

Exploded Views & Parts Lists

ITEM

PART NO.

QTY.

DESCRIPTION

0E3812

0D4788

073144

0G7260A

078699B

0A5776

0E9482

0C5315A

0C5314A

0E9379

0E9382

0G0919

0E3372A

0E9345

076390

0G4379

0G4331

076389

0G1054

0G1063G

093064

0E9334F

080318

0E9352

0E9368

077168

084186

088156

0C4390

0C3733

0C3592

077161

077160

076307

0E9353A

0E9304

0C3591

0C3590

0E9351

0G5728

0E9455E

083235

0G7679

0E9350

0E9334G

0E9305

0E9429C

0E9366

0G5670

0C8566

0C5943

0G0273

0G5896

0G0275

0G0276

SEAL D 35 X 48.2

3/8” SQUARE HEAD PLUG

SCREW HHFC M8 – 1.25 X 45

GEAR COVER

SLEEVE DOWEL PIN

11/32 DIAMETER PRESSURE RELIEF BALL

OIL PRESSURE SPRING

GEAROTOR, OUTER

GEAROTOR, INNER

SCREEN, OIL PICK-UP

COVER, GEROTOR

SCREW, HHFCS M6-1.0 x 12

BREATHER SEPARATOR

GEAR, GEAROTOR

RETAINER RING

PISTON RING SET

PISTON

PISTON PIN

CONNECTING ROD ASSEMBLY

CRANKSHAFT

OIL FILL CAP

COVER ROCKER W/FILL

SCREW HHFC M6-1.0 X 25

GASKET, VALVE COVER

SPARK PLUG

SCREW HHC M8-1.25 X 56

WASHER, VALVE SPRING

SEAL, VALVE STEM

VALVE SPRING

VALVE RETAINER

KEEPER, VALVE SPRING

STUD, ROCKER ARM

ROCKER ARM

JAM NUT, ROCKER ARM

PUSH ROD GUIDE PLATE

CYLINDER HEAD CYL. 1

INTAKE VALVE

EXHAUST VALVE

GASKET CYLINDER HEAD

SCREEN

PUSHROD

TAPPET

CAM SHAFT & GEAR

GASKET, CRANKCASE

COVER ROCKER

CYLINDER HEAD CYL 2

CRANKCASE

GASKET, BREATHER ASSEMBLY

BREATHER ASSY

SCREW HHFC M6-1.0 X 20

SEAL, OIL PASSAGE

GASKET KIT

BREATHER KIT

KIT HEAD ASSY CYLINDER #1

KIT HEAD ASSY CYLINDER #2

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Exploded Views & Parts Lists

Rotor & Stator Drawing No. 0G3953-B

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Rotor & Stator Drawing No. 0G3953-B

Exploded Views & Parts Lists

ITEM

PART NO.

QTY.

DESCRIPTION

052858

075237

075242

0C1878

073146

052203

022145

0G3913

029459

075215

0G3382

0G3877H

0G3878H

0G3879H

0G3893H

0G3894H

0G3895H

0G3381

022129

045771

066386

066849

0G3542

022131

042633

022237

NUT TOP LOCK FL M8-1.25

WASHER, SPRNG CENTER

SPRING, GEN. MOUNT

SUPPORT, SLIDE

SLIDE, NYLON

SCREW HHC M8-1.25 X 70 G8.8

WASHER FLAT 5/16-M8 ZINC

STUD, 530 RV STATOR

TENSION SPRING

WASHER, SPRING CENTR

LOWER BEARING CARRIER

RTR 200 4.5AD1 RV

RTR 200 5.5AD1 RV

RTR 200 6.5AD1 RV

STR 200-4.5AD1 RV

STR 200-5.5AD1 RV

STR 200-6.5AD1 RV

UPPER BEARING CARRIER

WASHER LOCK M8-5/16

NUT HEX M8-1.25 G8 CLEAR ZINC

ASSEMBLY, BRUSH HOLDER

SCREW HHTT M5-0.8 X 16

FAN UPPER ALTERNATOR

WASHER FLAT 3/8-M10 ZINC

SCREW HHC 3/8-24 X 1 G5

WASHER LOCK 3/8

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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 equip-

ment 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 associ-

ated 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 replace-

ment 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

Part 1

Part No. 0H1912 Rev. A 05/09

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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 part fails prior to the first scheduled replacement, the part shall be repaired or replaced by

Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS warranty shall be warranted for

the remainder of the 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" part.

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

4) AIR INJECTION SYSTEM

A. PULSE AIR VALVE

5) EXHAUST SYSTEM

A. CATALYST

B. THERMAL REACTOR

C. EXHAUST MANIFOLD

B. AIR FILTER

3) IGNITION SYSTEM

A. SPARK PLUGS

B. IGNITION COILS / MODULE

Part 2

Part No. 0H1912 Rev. A 05/09

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Warranty

GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY

FOR GENERAC RECREATIONAL VEHICLE GENERATORS

NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3

(three) years of operation from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part

which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective

under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to

be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility. All transportation costs under

the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac

generators sold and rated for “Recreational Vehicle” (RV) applications, as Generac has defined Recreational Vehicle generator applications.

The factory recommends exercising the unit one half-hour every month.

WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS

YEAR ONE – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:

• Engine – All components

• Alternator – All components

WARRANTY SCHEDULE – CONSUMER/PERSONAL APPLICATIONS

YEARS ONE AND TWO – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:

• Engine – All components

• Alternator – All components

YEAR THREE – 100% (one hundred percent) only on selected part(s) and labor listed [Any labor and part(s) not listed, and removal and

reinstallation are the owner’s responsibility]:

• Rotor, Stator, Computer Control Board (part numbers 0A6060 and 0A3369) and inverter, (if applicable with regard to the generator) Cylinder

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

Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators manu-

factured after January 1, 1998, have a transferable warranty to the second owner ONLY for the remainder of the three-year limited warranty.

Proof-of-purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any

warranty service.

All warranty expense allowances are subject to the conditions defined in Guardian’s Warranty Policies and Procedures Guide.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Generac Guardian generators that utilize non-Generac replacement parts.

• Costs of normal maintenance, adjustments, installation and start-up.

• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac

Power Systems.

• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechani-

cal devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when

normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing,

lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.

• Damage related to rodent and/or insect infestation.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement

of the defective part(s).

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty

period.

• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Overnight freight costs for replacement part(s).

• Overtime labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES

AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty

lasts, so the above limitation may not apply to you.

GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE

LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.

This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC^®POWER SYSTEMS, INC.

P.O. BOX 297

•

WHITEWATER, WI 53190

Rev. A 06.09

Part No. 0H3467

Revision B (04/15/10)

Printed in U.S.A.

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