Generac Portable Generator 004709 0 User Manual

Models: 004709-0,

005852-0

Owner's Manual and

Installation Instructions

Air-cooled Recreational

Vehicle Generators

Quietpact 40G

This manual should remain with the unit.

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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

Thank you for purchasing this model by Generac Power Systems

Inc. This model is designed and manufactured to supply electrical

power for recreational vehicles.

READ THIS MANUAL THOROUGHLY

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

est Authorized Service Dealer for starting, operating and servicing

procedures.

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.

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:

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.

Indicates a hazardous situation or action which, if

not avoided, will result in death or serious injury.

Indicates a hazardous situation or action which,

if not avoided, could result in death or serious

injury.

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.

Indicates a hazardous situation or action which,

if not avoided, could result in minor or moderate

injury.

HOW TO OBTAIN SERVICE

NOTE:

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.

Notes contain additional information important to a procedure

and will be found within the regular text body of this manual.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliance with the special

instructions while performing the action or service are essential to

preventing accidents.

When contacting an Authorized Service Dealer or the factory about

parts and service, always supply the complete model number and

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

on the generator.

Four commonly used safety symbols accompany the DANGER,

WARNING and CAUTION blocks. The type of information each

indicates is as follows:

Model No. _________________ Serial No.______________

n^{This symbol points out important safety}

information that, if not followed, could

endanger personal safety and/or property of

others.

AUTHORIZED SERVICE

DEALER LOCATION

This symbol points out potential explosion

hazard.

^

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

^T^{his symbol points out potential electrical}

To locate the nearest AUTHORIZED SERVICE

DEALER, please call this number:

shock hazard.

1-800-333-1322

or locate us on the web at:

www.guardiangenerators.com

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Safety Rules

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

copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to

all operators and potential operators of this equipment.

Study these SAFETY RULES carefully before installing, operating

or servicing this equipment. Become familiar with this manual and

with the unit. The generator can operate safely, efficiently and 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.

• 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 instal-

lation manual. Make sure there is ample fresh air when operat-

ing the genset in a confined area.

• The engine exhaust fumes contain carbon monoxide, which can

be DEADLY. This dangerous gas, if breathed in sufficient con-

centrations, can cause unconsciousness or even death. This

exhaust system must be installed properly, in strict compliance

with applicable codes and standards. Following installation, do

nothing that might render the system unsafe or in noncompli-

ance with such codes and standards. The generator compart-

ment must be completely vapor sealed from the vehicle interior.

There must be no possibility of exhaust fumes entering the

vehicle interior. Never operate this equipment with a leaking or

defective exhaust system.

The manufacturer cannot anticipate every possible circumstance

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

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

If using a procedure, work method or operating technique the

manufacturer does not specifically recommend, ensure that it is

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

operating technique utilized does not render the generator unsafe.

• 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.

Despite the safe design of this generator,

operating this equipment imprudently, neglect-

ing its maintenance or being careless can

cause

• 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.

• Inspect the generator regularly, and contact the nearest Authorized

Service Dealer immediately for parts needing repair or replace-

ment.

possible injury or death. Permit only respon-

sible and capable persons to operate or main-

tain this equipment.

^P^{otentially lethal voltages are generated by}

these machines. Ensure all steps are taken to

render the machine safe before attempting to

work on the generator.

Parts of the generator are rotating and/or

hot during operation. Exercise care near run-

ning generators.

GENERAL HAZARDS

• 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.

• For safety reasons, the manufacturer recommends that the

installation, initial start-up and maintenance of this equipment

is carried out by an Authorized Service Dealer.

• The generator engine releases DEADLY carbon monoxide gas

through its exhaust system. This dangerous gas, if breathed

in sufficient concentrations, can cause unconsciousness or

even death. Never operate the generator set with the vehicle

inside any garage or other enclosed area. DO NOT OPERATE

THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR

HAS BEEN DAMAGED. SYMPTOMS OF CARBON MONOXIDE

POISONING ARE (a) inability to think coherently, (b) nausea,

(f) dizziness, (g) headaches, (h) weakness, and (i) sleepi-

ness. IF EXPERIENCING ANY OF THESE SYMPTOMS, MOVE

INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET

MEDICAL HELP. Shut down the generator and do not operate it

until it has been inspected and repaired.

• Never 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.

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Safety Rules

EXPLOSION HAZARDS

ELECTRICAL 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.

• 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.

• 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.

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.

• 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.

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.

FIRE HAZARDS

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

properly. Installation always must comply with applicable

codes, standards, laws and regulations. Adhere strictly to local,

state and national electrical and building codes. Comply with

regulations the Occupational Safety and Health Administration

(OSHA) has established. Also, ensure that the generator is

installed in accordance with the manufacturer’s instructions

and recommendations. Following proper installation, do 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.

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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 _________________________

2. Serial Number _________________

4. Rated Voltage _________________

1. Generator Air Intake

2. Engine Start/Stop Switch

3. Fuse

10. Fuel Pump (Behind Access Panel)

11. Fuel Filter (Side View)

12. Oil Filter

4. Optional Remote Panel Receptacle (Side View)

5. Generator AC Output Leads (Side View)

6. Fuel Primer Switch

13. Oil Drain Cap

14. Oil Dipstick

15. Air Filter (Behind Access Panel)

16. Oil Fill

7. Circuit Breaker

8. Starter Contactor

17. Spark Plug

9. Fuel Inlet

18 Evaporative Port (model 004709-0 only)

2 6

14,16

CONTROL CENTER

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE

OIL LEVEL:

AIR FILTER:

CHECK DAIL

CLEAN PREFILTER

EVERY 100 HOURS.

REPLACE ELEMENT

EVERY 250 HOURS.

10/15

OIL

OIL FILTER:

CHANGE EVERY 100

HOURS. (OR ANNUALLY)

PERFORM MORE OFTEN IN DUSTY CONDITIONS

SPARK PLUGS:

FUEL FILTER:

INSPECT

CLEAN

PLUGS EVERY 100

HOURS. REPLACE PLUGS

EVERY 500 HOURS.

(IF NECESSARY)

CHANGE EVERY 400

HOURS. (OR ANNUALLY)

REPLACEMENT INFORMATION

PREFILTER P/N:

AIR FILTER P/N:

OIL FILTER P/N:

SPARK PLUG P/N:

FUEL FILTER P/N:

0D4511

0D3262

070185

072347

0D7515

OIL CAPACITY WITH FILTER:

0.8L/0.84QT

TEMPERATURE

SAE VISCOSITY

32°F AND HIGHER

10°F TO 100°F

0°F TO 80°F

15W-40

10W-30

5W-30

-20°F TO 50°F

WHEN SERVICE OR PARTS ARE NEEDED IN

THE USA OR CANADA, CONTACT THE GENERAC

SERVICE LOCATOR AT 1-800-333-1322.

9/11

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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 application,

contact an Authorized Service Dealer. Do not use the unit until

advised by a competent authority.

1.4 GENERATOR AC

CONNECTION SYSTEM

This generator set is equipped with dual stator AC power windings.

These two-stator windings supply electrical power to customer

electrical loads by means of a two-wire connection system. Note,

however, that the neutral is bonded to the frame of the engine-

generator.

The generator may have been installed so that it powers 120-volt AC

loads (Figure 1.1). It can be wired to connect 120-volt AC electri-

cal loads. This procedure should be done by an Authorized Service

Dealer or other qualified installer.

^F^{or 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.

Figure 1.1 – Connections for 120 Volts Only

Use this generator to supply electrical power for operating 120-volt,

single-phase, 60 Hertz, AC electrical loads. These loads can require

up to 3,600 watts (3.6 kW) of power, but cannot exceed 30 AC

amperes of current at 120 volts.

Do not overload the generator. Some instal-

lations may require that electrical loads be

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 electrical

device nameplate gives only volts and amps,

multiply volts times amps to obtain watts

(volts x amps = watts). Some electric motors

require more watts of power (or amps of cur-

rent) for starting than for continuous opera-

tion.

1.5 SPECIFICATIONS

1.5.1 FUEL REQUIREMENTS

This generator is equipped with a gasoline fuel system. Depending

on the installation, the generator may have either a separate fuel

tank, or it may “share” the vehicle engine’s fuel tank.

NOTE:

Some installations using a “shared” fuel tank may have a 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.

1.3 SAFETY

Before attempting to use the generator set, carefully read the

“Safety Rules” section of this manual. Comply strictly with these

rules to prevent accidents and damage to equipment and/or

property. We suggest copying and posting the “Safety Rules” in

potential hazard areas of the vehicle. Stress safety to all operators

and potential operators of this equipment.

To reduce lead and carbon deposits use high quality UNLEADED

gasoline with the generator. Leaded REGULAR grade gasoline is an

acceptable substitute.

NOTE:

Using unleaded gasoline contributes to longer engine valve life

by reducing lead and carbon deposits.

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General Information

1.5.5 GENERATOR

Rated Maximum Continuous

n^{The manufacturer does not recommend}

using any gasoline containing alcohol (such

AC Output (Gasoline)...................................................3,600 Watts (3.6 kW)

Rated Voltage...............................................................................120 Volts AC

Rated Maximum Continuous

AC Current (Gasoline).................................................................30 Amperes

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

ing alcohol, it must not contain more than

10 percent ethanol, and it must be removed

from the generator during storage. Do NOT

use any gasoline containing methanol. If

using gasoline with alcohol, inspect more

frequently for fuel leaks and other abnor-

malities.

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

Rotor RPM.............................................................................................. 3,600

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

Engine RPM............................................................................................ 3,600

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

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

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

Gasoline weight ............................................................................ 170 Pounds

Length............................................................................749.8 mm (29.52 in.)

Width .............................................................................483.1 mm (19.02 in.)

Height ............................................................................342.2 mm (13.47 in.)

1.5.2 FUEL CONSUMPTION

Model

No Load

1/2 Load

Full Load

004709-0

0.24

0.35

0.55

Fuel consumption is in gal/hr.

