Generac Power Systems Portable Generator 004700 00 User Manual

Owner’s Manual and  
Installation Instructions  
Air-cooled Recreational  
Vehicle Generators  
• Model: 004700-0  
QUIETPACT 40G  
This manual should remain with the unit.  
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Table of Contents  
Recreational Vehicle Generator  
Part I – Owner’s Manual  