* Maximum wattage and current are subject to, and limited by, such factors as

fuel Btu content, ambient temperature, altitude, engine condition, etc.. Maximum

power decreases about 3.5% for each 1,000 feet above sea level; and will

also decrease about 1% for each 6° C (10° F) above 16° C (60° F) ambient

temperature.

1.5.3 ENGINE OIL REQUIREMENTS

Use only high quality detergent oil rated with American Petroleum

Institute (API) Service Classification SF, SG or SH. The recom-

mended oil weights include the following:

1.5.6 EMISSIONS COMPLIANCE PERIOD

For non-handheld engines the Emissions Compliance Period

referred to on the Emissions Compliance Label indicates the num-

ber of operating hours for which the engine has been shown to

meet Federal emission requirements.

• During summer months: SAE 30. An acceptable substitute is

SAE 10W-30.

• During winter months: SAE 5W-30. DO NOT USE SAE

10-W40.

• For engines less than 225 cc displacement, Category C=125

hours, B=250 hours, and A=500 hours.

Crankcase and oil filter capacity is approximately 800 mL or .84

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 fill procedures.

• For engines of 225 cc or more, Category C=250 hours, B=500

hours, and A=1000 hours.

1.5.7 EVAPORATIVE EMISSIONS INFORMATION

1.5.4 ENGINE

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.

Type of Engine ............................................................GN-220, Single-cylinder

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

Rated Horsepower...............................................................7.8 @ 4,200 rpm

Displacement......................................................................................... 220cc

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

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

Air Cleaner ................................................. Paper Element w/Foam Precleaner

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

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

Recommended Spark Plug

Champion......................................................................................... RC14YC

AC..........................................................................................................R45S

Fram Autolite.............................................................................................. 65

Spark Plug Gap................................................................0.030 inch (76 mm)

Recommended Minimum Battery....................................... 400 Cold-cranking

Amperes

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.

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Operation

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.

2.2 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.

Order part number 0F0429 or 0F0430, a remote panel that includes

a Start/Stop switch, a generator run lamp, a fuel prime switch, and

an hourmeter. The hourmeter provides a continuous indication of

engine/generator operating time. Use the hourmeter for checking

off periodic maintenance requirements on the unit.

2.1 GENERATOR CONTROL PANEL

The following features are mounted on the generator control panel

(Figure 2.1):

Figure 2.1 – Generator Control Panel

2.3 AUTOMATIC CHOKE

The engine is equipped with an automatic choke that consists of

two main components: a choke solenoid and prechoke.

CONTROL CENTER

. B

2.3.1 CHOKE SOLENOID

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

choke module signals the choke solenoid to activate and cycle

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

thus opens and closes the carburetor choke valve only when the

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

cycling.

I M

F U S E

7. 5

2.3.2 PRECHOKE

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

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

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

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

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

take about three minutes in cooler weather.

2.1.1 FUEL PRIMER

Before starting a cold engine (if it has not been started in more

than two weeks), press this switch for approximately 10 to 15

seconds to bring fuel from the tank to the carburetor. This rocker

type switch springs back into its original position when released.

2.4 BEFORE STARTING THE

2.1.2 START/STOP SWITCH

To crank and start the engine, hold this switch in the START posi-

tion. Release the switch when the engine starts. To stop an operat-

ing engine, press and hold the switch in the STOP position until the

engine shuts off. The switch center position is the RUN position.

ENGINE

NOTE:

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.

2.1.3 FUSE

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

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

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

only an identical replacement.

2.4.1 INSTALLATION

Generator installation must have been properly completed so it

complies with all applicable codes, standards and regulations and

with the manufacturer's recommendations.

2.1.4 MAIN BREAKER

The main breaker protects the generator’s AC output circuit against

overload and provides a method of turning OFF the generator’s

120-volt AC output to the vehicle circuits. This generator has

30-amp breaker.

2.4.2 ENGINE LUBRICATION

Have the engine crankcase properly serviced with the recommended

oil before starting. Refer to sections "Engine Oil Requiremtents",

"Checking the Engine Oil Level" and "Changing the Engine Oil and/

or Oil Filter" for oil servicing procedures and recommendations.

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Operation

2.5 STARTING THE GENERATOR

NOTE:

Any attempt to crank or start the engine

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 cer-

tain DC lighting and other DC loads.

before it has been properly serviced with the

recommended oil may result in an engine

failure.

2.4.3 FUEL SUPPLY

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

ate. Before starting it, check that sufficient fuel is available.

To start the generator from either the generator control panel or

from the optional remote panel, proceed as follows:

NOTE:

Depending on the installation, the generator may have either a

separate fuel tank, or it may “share” the vehicle engine’s fuel

tank.

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

vehicle (such as a main line circuit breaker or transfer

switch).

2.4.4 COOLING AND VENTILATING AIR

NOTE:

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.

If starting from the generator control panel, turn OFF loads

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

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

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

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

generator has started, stabilized and warmed up.

2.4.5 ENGINE EXHAUST GAS

2. If the engine has not been started in more than two weeks,

press the Fuel Pump Primer switch and hold it for about 10 to

15 seconds to prime the fuel system. However, if the engine

is warm, skip Step 2.

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.

3. Hold the engine Start/Stop switch in the START position to

crank the engine. Release the switch when the engine starts.

The generator engine releases DEADLY

carbon monoxide gas through its exhaust

n_{system. This dangerous gas, if breathed in}

If the engine does not start after it has been

cranking for 15 seconds, release the Start/

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) nausea, (c) vomiting,

(d) twitching muscles, (e) throbbing tem-

ples, (f) dizziness, (g) headaches, (h) weak-

ness, and (i) sleepiness. IF EXPERIENCING

ANY OF THESE SYMPTOMS, MOVE INTO

FRESH AIR IMMEDIATELY. IF SYMPTOMS

PERSIST, GET MEDICAL HELP. Shut down

the generator and do not operate it until it

has been inspected and repaired.

Stop switch, wait one minute and try again.

Holding the switch for longer than 15 sec-

onds can damage the starter motor.

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

warm up.

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

main circuit breaker or transfer switch).

2.6 STOPPING THE GENERATOR

1. Turn OFF all electrical loads using the means provided (such

as a main circuit breaker or transfer switch).

2. Let generator run at no-load for a few minutes, to stabilize inter-

nal engine generator temperatures.

3. Place the Start/Stop switch in its STOP position.

2.7 APPLYING LOADS TO

Never sleep in the vehicle while the genset

GENERATOR

is running unless the vehicle has a working

When applying electrical loads to the generator, observe these

guidelines:

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.

• Before applying electrical loads, let the generator stabilize and

warm up for a minute or two.

• DO NOT overload the generator.

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Operation

Figure 2.2 – Low Oil Pressure and

2.7.1 LETTING THE ENGINE STABILIZE

High Temperature Switches

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.

High Temperature Switch

Low Oil Pressure

Switch

If electrical loads are applied at reduced operating speeds, such

loads imposed on the engine when sufficient power is not available

may shorten engine life. Never turn ON electrical loads until after the

generator engine has started and stabilized at no-load.

2.8 DO NOT OVERLOAD THE

GENERATOR

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

generator data label (see "Generator Identification").

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

cause the engine/generator to automatically shut down.

To avoid overloading, add up the wattage of all connected electrical

lighting, appliance, tool and motor loads. This total should not be

greater than the generator’s rated wattage capacity.

2.9.3 FIELD BOOST

The Controller Circuit Board houses a field boost diode and resistor

that are not part of the automatic choke circuit. These two compo-

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

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

the diode, resistor, brushes and slip rings, to 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.

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

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

simply note the wattage rating of the bulb.

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

rated VOLTS times AMPS to obtain WATTS.

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

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

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

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

when connecting electrical loads to the generator. First, figure

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

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

2.9 PROTECTION SYSTEMS

2.9.1 LOW OIL PRESSURE SWITCH

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

are held open by engine oil pressure during cranking and operating.

Should oil pressure drop below a preset level, switch contacts close,

and the engine automatically shuts down. The unit should not be

restarted until oil is added.

2.9.2 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 305º F (152º C), initiating an engine

shutdown.

2.9.4 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 120 volts (voltage-to-frequency

ratio is 2-to-1).

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Maintenance

Figure 2.4 – Solid State Voltage Regulator

3.1 CHECKING THE ENGINE OIL

LEVEL

For oil capacities and requirements, see “Engine Oil Requirements”.

Check the engine crankcase oil level at least every eight hours of

operation, or before each use. To check the engine oil level, pro-

ceed 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.

The voltage regulator also incorporates a “voltage surge protection

circuit.” This circuit prevents troublesome surges in the generator

AC output voltage. Voltage surge is a common cause of damage

to electronic equipment.

Never operate the engine with the oil level

below the “Add” mark on the dipstick. Doing

this could damage the engine.

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

ating the engine.

2.10 ADDITIONAL INFORMATION

2.10.1 ATTENTION REQUIRED AFTER SUBMERSION

3.2 CHANGING THE ENGINE OIL

If the recreational vehicle generator has been submerged in water,

it be started and operated. Following any submersion in water,

have an Authorized Service Dealer thoroughly clean and dry the

generator.

AND/OR OIL FILTER

• Change the after the first 25 hours of operation. Thereafter,

change the oil every 100 operating hours. Change the oil more

frequently if operating consistently under heavy load or at high

ambient temperatures.

2.10.2 OPERATION IN HIGH GRASS OR BRUSH

• Change the engine after the first 25 hours of operation, and

Never operate the generator while the vehicle is parked over high

grass, weeds, brush, leaves or any other combustible substance.

Such materials can ignite and burn from the heat of the exhaust

system. The generator exhaust system becomes extremely hot

during operation and remains hot for a long time after it has shut

down.

every 100 operating hours thereafter.

• To change the oil and/or oil filter, proceed as follows (see Figure

3.1):

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

minutes) then shut OFF the engine.

2. Immediately after the engine shuts OFF, pull the oil drain

cover free of the base. Remove the plug from the tube with a

5/16” allen wrench and drain the oil into a suitable container.

Loosening the oil fill cap will allow the crankcase to drain

faster.

2.10.3 EFFECTS OF MOISTURE AND DIRT

Keep the generator set as clean and dry as possible. Protect the

unit against excessive dust, dirt, corrosive vapors, road splash,

etc. Permitting dirt and moisture to accumulate on generator

windings will have an adverse effect on the insulation resistance

of those windings.

3. After the oil has drained, replace the plug onto the end of the oil

drain tube. Retain the cover in the base.

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

terclockwise. Place a towel underneath to catch excess oil.

5. Apply a light coating of clean engine oil to the gasket of the

new filter. Fill the filter until saturated with clean oil.

6. Screw the new filter on by hand until its gasket lightly contacts

the oil filter adapter. Then, tighten the filter an additional 3/4 to

one turn.

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.

7. Remove the dipstick and wipe it dry with a clean, lint-free

cloth. This will be used later to check the oil level.

8. Remove the oil fill cap on the oil fill tube and slowly add the

proper type and amount of recommended oil (see “Engine Oil

Requirements”). Periodically use the dipstick to check the oil

level and continue to fill the crankcase until the oil reaches

the dipstick “Full” mark. DO NOT FILL ABOVE THE “FULL”

MARK.

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Maintenance

Figure 3.1 – Oil Maintenance Features

CONTROL CENTER

I M

7.5

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE

OIL LEVEL:

AIR FILTER:

CHECK DAILY

CLEAN PREFILTER

EVERY 100 HOURS.

REPLACE ELEMENT

EVERY 250 HOURS.

OIL

OIL FILTER:

CHANGE EVERY 100

HOURS. (OR ANNUALLY)

PERFORM MORE OFTEN IN DUSTY CONDITIONS

SPARK PLUGS:

FUEL FILTER:

INSPECT

CLEAN

PLUGS EVERY 100

HOURS. REPLACE PLUGS

EVERY 500 HOURS.

(IF NECESSARY)

GENERAC

CHANGE EVERY 400

HOURS. (OR ANNUALLY)

POWERED

OHVI

REPLACEMENT INFORMATION

PREFILTER P/N:

AIR FILTER P/N:

OIL FILTER P/N:

SPARK PLUG P/N:

FUEL FILTER P/N:

0D4511

0D3262

070185

072347

0D7515

OIL CAPACITY WITH FILTER:

0.8L/0.84QT

TEMPERATURE

SAE VISCOSITY

32˚F AND HIGHER

10˚F TO 100˚F

0˚F TO 80˚F

15W-40

10W-30

5W-30

GENERAC OHVI INDUSTRIAL ENGINE

-20˚F TO 50˚F

WHEN SERVICE OR PARTS ARE NEEDED IN

THE USA OR CANADA, CONTACT THE GENERAC

SERVICE LOCATOR AT 1-800-333-1322.

QUIETPACT 40G

RV SERVICE LOCATOR:

1.800.333.1322

Oil Drain

Oil Filter

Oil Dipstick/Oil Fill

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

Figure 3.2 – Engine Air Cleaner

ating the engine.

10. Start the engine and check for leaks.

NOTE:

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

leaks. The filter will retain some oil.

3.3 MAINTAINING THE ENGINE

AIR CLEANER

3.3.1 CLEANING THE FOAM PRECLEANER

Clean and re-oil the foam precleaner every three months or every

25 hours of operation, whichever occurs first. Service the foam

precleaner more frequently if operating the generator in extremely

dusty or dirty conditions. Use the following procedure (Figure

3.2):

3.3.2 CLEANING OR REPLACING THE PAPER FILTER

Once each year or every 100 hours of operation (whichever comes

first), clean or replace the paper filter. The new replacement filter

must be flame retardant. Service the paper filter more frequently if

operating the generator in extremely dusty or dirty conditions. Use

the following procedure (Figure 3.2):

1. Turn the two screws counterclockwise to loosen.

2. Remove the cover, foam precleaner and paper filter.

3. Remove the foam precleaner from the cover.

4. Wash the foam precleaner in liquid detergent and water.

5. Wrap the foam precleaner in a clean cloth and gently squeeze

it dry.

6. Saturate the foam precleaner in clean engine oil. Gently

squeeze it in a clean cloth to remove excess oil and to distrib-

ute oil (DO NOT TWIST).

1. Follow steps 1-3 in "Cleaning the Foam Precleaner"; service

the foam precleaner if necessary.

2. Remove the paper filter.

3. Clean the air filter by tapping it gently on a solid surface. If the

filter is too dirty, replace it with a new one. Dispose of the old

filter properly.

4. Clean the air cleaner cover then reassemble following steps

7. Install the foam precleaner into the cover, followed by the

7-9 in section "Cleaning the Foam Precleaner".

paper filter.

8. Install the cover, foam precleaner and paper filter.

9. Tighten the two screws to retain the filter in place.

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Maintenance

3.4 CLEAN AIR INTAKE

Clean all foreign material from the air intake (Figure 3.3) at least

once every 100 hours of operation. Clean more often if neces-

sary.

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.

Inspect the area around the generator exhaust muffler periodically

and remove all grass, leaves, dirt, etc., from this area.

3.6 FUEL FILTER

Figure 3.3 – Cleaning Air Intake

Remove and replace the fuel filter (Figure 3.5) once each year or

every 400 hours of operation, whichever comes first. Fuel filter is

removed with a 15/16” deep well socket.

Figure 3.5 – Fuel Filter

POS

FUEL

NEG

USTC

3.5 CHECKING THE ENGINE

3.7 CLEAN SPARK ARRESTOR

The engine exhaust muffler has a spark arrestor screen. Inspect

and clean the screen every 50 hours of operation or once each

year, whichever comes first.

SPARK PLUG

Clean the spark plug and reset the spark plug gap every 100 hours

of operation.

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

and debris out of the engine. Remove the spark plug and

check the condition. Replace the spark plug if worn or if reuse

is questionable.

2. Clean spark plug by scraping or washing using a wire brush

and commercial solvent. Do not blast the spark plug to

clean.

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

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

electrode (Figure 3.4).

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.

• Remove the screen retaining bracket by removing the screw.

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

• Inspect screen and replace if torn, perforated or otherwise

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

damaged, clean it with commercial solvent.

Figure 3.4 – Setting the Spark Plug Gap

• Replace the screen and the retaining bracket.

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Maintenance

Figure 3.6 - Spark Arrestor

3.9.2 EVERY SIX MONTHS

• Have the state of charge and condition checked. This should be

done with an automotive-type battery hydrometer.

Note:

Servicing of the battery is to be performed or supervised by

personnel knowledgeable of batteries and the required precau-

tions. Keep unauthorized personnel away from batteries.

TAILPIPE

P/N 0E0683

Damage will result if the battery connections are made in

reverse.

^D^{o not dispose of the battery in a fire. The}

battery is capable of exploding. Storage bat-

SPARK ARRRESTOR

SCREEN P/N 089680

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.

RETAINING

SCREW P/N 056892

3.8 CLEANING THE GENERATOR

Keep the generator set as clean and dry as possible. Protect the

unit against excessive dust, dirt, corrosive vapors, road splash,

etc. Permitting dirt and moisture to accumulate on generator

windings will have an adverse effect on the insulation resistance

of those windings.

When moisture is allowed to remain in contact with windings,

some of the moisture will be retained in voids and cracks in the

insulation. This causes a reduced insulation resistance and will

eventually cause problems. Dirt will make the problem worse,

since dirt tends to hold moisture in contact with windings. Salt (as

from sea air) also will worsen the problem since it tends to absorb

moisture from the air. Salt and moisture, when combined, form a

good electrical conductor which can be damaging to the generator

windings.

^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:

• Remove watches, rings or other metal objects;

• Use tools with insulated handles;

• Wear rubber gloves and boots;

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

battery;

• Disconnect any charging source prior to connect-

ing or disconnecting battery terminals; and

• Do not use any jumper cables or booster battery

to crank and start the generator engine. If any

battery has discharged, remove it for recharging.

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.

3.9 BATTERY MAINTENANCE

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

tor battery should be inspected as follows:

Do not open or mutilate the battery.

Released electrolyte has been known to

be harmful to the skin and eyes, and to be

toxic.

3.9.1 WEEKLY

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

sion. Tighten and clean as necessary.

• Check the battery fluid level of unsealed batteries and, if nec-

essary, fill with Distilled Water Only. Do not use tap water in

batteries.

The electrolyte is a dilute sulfuric acid that

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

cally conductive and corrosive. The follow-

ing procedures are to be observed:

• Wear full eye protection and protective clothing;

• Where electrolyte contacts the skin, wash it off

immediately with water;

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Maintenance

• Where electrolyte contacts the eyes, flush

thoroughly and immediately with water and

seek medical attention; and

3.12.2 RETURN TO SERVICE

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

1. Check the tag on the engine for oil viscosity and classification.

Verify that the correct recommended oil is used in the engine

(see "Engine Oil Requirements"). If necessary, drain and refill

with the proper oil.

2. Check the state of the battery. Fill all cells of unsealed batteries

to the proper level with distilled water. DO NOT USE TAP WATER

IN THE BATTERY. Recharge the battery to 100 percent state of

charge, or, if defective, replace the battery.

• 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.

3. Clean and wipe the entire generator.

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

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.

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 run for several minutes to warm up.

7. Apply electrical loads to at least 50 percent of the unit’s rated

wattage capacity.

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

9. The generator is now ready for service.

3.11 EXERCISING THE GENERATOR

The manufacturer recommends that the generator be started and

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

least 30 minutes to “exercise” the engine.

3.13 ADJUSTING VALVE

3.12 OUT OF SERVICE PROCEDURE

CLEARANCE

After the first 50 hours of operation, adjust the valve clearance in

the engine.

3.12.1 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:

When adjusting valve clearance, the engine should be at room

temperature and the piston should be at Top Dead Center (TDC)

of its compression stroke (both valves closed). Correct clearance

is 0.001-0.003 inch (0.03-0.07mm). Adjust valve clearance as

follows:

1. Start the engine and let it warm up.

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

the unit to shut down.

1. Loosen the rocker arm jam nut. Use an allen wrench to turn

the pivot ball stud while checking clearance between the

rocker arm and the valve stem with a feeler gauge (Figure

3.7).

Note:

Using a fuel additive such as STA-BIL fuel stabilizer, or an

equivalent, will prevent gum deposits from forming in the

engine’s fuel system.

Figure 3.7 — Adjusting Valve Clearance

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

pletely. Refill the crankcase with SAE 10W-30 oil having API

classification “For Service SF.”

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

sification of the oil in the crankcase.

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

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

Reinstall and tighten the spark plug.

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

wooden board. Never store the battery on any concrete or

earthen floor.

7. Clean and wipe the entire generator.

FEELER GAUGE

ALLEN WRENCH

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Maintenance

2. When valve clearance is correct, hold the pivot ball stud with

the allen wrench and tighten the rocker arm jam nut with a

crows foot. Tighten the jam nut to 65-85 inch-pounds torque.

After tightening the jam nut, recheck valve clearance to make

sure it did not change (Figure 3.8).

Figure 3.8 — Tightening Jam Nut

CROW'S

FOOT

3.14 RV GENERATOR SERVICE

INTERVAL

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

100 Hours ..............................................Change Engine Oil/filter

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

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

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

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

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

1st 50 Hours-then

every 500 Hrs. ............................................ Adjust Valve Lash

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Notes

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PART II –

INSTALLATION

INSTRUCTIONS

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!

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Safety Rules

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

article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational

Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the

manufacturer’s instructions and recommendations.

GENERAL HAZARDS

NOTICE TO INSTALLER

These Installation Instructions have been published by the manu-

facturer to aid in the installation of the products described in this

manual. The manufacturer assumes that installation personnel

are familiar with the procedures for installing such products, or

similar products manufactured. The manufacturer also assumes

that personnel have been trained in the recommended installation

procedures for these products and that such training includes (a)

use of common hand tools, (b) use of special tools, and (c) use of

any tools and/or equipment from other suppliers.

• 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 engine exhaust fumes contain carbon monoxide, which can

be DEADLY. This dangerous gas, if breathed in sufficient con-

centrations, can cause unconsciousness or even death. This

exhaust system must be installed properly, in strict compliance

with applicable codes and standards. Following installation, do

nothing that might render the system unsafe or in noncompli-

ance with such codes and standards. The generator compart-

ment must be completely vapor sealed from the vehicle interior.

There must be no possibility of exhaust fumes entering the

vehicle interior. Never operate this equipment with a leaking or

defective exhaust system.

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 we

anticipate every possible hazard that might result from each instal-

lation method, procedure or technique. The manufacturer has not

undertaken any such wide evaluation. Therefore, people who use

a method, procedure or technique that the manufacturer does not

specifically recommend must first completely satisfy themselves

that their safety, the safety of the vehicle's occupants and the

product's safety is not endangered by the method, procedure or

technique selected.

• 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.

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.

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

Never work on the equipment when physically or mentally

fatigued.

• Before performing any maintenance on the generator, discon-

nect its battery cables to prevent accidental start up. Disconnect

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

or (–) first. Reconnect that cable last.

• Never use the generator or any of its parts as a step. Stepping

on the unit can stress and break parts, and may result in dan-

gerous operating conditions from leaking exhaust gases, fuel

leakage, oil leakage, etc.

Despite the safe design of this generator,

operating this equipment imprudently, neglect-

ing its maintenance or being careless can

cause possible injury or death. Permit only

responsible and capable persons to operate

or maintain this equipment.

Potentially lethal voltages are generated by

these machines. Ensure all steps are taken



• 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 may occur.

to render the machine safe before attempting

to work on the generator.

Parts of the generator are rotating and/or

hot during operation. Exercise care near run-

ning generators.

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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 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.

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 to install an approved, flexible, nonconductive fuel

line between the generator fuel connection point and rigid fuel

lines.

• 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.

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General Information

1.1 PURPOSE AND SCOPE

1.4 EQUIPMENT DESCRIPTION

Instructions and information in this section pertain to air-cooled

generators. This generator is designed specifically for installing in

recreational vehicles. This generator operates 120-volts, single-

phase, 60-Hertz, AC electrical loads that require 30.0 amps.

OF THE MANUAL

These Installation Instructions have been prepared especially for

the purpose of familiarizing installers and owners of the applicable

equipment with the product's installation requirements. Give 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

Because of the different recreational vehicle models and the

variations between the models, it would be extremely difficult, if

not impractical, to provide detailed instructions for every possible

installation. For that reason, instructions and illustrations in this

manual are general in nature. Illustrations are not intended to serve

as detailed installation blueprints.

The generator’s revolving field (rotor) is driven by a single-cylinder,

four-cycle engine. The generator supplies 120 volts AC at 60 Hertz

when the rotor is operating at 3,600 rpm.

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

The generator is equipped with dual stator power windings as

shown in Figure 1.1.

Figure 1.1 – 120-volt Single Voltage Connection

1.2 SAFETY

BLACK

Before handling, installing, operating or servicing this equipment,

carefully read the “Notice to Installer” and “Safety Rules”. Comply

with all safety rules to prevent death, personal injury or damage to

equipment and/or property. Stress safety to all installers, operators

and service technicians who work on this equipment.

1.3 STANDARDS BOOKLETS

Installation, use and servicing of this equipment should comply

strictly with published standards, as well as the manufacturer's

recommendations. The following standards booklets (latest revi-

sion) are available from the sources indicated:

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

available from the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

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

GROUNDED neutral.

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

• A separate green ground wire is connected to the recreational

available same as Item 1.

vehicle’s junction box.

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

American National Standards Institute, 1430 Broadway, New

York, NY 10018.

NOTE:

Do NOT connect loads in excess of circuit breaker ratings.

4. ANSI A119.2/NFPA 501C, available from the Recreational

Vehicle Association, 1896 Preston White Drive, Reston, VA

22090.

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

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

Highlands, CA 95660.

6. CSA Electrical Bulletin 946, available from the Canadian

Standards Association, Housing and Constructions Materials

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

M9W 1R3.

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General Information

Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-K)

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Installation

• 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.

2.1 LOCATION AND SUPPORT

2.1.1 GENERATOR LOCATION

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.

Figure 2.1 – Typical Horizontal Support Frame

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.

Plan the generator location based on the following:

• The generator set must be installed on a framework that is

part of the recreational vehicle, as outlined in the "Generator

Support" section.

• The location must provide an access opening that is large

enough to permit generator removal (unless the generator is to

be removed from underneath the supporting framework).

• The location must provide easy access to frequently serviced

components, such as filters, oil drains, spark plugs and other

common maintenance parts.

• The location must provide sufficient room to allow minimum

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.

2.1.3 SUSPENDED MOUNTING

If the generator will be suspended below the horizontal support

tubing, the suspension method used with the vehicle frame mem-

bers must (a) be able to support the weight of the generator AND

(b) provide sufficient restraint for the generator. One typical sus-

pended mounting system is shown in Figure 2.2. The location of

a suspended mounting system must be carefully planned, keeping

the following general rules in mind:

• 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.

• 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.

• The installer must make certain that the selected location will

permit adequate cooling and ventilating airflow to be supplied.

Figure 2.2 – Typical Suspended Mounting System

2.1.2 GENERATOR SUPPORT

The generator must be securely attached to a metal framework that

has been made part of the vehicle frame structure by bolting or

welding. The metal framework on which the generator will rest and

which will restrain the generator set should consist of at least two

horizontal beams. These beams should consist of (a) 1-1/2-inch

square, 11-gauge steel tubing OR (b) 1-1/2-inch, 11-gauge angle

iron. A typical supporting frame with horizontal support tubing, is

shown in Figure 2.1.

GENERATOR

SUPPORT FRAME

(MODEL 004718-0)

GENERATOR MOUNTING

HOLES FOR 5/16" - 18

BOLTS (6 PLACES)

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:

2.1.4 GENERATOR RESTRAINT

Use four 5/16"-18 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 sup-

porting 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.

• 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.

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Installation

• 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).

Figure 2.3 – Typical Generator Restraint

Figure 2.5 – Typical Compartment Construction

2.2 GENERATOR COMPARTMENTS

Whether the generator set is being installed inside a compartment

specifically manufactured to house a generator or inside a com-

partment that the installer constructs, the compartment must meet

certain specifications as outlined in the following sections:

2.2.1 COMPARTMENT SIZE

Plan the compartment size carefully. Provide a minimum clearance

of 1/2 inch (13 mm) on the front and top, one (1) inch (25 mm) on

the sides, and one (1) inch (25 mm) from the back for air circula-

tion AFTER the compartment has been lined with metal and sound

insulation (Figure 2.4).

Figure 2.4 – Clearances

• 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.

Plywood

Compartment

1/2" Clearance on Top

1" Clearance

in Back

NOTE:

Caulking must be done so that the caulking material will stay in

place permanently. Pressing such materials as putty tape onto

joints and seams is NOT acceptable. A high quality silicone rubber

base sealant is recommended.

1" Each Side

1/2"

Insulation

in Front

• Holes and openings made in the compartment walls to allow for

the passage of electrical conduit, conductors, hoses, cables,

etc., into the vehicle living area must be sealed vapor tight with

silicone rubber base sealant.

• If flexible metal conduit is used, it must be sealed internally at

the end where it terminates inside the compartment’s electrical

junction box.

NOTE:

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

NOTE:

Flexible metal conduit, due to its unique construction, is NOT

vapor tight along its entire length.

2.2.2 COMPARTMENT CONSTRUCTION

• The generator compartment should be either constructed of, or

• 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.

lined with, 26-gauge galvanized steel.

NOTE:

Aluminum is NOT an acceptable alternative to galvanized steel

due to aluminum’s low melting point.

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Installation

NOTE:

Figure 2.6 – Types of Lock Seams

Any method used to reduce noise must not adversely affect the

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

ment.

In addition to the effective use of sound insulating materials,

construction of a special noise abatement compartment might be

considered to reduce noise levels. Such a compartment might be

constructed as follows (Figure 2.7):

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

ment.

• Construct the compartment floor of a double thickness of 5/8-

inch or 3/4-inch plywood.

Figure 2.7 – Typical Noise Abatement

• 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").

^D^{o 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

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.

• 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.

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.

• Over the galvanized steel lining, install a combination of acousti-

cal materials as mentioned in "Sound Insulating Materials".

^T^{o prevent fire or explosion, do not install}

any insulation or other absorbent materials

on the interior or underside of the compart-

ment floor.

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

bent material on the compartment floor inte-

rior. Such materials will become soaked with

combustible or explosive vapors and

liquids and will become a fire hazard.

• Seal all compartment door edges to prevent noise leakage

around the door perimeter.

• 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).

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.

2.2.5 COMPARTMENT FLOOR CUTOUTS

Provide openings in the generator compartment for the following

items (Figure 2.8 on page 26):

2.2.4 ACOUSTICS

For additional noise abatement, the installer may wish to consider

the following:

• Engine exhaust and cooling air outlets

• Generator cooling air inlet

• Using special sound insulating materials.

• Construction of a special noise abatement compartment.

• Four holes for passage of generator mounting bolts (see

"Generator Restraint").

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Installation

Figure 2.8 – Compartment Floor Cutout (Drawing 0G3723-A)

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Installation

2.3.2 TESTING THE INSTALLATION

The manufacturer recommends testing the installation to be sure

adequate cooling airflow is available to the unit before placing the

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

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

that cooling and ventilation is adequate.

Fuel lines and exhaust piping must not pen-

etrate into the vehicle living area.

2.3 COOLING AND VENTILATING

NOTE:

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.

Test the installation, especially if bringing in air from below the

generator set.

2.4 GASOLINE FUEL SYSTEM

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.

^N^{ever use discharged cooling air for heating}

or permit such air to enter the vehicle inte-

Figure 2.10 – Generator Fuel System

rior. This air contains deadly carbon monox-

ide gas and other poisonous, flammable or

explosive gases.

CONTROL CENTER

7.5

2.3.1 GENERATOR AIRFLOW

AIR FILTER LOCATED BEHIND PANEL.

MAINTENANCE SCHEDULE

OIL LEVEL:

AIR FILTER:

CHECK DAILY

CLEAN PREFILTER

EVERY 100 HOURS.

REPLACE ELEMENT

EVERY 250 HOURS.

Engine operation drives cooling fans for the two-stage cooling air

system. A pressure fan draws cooling air into the bottom right side

of the generator (Figure 2.9). This airflow cools the engine/generator

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

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

tor compartment at the left side of the unit. This heated air (although

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

the ground.

OIL

OIL FILTER:

CHANGE EVERY 100

HOURS. (OR ANNUALLY)

PERFORM MORE OFTEN IN DUSTY CONDITIONS

SPARK PLUGS:

FUEL FILTER:

INSPECT

CLEAN

PLUGS EVERY 100

HOURS. REPLACE PLUGS

EVERY 500 HOURS.

(IF NECESSARY)

GENERAC

CHANGE EVERY 400

HOURS. (OR ANNUALLY)

POWERED

OHVI

REPLACEMENT INFORMATION

PREFILTER P/N:

AIR FILTER P/N:

OIL FILTER P/N:

SPARK PLUG P/N:

FUEL FILTER P/N:

0D4511

0D3262

070185

072347

0D7515

OIL CAPACITY WITH FILTER:

0.8L/0.84QT

TEMPERATURE

SAE VISCOSITY

32˚F AND HIGHER

10˚F TO 100˚F

0˚F TO 80˚F

15W-40

10W-30

5W-30

GENERAC OHVI INDUSTRIAL ENGINE

-20˚F TO 50˚F

WHEN SERVICE OR PARTS ARE NEEDED IN

THE USA OR CANADA, CONTACT THE GENERAC

SERVICE LOCATOR AT 1-800-333-1322.

QUIETPACT 40G

RV SERVICE LOCATOR:

1.800.333.1322

Fuel Pump & Fuel Filter

(Behind Access Panel & Air Filter)

Figure 2.9 – Airflow Through Engine/Generator

^G^{asoline 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.

Factory installed generator fuel system components include (a)

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

(d) interconnecting lines and fittings. Connect a fuel supply line

to the fuel filter inlet. Use a flexible length of approved fuel hose

between the fuel filter inlet connection and rigid fuel lines.

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Installation

2.4.1 FUEL TANK

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.

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

or install a separate fuel tank for the generator set. All fuel tanks

installed on the vehicle must be constructed, installed and

restrained so they comply with applicable codes, standards and

regulations.

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 2 to

3 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.

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.

Do NOT tee the generator fuel supply line

into the vehicle engine fuel supply line. If

this is done, the generator will be starved of

fuel when both engines are operating at the

same time. Also, while the vehicle engine is

not running, generator operation may drain

the vehicle engine supply line, making it dif-

ficult to start the vehicle engine.

2.4.2 GENERATOR FUEL SUPPLY LINE

2.4.2.1 Rigid Fuel Lines

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

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

lowing general rules apply to rigid fuel lines:

Never tee the generator engine exhaust pipe

into the vehicle engine exhaust piping. This

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

or steel.

• Lines and fittings must comply with SAE J512F, “Standard

Automotive Fittings,” or with ANSI B126.26 (latest edition).

• Route the fuel line so that at least 2 inches (51 mm) of clear-

ance is maintained between the line and any exhaust system

parts.

• Do not attach electrical wiring to fuel lines. Route the wiring so

it cannot come into contact with any fuel line.

• Route fuel lines so if they leak, fuel does not drip onto any

electrical or exhaust system parts.

causes excessive back pressure on the gen-

erator engine. Also, water from one engine

can damage the other engine.

2.5.1 SPARK ARRESTOR

This spark arrestor assembly meets code and standard require-

ments of the U.S. Forest Service. Use only mufflers and parts

approved by the manufacturer. Any person(s) installing an unap-

proved muffler, or an unapproved exhaust system part, or modify-

ing 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.

• Use nonferrous metal straps without sharp edges to secure

fuel lines.

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, provide a spark arres-

tor. 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.

2.4.2.2 Flexible Fuel Line

Use an approved flexible length of fuel hose between the generator

fuel inlet connection and rigid fuel lines. This prevents breaking of

the line caused by vibration, shifting, settling or movement. The

following rules apply:

• The flexible hose must comply with SAE J30R7, “Standard for

Fuel and Oil Hose.” It must be approved for use with gasoline

and low permeability.

• The hose should be at least 6 inches (152 mm) longer than

is needed to prevent the hose from rupturing if the generator

shifts or settles.

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.

Figure 2.11 - Spark Arrestor

• 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.

TAILPIPE

P/N 0E0683

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

cable codes, standards and regulations.

SPARK ARRRESTOR

SCREEN P/N 089680

2.6 ELECTRICAL CONNECTIONS

The following general rules apply to electrical connections in a

recreational vehicle:

RETAINING

• 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.

SCREW P/N 056892

Figure 2.12 — Spark Arrestor Installation

• 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.

27.4 [1.08"] I.D.

5.5 [7/32"] DRILL

BOTTOM SIDE ONLY

40 [1.58"]

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.

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 cannont be maintained, locate,

insulate or shield the exhaust part(s) so that the temperature of

any combustible material is not raised more than 117° F (65°

C) above the ambient air temperature.

• Extend the exhaust system at least 1 inch (25 mm) past the

outer edge of the vehicle. Do not terminate the exhaust system

under the vehicle.

• Terminate the exhaust tailpipe such that exhaust gases will not

be drawn back into the generator compartment and recircu-

lated.

• If there is any possibility of the tailpipe or muffler being damaged,

protect these damage-prone areas by means of a protective

device (such as a skid bar).

2.6.2 WIRING

• Wiring should be of stranded copper to reduce the chance that

vibration may cause breakage.

• Wire gauge size should be large enough to handle at least 115

percent of the installed generator's rated maximum current.

• Neutral conductors must be the same size as other leg wires.

• Route power supply conductors from generator AC output leads

(white), (black) and the green ground wire through approved

flexible conduit to the electrical junction box on the compart-

ment 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.

• 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.

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Installation

• 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).

2.6.4 CONDUIT

Route the connections between the generator and the junction box

through approved, flexible conduit. The following general rules

apply:

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

tion box connections.

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

• Carefully prepare conduit ends to prevent sharp edges from

larger conductor size.

cutting through wiring insulation.

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

ment.

2.6.3 GENERATOR AC CONNECTIONS

• 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 vaporproof along its entire length.

Generator AC output leads (BLACK) “hot” and (WHITE) grounded

neutral come out of the generator as shown in Figure 2.13. There

is also a green lead that connects to ground in the junction box of

the recreational vehicle.

2.6.5 ISOLATING DIFFERENT POWER SOURCES

Leads BLACK to WHITE are protected against overload by a

30-amp circuit breaker (CB1). Use this line-to-neutral connection

separately to operate 120-volt, single-phase, 60 Hertz, AC loads

requiring up to 3,600 watts (3.6 kW) of power.

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.

Figure 2.13 – Generator AC Output Leads

2.6.6 POWER SUPPLY CORD

483.1

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.

REMOTE PANEL

CONNECTOR

2.6.7 GROUND FAULT CIRCUIT INTERRUPTERS

The National Electrical Code (NFPA 70, 551-7) requires that

ground fault circuit interrupters (GFCIs) be installed on all external

and some internal electrical receptacles. Contact the dealer for

recommendations.

AC OUTPUT

HARNESS

FUEL FILTER

2.7 BATTERY INSTALLATION

BATTERY

CONNECTIONS

2.7.1 RECOMMENDED BATTERY

Install a battery that meets the following requirements:

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

tery.

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

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

cold-cranking amperes.

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

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

cold-cranking amperes.

^D^{o NOT connect electrical loads in excess}

of any circuit breaker rating or problems will

develop with circuit breaker tripping, which

causes a loss of AC output. Also, do NOT

exceed the generator's rated wattage 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.

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Installation

Figure 2.14 – Transfer Switch Isolation Method

Figure 2.15 – Installation With Isolation Receptacle

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Installation

2.7.2 BATTERY CABLES

2.7.4 BATTERY COMPARTMENT

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.

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

the battery compartment away from any source of heat, sparks

or flame.

Provide ventilation openings in the battery compartment. The

minimum size of openings should be 2 square inches at the top

of the compartment. Mount the battery on a strong, rigid support-

ing structure, where leaks and spills of battery fluid will not cause

damage.

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.

2.8 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.

CABLE LENGTH

CABLE SIZE

in Feet (Meters)

0 to 10 (0 to 3)

11 to 15 (3.4 to 4.5)

16 to 20 (4.5 to 6)

Figure 2.17 – Remote Panel Plug-in Receptacle

000

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

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).

14A

NOTE:

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

been installed.

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

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

2.16).

12.00"

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

WIRE

No.

WIRE

COLOR

LENGTH (mm)

FUNCTION

GROUND

Figure 2.16 – Connecting Battery Cables

WHITE

RED

ORANGE

YELLOW

BROWN

BLUE

12.0 (305)

ENGINE RUN SIGNAL

12 VDC

START

STOP

PRIME

POS

14A

FUEL

P/N: 0D9099-B

NEG

2.8.1 REMOTE START/STOP PANEL

A remote mounted Start/Stop panel is available that allows the

user to start and stop the generator engine conveniently from

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

hourmeter, generator run lamp, a fuel prime switch, and a wire

harness. The hourmeter should be used in conjunction with the

maintenance operations found in Part I of this manual.

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Post Installation Start-up Adjustments

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.

3.1 POST INSTALLATION TESTS

The air-cooled generator set was factory tested and adjusted. It

should not be required to adjust the unit any further except under

special circumstances.

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.

Do not make any unnecessary adjustments.

Factory settings are correct for most appli-

cations. When making adjustments, however,

be careful to avoid overspeeding the engine.

3.2 BEFORE INITIAL START-UP

Before starting, complete the following:

NOTE:

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.

The generator set was thoroughly tested and adjusted at the

factory before shipping. No additional adjustment should be

necessary. Only qualified service technicians who have been

trained should perform adjustments outlined in this manual.

3.4 TESTING UNDER LOAD

Apply electrical loads equal to about 75 to 100 percent of the unit's

rated wattage/amperage capacity.

If a liquid propane (LP) gas fuel system has

been installed, it must be properly tested for

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.

leaks before operating the system in compli-

ance with ANSI A119.2/NFPA 501C. No leak-

age is permitted. Be sure that no gasoline

fuel vapors enter the vehicle interior.

NOTE:

The generator engine is equipped with a high temperature

switch. The switch has normally closed (N.C.) contacts. When

the engine temperature is too high, switch contacts close, and

the engine shuts down automatically.

3.3 INITIAL START

When absolutely certain that the unit has been properly installed

and prepared for use, start the engine as follows:

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

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

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

starting instructions. The engine may require more cranking

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

of the primer switch will shorten this time).

THE MANUFACTURER RECOMMENDS THAT THE GENERATOR

BE TESTED FOR ADEQUATE COOLING.

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Post Installation Start-up Adjustments

EXHAUST SYSTEM

❑ Exhaust system complies with all applicable codes.

3.5 INSTALLATION CHECKLIST

LOCATION AND SUPPORT

❑ Exhaust system is properly and safely installed.

❑ Generator is properly located.

❑ Generator is properly supported.

❑ Generator is properly restrained.

ELECTRICAL CONNECTIONS

❑ Connections comply with local code requirements and all

National Electrical Codes.

GENERATOR COMPARTMENT

❑ Compartment construction is proper.

❑ Holes/Openings are vapor-sealed.

❑ Compartment size is correct.

❑ Compartment is vapor-sealed.

❑ Sound insulation is correct.

❑ Junction box is properly installed.

❑ Wiring meets all standards.

❑ All connections are correct.

❑ Conduit is properly installed and sealed.

❑ Generator is properly bonded to the vehicle.

BATTERY INSTALLATION

❑ Floor cutouts are properly completed.

❑ Recommended battery is installed.

❑ Recommended cables are installed.

❑ Cables are clean and tight.

COOLING AND VENTILATING AIR

❑ Airflow is adequate.

❑ Air inlet opening is correct.

❑ Compensate for restrictions.

❑ Check that installation has been tested.

❑ Cables are connected properly.

❑ Proper ventilation is provided.

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

covers are positioned.

GASOLINE FUEL SYSTEM

❑ Fuel tank complies with all applicable codes.

OPTIONAL ACCESSORIES

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

❑ Fuel system is properly installed and checked

properly.

for leaks.

❑ Check that hourmeter kit (if used) is installed

properly.

OPTIONAL LP GAS FUEL SYSTEM

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

❑ Fuel system is properly installed and checked

installed properly.

for leaks.

❑ Pressure at regulator inlet is correct.

❑ Rated flow of primary regulator is correct.

❑ All parts are properly installed.

POST INSTALLATION TESTS

❑ Check that all tests are completed properly.

❑ Fuel system is properly tested/adjusted.

DATE OF INSTALLATION _______________________________________________________

NAME OF INSTALLER__________________________________________________________

SIGNATURE OF INSTALLER ____________________________________________________

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Troubleshooting

TROUBLESHOOTING GUIDE

Problem

Cause

Correction

The engine will not crank.

1. Fuse blown

1. Replace fuse.

2. Loose, corroded or defective

2. Tighten, clean or replace as necessary.

battery cables.

3. Defective engine Start/Stop switch

4. Defective starter contactor

5. Defective starter motor

6. Low or defective battery

3. Replace Start/Stop switch.

4. Replace contactor.

5. Replace starter motor.

6. Charge or replace battery.

The engine cranks but

will not start.

1. Out of fuel

1. Replenish fuel.

2. Replace fuel pump.

2. Defective fuel pump

3. Open #14 wire from

engine control board

3. Check connections and.

insulation of #14 wires.

4. Flooded engine

4. Wait 5-10 minutes before trying.

5. Clean, re-gap or replace plug(s).

6. Open fuel line shut-off.

7. Clean or replace fuel filter.

5. Defective spark plug(s)

6. Fuel line shut-off closed

7. Plugged fuel filter

The engine starts hard

and runs rough.

1. Air cleaner plugged or damaged.

2. Defective spark plug(s)

1. Check, clean or replace air cleaner.

2. Clean, re-gap or replace plug(s).

The engine starts, but shuts

down when the Start/Stop

switch is released.

1. Engine oil level low

1. Check oil and add oil as needed.

2. Replace pressure switch.

3. Replace temperature switch.

4. Replace control board.

5. Check that the airflow openings

are adequate.

2. Defective low oil pressure switch.

3. Defective high temperature switch.

4. Defective engine control board

5. Overheated engine

The Start/Stop switch is

set to Stop, but the engine

continues to run.

1. Defective Start/Stop switch

2. Open/Disconnected #18 wire

between Start/Stop switch

1. Replace switch.

2. Reconnect or close wire.

and engine control board

3. Open/Disconnected #0 wire

3. Reconnect or close wire.

4. Replace control board.

between Start/Stop switch

and engine control board

4. Defective engine control board

There is no AC output from

the generator.

1. Main line circuit breaker open

2. Fault with vehicle circuit

breaker and/or fuses

1. Reset circuit breaker to ON (or closed).

2. Reset and replace if necessary.

3. Transfer switch set to NORMAL

4. Start switch not held long

enough to flash the field

3. Set switch to GENERATOR.

4. Stop, then restart the engine

(Hold Start switch for at least

2 seconds).

5. Generator internal failure

5. Contact aN Authorized Service Dealer.

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Notes

Generac Power Systems, Inc.

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Electrical Data

Electrical Schematic/Wiring Diagram Drawing No. 0D8063-D

BATTERY

RED

BLK

14A

SW2

PCB

J1-1

J1-2

J1-3

J1-4

18A

J1-5

J1-6

(START)

(STOP)

SW1

J1-7

J1-8

HTO

J1-9

J1-10

J1-11

J1-12

J1-13

J1-14

J1-15

LOP

REMOTE

PANEL

CONNECTOR

BCR

14 A

BATTERY CHARGE WINDING

STOP

START

POWER WINDING

22S

11S

FUEL

PRIME

11P

22P

REMOTE PANEL

(OPTIONAL)

ELECTRONIC

VOLTAGE

CB1

LEGEND

REGULATOR

BCR - BATTERY CHARGE RECTIFIER

CB1 - CIRCUIT BREAKER, 30A

CB3 - CIRCUIT BREAKER, 2.5A

CH - CHOKE HEATER (GASOLINE ONLY)

CS - CHOKE SOLENOID

CB3

F1 - FUSE, 7.5A

FP - FUEL PUMP-OR-LPG SHUT OFF VALVE

FS - FUEL SOLENOID (GASOLINE ONLY)

GT - TERMINAL, GROUND 4-TAB

HM - METER, HOUR (OPTIONAL)

DPE WINDING

HTO - SWITCH, HIGH TEMP. OIL (CLOSES ON HIGH TEMP.)

IM - IGNITION MAGNETO

L1 - LIGHT, RUN (OPTIONAL)

LOP - SWITCH, LOW OIL PRESSURE (CLOSES ON LOW PRESSURE)

PCB - ENGINE CONTROLLER

FIELD

BLACK

WHITE

GREEN

R1 - RESISTOR, 1 OHM 25W

SC - STARTER CONTACTOR

SM - STARTER MOTOR

120V 30A

SW1 - SWITCH, START/STOP

SW2 - SWITCH FUEL PRIMER

SP - SPARK PLUG

NEUTRAL CONNECTION

BY CUSTOMER

TC - TERMINAL, CONN. 4-TAB

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Electrical Schematic/Wiring Diagram Drawing No. 0D8063-D

Electrical Data

SUPPLIED BY

CUSTOMER

SUPPLIED BY

CUSTOMER

12V

BATTERY

11S

ELECTRONIC

VOLTAGE

REGULATOR

22S

STATOR

16 56

J1-1

J1-2

J1-3

22S

11S

18A

J1-4

J1-5

J1-6

J1-7

J1-8

J1-9

PCB

CLOSEST TO BEARING

11P

22P

J1-10

J1-11

J1-12

J1-13

J1-14

J1-15

RED

FIELD

CB3

11P

BCR

22P

18A

CONN. 1

PIN#

14A

REMOTE

PANEL

CONN. 2

PIN#

SW1

SW2

CONNECTOR

11P

14A

11P

14A

WHITE

BLACK

CB1

14A

18A

FILTER MTG

SCREW

LOP

HTO

GREEN

18A

CUSTOMER

AC CONNECTION

GREEN

BLACK

WHITE

SP1

NEUTRAL CONNECTION

BY CUSTOMER

IM1

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Exploded Views & Parts Lists

Enclosure Drawing No. 0D8352-N

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Enclosure Drawing No. 0D8352-N

Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

0D6822

0D6942

0D6939

0D6943

0D6941

0D6941A

TRAY, ENCLOSURE

022237

022131

0C5443

0C7423

029451

074908

0D8717

0D9020

0742600144

0E0724

0G4933

0742600143

0D8595

0D8627

0D8628

0D8628A

0D8691

0D7176

0A2115

0D9282

2.1’

WASHER LOCK 3/8”

PANEL, ENCLOSURE SIDE

PANEL, REAR DIVIDER

PANEL, ENCLOSURE ROOF

PANEL, ENCLOSURE BACK

PANEL, ENCLOSURE BACK, EXTERNAL

PORT (04709 ONLY)

PANEL, FRONT DIVIDER

PANEL, FRONT DIVIDER, EXTERNAL

PORT (04709 ONLY)

COMPARTMENT, AIR INTAKE

PANEL, ENCLOSURE DOOR 4KW RV

SHIELD, MUFFLER

SLIDE LATCH, FLUSH

PUMP, FUEL

WASHER FLAT 3/8-M10”

BLOCK, TERMINAL BATTERY POST

STUD 3/8”-16 X 2”-1/4” BRASS

TAPE FOAM 1/8” X ½”

SCREW HHTT M5-0.8 X 10

CUSTOMER CONNECTION HARNESS

FOAM, AIR OUT COMPARTMENT SIDE

CABLE, STARTER

0D6940

0D6940A

ASSEMBLY OIL DRAIN

0D6945

0D6944

0D8254

0C5644

0D7513

087769

0D7613

0D7614

040173

047411

022473

023484S

022097

086729

0D3700

022129

022259

075763A

0D7293

064113

0C7561

0A4456

049813

SCREW SWT 1/4-20 X 5/8 W/W

CABLE, BATTERY CONNECTION

MOUNT, FUEL FILTER SUPPORT

FOAM, AIR INTAKE COMPARTMENT

FOAM, ROOF AIR OUT COMPARTMENT

FOAM, BACK COMPARTMENT

FOAM, DOOR PANEL

WASHER SELF LOCKING 1"

WASHER NYLON .250”

HARDWARE CLOTH COMPARTMENT

AIR OUT

FILTER, FUEL

FUEL LINE, FILTER TO PUMP

FUEL LINE, PUMP TO CARB

CLAMP,HOSE WORM GEAR

SCREW HHC M6-1.0 X 16

WASHER FLAT ¼”

BUSHING, 1.09” SNAP

WASHER LOCK M6-1/4”

CONTACTOR, STARTER

NUT FLANGE M6-1.0 NYLOK

WASHER LOCK M8-5/16”

NUT HEX 5/16”-18

BOOT BATTERY CABLE

PANEL AIR BOX COVER

SCREW, M6-1.00 X 20MM WING

BOLT CARR 3/8”-16 X 1”

3/8” SPECIAL L/WASHER

NUT HEX M6 X 1.0

023484E

0F9176

0E0014

0E0017

0C7968

0E0393

0D8981

029451A

0D8628B

8.5”

BUSHING, 0.50” SNAP

HOSE, 1/4” ID

BOX, MUFFLER TAIL PIPE

GASKET, MUFFLER TAIL PIPE BOX

NUT HEX JAM 3/8”-16 BRASS

ASSEMBLY, CAP & DIPSTICK

FILTER GASKET

8.75’ FOAM TAPE 1/16” X ½”

FOAM, FRONT AIR OUT

COMPARTMENT

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Exploded Views & Parts Lists

Generator Drawing No. 0D8353-M

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Generator Drawing No. 0D8353-M

Exploded Views & Parts Lists

ITEM

PART NO.

QTY.

DESCRIPTION

029092

022129

049451

0C8096A

0D8120

066849

066386

0D4217

073159

0D4484H

0D4430H

0D4216

048614

0F9533

022131

027028

0D6832

022145

030231

0C3168

022259

0C8565

0D8048

083512

0D6831

029451

0D6918

0D2558

087680

0D7530

0D9723

2.14’

SCREW IHHC 5/16”-24 X 11-1/4” G5

WASHER LOCK M8-5/16”

WASHER FLAT .406” I.D. X 1.62” O.D.

FAN, 8" CURVE BLADE, 16.5MM I.D.

SCREW IHHC M8-1.25 X 260MM

SCREW HHTT M5-0.8 X 16

ASSEMBLY, BRUSH HOLDER

CARRIER, REAR BEARING

BEARING

ROTOR

STATOR

ADAPTOR, ENGINE

SCREW HHC 5/16”-24 X 3/4"

GASKET, FRONT DIVIDER

WASHER FLAT 3/8”-M10

NUT LOCK HEX 5/16”-18 NYLON INSERT

BRACKET, ENGINE MOUNTING

WASHER FLAT 5/16”

SCREW HHC 5/16”-18 X 1-1/2”

5/16” SPECIAL LOCK WASHER

NUT HEX 5/16”-18

SCREW SHC M8-1.25 X 18MM

VIBRATION MOUNT

SCREW HHTT M8-1.2 X 16MM

BRACKET, ALTERNATOR MOUNTING

TAPE ELEC. UL FOAM 1/8” X 1/2”

DUCT, ALTERNATOR AIR

GASKET, ALTERNATOR DUCT

NUT WING M6-1.0

STUD, M6-1.0 OFFSET

ELEMENT, AIR FILTER

0D8451

022097

0G3671

090388

0D7441

081105

089476

022531

0D8981

WASHER FLAT .281" I.D. X 1.50" O.D.

WASHER LOCK M6-1/4”

MUFFLER W/ CATALYST

SCREW HHTT M6-1.0 X 12MM

BOLT CARR 5/16"-18 X 2"

NUT FLANG 5/16”-18 LOCK

GASKET, EXHAUST

SCREW HHC 5/16”-18 X 1-3/4”

FILTER GASKET RV

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Exploded Views & Parts Lists

Control Panel Drawing No. 0D8354-H

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Control Panel Drawing No. 0D8354-H

Exploded Views & Parts Lists

ITEM

PART NO.

QTY.

DESCRIPTION

0F9719

075210A

092234

065795

023484F

023484R

075234

057159

054502

087798

092113

032300

0A9611

090145

0E2314

0A1658

075235

047411

049226

051716

075476

022264

051715

0A2053

022473

022097

049813

055440

049815

038750

051714

0D8794

025105

028739

0D8308

0D8418

023484S

043182

031879

0D6575D

0A9973

REGULATOR VOLTAGE

TERMINAL BLOCK

CONTROLLER P.C.B.

BATTERY CHARGER RECTIFIER

BUSHING SNAP 1”

BUSHING SNAP 1” (04709 ONLY)

BUSHING SNAP 1-1/4”

RESISTOR, 1 OHM 25W

CIRCUIT BREAKER 2.0 Amp (60Hz)

CIRCUIT BREAKER 3.0 Amp (50Hz)

SWITCH S.P.D.T.

SWITCH S.P.D.T. ON-MOM-ON

HOLDER FUSE

FUSE 7.5A

CIRCUIT BREAKER, 30 X 1 (60HZ)

CIRCUIT BREAKER, 15A 2 POLE (50HZ)

LOCK WASHER SPECIAL

SCREW HHC M5-0.8 x 30mm

SCREW HHC M6-1.0 X 16mm

WASHER LOCK M5

NUT HEX M5-0.8

SCREW PPHM M4-0.7 x 16mm

WASHER LOCK #8-M4

NUT HEX M4-0.7

SCREW HHC M6-1.0 x 65mm

WASHER FLAT 1/4”

WASHER LOCK M6-1/4”

NUT HEX M6-1.0

SCREW HHC M5-0.8 X 25mm

SCREW HHC M5-0.8 X 16mm

SCREW HHC M6-1.0 X 30mm

NUT, HEX M3-0.5

PANEL CONTROL

SCREW RHM #6-32 X 1/4” SIMS

TIE WRAP UL 4” (NOT SHOWN)

DECAL (NOT SHOWN)

HARNESS (NOT SHOWN)

BUSHING, SNAP 1.09”

WASHER LOCK M3

WASHER FLAT M3

DEUTSCH, MOUNTING CLIP

RIVET POP 0.125” LARGE FLANGE

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Exploded Views & Parts Lists

GN-220 H/SH Engine Drawing No. 0D8355-AG Part 1

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GN-220 H/SH Engine Drawing No. 0D8355-AG Part 1

ITEM PART NO. QTY. DESCRIPTION

Exploded Views & Parts Lists

ITEM PART NO. QTY. DESCRIPTION

0D8433

0C1069

090965F

0G6468

GUARD, FAN

SCREW, HHTT M6-1.0 X 8MM

(04709 ONLY)

BLOWER HOUSING

BLOWER HOUSING 220RV (04709

ONLY)

091638A

0G7967

SPRING, GOVERNOR

SCREW, HHTT 5/16” X ½” SEMI-

GIMLET

NUT, M5-0.8 LOCK

TOP WRAPPER

PLUG, EXPANSION

LOWER WRAPPER

GASKET, OIL PSI PAD

(04709 ONLY)

082025

092984

094820

089739

091848

0D8778

040945

040946

081810

083312

0D8400

NUT, HEX M16-1.5

WASHER, M16 CONICAL

ASSEMBLY CHOKE SOLENOID

BRACKET

FLYWHEEL, WITH RING GEAR

BACKPLATE, ELECTRIC START

SCREW HHTT M6-1.0 X 10MM

KEY, WOODRUFF 4 X 19D

5/16”-M8 LOCK WASHER

SCREW SHC M8-1.25 X 40MM

ASSY, STARTER

ADAPTER, OIL FILTER

0C8917A

0C8798A

045756

082774

022129

081990

0D9004A

0E7585

SCREW SHC M6-1.0 X 20MM G12.9

SCREW SHC M6-1.0 X 35MM G12.9

(04709)

SWITCH, OIL- 5 PSI

FILTER, OIL

0D9235

070185B

0G6437

043182

0C4739

0D9689

0A7095

077091

0D8397

077075

0C2824

0A7094

0D8590

0D8591

0G6277A

0G6273

0G7458

069598

059502

045764

0E9406A

0G3662B

0G4695B

0A6344

0G6502

040143

0F9176F

21”

SWITCH, THERMAL 305F

WASHER LOCK M3

SCREW PPHM M3-0.5 X 6MM

ELBOW 90D STREET 1/8NPT

RHMS #4-40 X 5/16” SEMS

COTTER PIN

ROD, CHOKE CONTROL

BOOT CHOKE SOLENOID PLASTIC

SCREW TAP-R #10-32 X 9/16”

RHMS #4-40 X 1/4” SEMS

ASSEMBLY, BI-METAL/HEATER

SOLENOID, CHOKE

FUEL HOSE 3/8 LO-PERM

BARBED TEE 1/2X3/8X1/2

BARBED EL 90 1/4NPT X 3/8

BULKHEAD ADAPTOR FITTING

BARBED EL 90 1/4 NPT X 5/16

SCREW HHTT M4-0.7 X 8 BP

OIL COOLER 220

SPARK PLUG, CHAMPION RC14YC

0G3111

0G3231

TAPTITE, M6-1.0 X 25 ZINC

ASSEMBLY, IGNITION COIL ADV. W/

DIODE

0D7666A

0D7666B

090051

080316

090948

078631

0D8332

091846

0D7558

078643

0D8372

0C2756

0D7458

0C3979

085953

0D8739

BREATHER TUBE

BREATHER TUBE (04709 ONLY)

GASKET, MANIFOLD/ HEAD

SCREW HHFC M6-1.0 X 30MM

INTAKE MANIFOLD

GASKET CARBURETOR/MANIFOLD

CARBURETOR

GASKET, CARB/ ADAPTOR

ADAPTOR, CARB

BOLT, CARB MOUNT M6-1.0 X 75MM

GASKET, CARB TO AIRBOX

ASSEMBLY, GOVERNOR LEVER

ROD, GOVERNOR

CLAMP,HOSE OETIKER STEPLESS 18.5

HOSE 3/8" X 16.25" BRAID-WRAP

BARBED EL 90 1/8NPT X 3/8

OIL FILTER SPACER 220RV

CLAMP, HOSE #5.5

SPRING, ANTI LASH

WASHER, CARB WEAR

ASSEMBLY BRACKET GOVERNOR

ADJUST

0D8398

ROD, CHOKE LINKAGE

HOSE, ¼” SAE30R11 GREENBAR 7”

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Exploded Views & Parts Lists

GN-220 H/SH Engine Drawing No. 0D8355-AG Part 2

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GN-220 H/SH Engine Drawing No. 0D8355-AG Part 2

Exploded Views & Parts Lists

ITEM

PART NO.

QTY.

DESCRIPTION

N/A

0E8804

078621

076389

0G4379

0A8897B

077168

0G4331

076390

0G5827

078658

0F0967

089213E

0A7637

0E3811

0D1303

078645

0A7811

072683A

0A9878

089096

088156

0A8822

078691

0A5772

0A5776

074908

078606

076361

0D2414

099922

0C3733

0C4390

084186

083192

0E0057

078699B

021705B

0C3590

0C3591

0D9853A

083235

080336

0C8754

077161

077160

076307

088403

026073A

0D1411A

076329

0C3592

049340A

045761A

LONG BLOCK ASSEMBLY

CONNECTING ROD ASSEMBLY

PISTON PIN

PISTON RING SET DIA 75 PLATEAU HONED

GEAR COVER ASSEMBLY

M8 X 56MM HEAD BOLT

PISTON, COATED DIA 75

PIN RETAINER RING

ASSY, CRANKSHAFT GH220 TAPER

GOVERNOR “R” PIN

WASHER FLAT 1/4, .015 THK

CRANKCASE ASSEMBLY

GOVERNOR ARM

OIL SEAL

GOVERNOR GEAR ASSEMBLY

GOVERNOR GEAR C-RING

GOVERNOR SPOOL

1/8” NPT PIPE PLUG

CAMSHAFT ASSEMBLY

CRANKCASE GASKET

VALVE STEM SEAL

CYLINDER HEAD GASKET

OIL PRESSURE RELIEF COVER

OIL PRESSURE SPRING

11/32” BALL

M5 FORM SCREW

M6-1.0 X 12MM SCREW

GOVERNOR GEAR THRUST WASHER

SCREW, HHFC M8-1.25 X 35MM

SPRING WASHER

VALVE RETAINER

VALVE SPRING

VALVE SPRING WEAR WASHER

GEROTER SET

“O” RING

SLEEVE, SEAM DWL

CYLINDER HEAD ASSEMBLY

EXHAUST VALVE

INTAKE VALVE

PUSH ROD

TAPPET

OIL PICK-UP ASSEMBLY

ROCKER COVER GASKET

PIVOT BALL STUD

GN- 191/220 ROCKER ARM

ROCKER ARM JAM NUT

PUSH ROD GUIDE PLATE

1/4” NPT PIPE PLUG

ROCKER COVER ASSEMBLY

PLASTIC OIL FILL PLUG

VALVE SPRING KEEPER

BARBED ELBOW 90 1/4” NPT X 3/8”

STUD M8-1.25 / 10MM X 30MM

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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 engine.* New utility, and lawn and garden equipment 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 emis-

sion control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improper

maintenance of your engine.

Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair your engine at no cost to you

for diagnosis, replacement parts and labor, should a warrantable condition occur.

MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted. If, during such warranty period, any

emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by

a Generac Authorized Warranty Service Facility.

PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:

As the engine purchaser/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 engine. However, Generac cannot deny warranty solely

because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.

As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility if your engine,

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 presenting your engine to a Generac Authorized Warranty Service Facility 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 Facility. To locate the Generac

Authorized Warranty Service Facility 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. The ECS Warranty applies only to the emission control system of your new

engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where

the Generac Warranty may provide a longer warranty period. 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. The purchaser/owner shall be responsible for any expenses or other charges incurred for

service calls and/or transportation of the product to/from the inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or

all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs.

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

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Warranty

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:

(a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or 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 subse-

quent purchaser/owner, that each of its engines is ...

(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective authority,

and

(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted emissions-related part

to fail to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.

(1) Any warranted, emissions-related parts that are 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, emissions-related 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 such written instructions 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, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the

period of time prior to the 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 ECS Warranty Period prior to the first scheduled replacement point for such emissions-related 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) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible for diagnostic costs if the

repair is deemed warrantable.

(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty

of any emission-related part covered by the ECS Warranty.

(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand

for such emission-related parts.

(8) Any Generac authorized and approved emission-related replacement part 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’s 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 a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or ‘grey market’ part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

*Generac engine types covered by this warranty statement include the following:

1) Utility

2) Lawn and Garden Equipment

3) Recreational Vehicle (RV) Generator

4) Industrial Mobile (IM) Generator

1) Fuel Metering System:

2) Air Induction System including:

a) Intake pipe/manifold

b) Air cleaner

3) Ignition System including:

a) Spark plug

b) Ignition module

1.1) Gasoline carburetor assembly and its

internal components (if so equipped).

a) Fuel filter (if so equipped)

b) Carburetor gaskets

c) Fuel pump (if so equipped)

1.2) LPG carburetion assembly and its

internal components (if so equipped).

a) Fuel controller (if so equipped)

4) Catalytic Muffler Assembly (if so equipped) including:

a) Muffler gasket

b) Exhaust manifold

b) Mixer and its gaskets (if so equipped)

c) Carburetor and its gaskets (if so equipped)

d) Primary gas regulator (if so equipped)

e) LP liquid vaporizer (if so equipped)

5) Crankcase Breather Assembly including:

a) Breather connection tube

Part 2

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Warranty

GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR

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

NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES.

For a period of 3 (three) years of operation from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which,

upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective under normal use and service, in

accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to be defective must be returned to and examined by the

nearest Generac Authorized Warranty Service Facility. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the

purchaser/owner. This warranty applies only to Generac generators sold and rated for “Recreational Vehicle” (RV) applications, as Generac has defined Recreational

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

WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS

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

• Engine – All components

• Alternator – All components

WARRANTY SCHEDULE – CONSUMER/PERSONAL APPLICATIONS

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

• Engine – All components

• Alternator – All components

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

responsibility]:

• Rotor, Stator, Computer Control Board, Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Valve, Valve Lifter(s), Intake and Exhaust Manifolds.

INTERNATIONAL

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

• All COMPONENTS

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

Generac RV generators manufactured after January 1, 2006, have a transferable warranty to the second owner ONLY for the remainder of the three-year limited war-

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

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

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Generac generators that utilize non-Generac replacement parts.

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

• Repairs or diagnostics performed by individuals other than Generac authorized dealers not authorized in writing by Generac Power Systems.

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

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechanical devices, the Generac engines

need periodic part(s) service and replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.

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

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

• Damage related to rodent and/or insect infestation.

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

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).

• Failure due to misapplication.

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

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

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

• Rental equipment used while warranty repairs are being performed.

• Overnight freight costs for replacement part(s).

• Overtime labor.

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

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

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation

may not apply to you. Any implied warranties which are allowed by law, shall be limited in duration of the terms of the express warranty provided herein.

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

INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclu-

sion or limitation of incidental or consequential damages, so the above limitation may not apply to you. This warranty gives you specific legal rights. You also have

other rights from state to state.

GENERAC^®POWER SYSTEMS, INC. • P.O. BOX 297

•

WHITEWATER, WI 53190

Part No. 0H8812

Rev.A 06.02.10

Part No. 0D8351

Revision AA (06/02/10)

Printed in U.S.A.

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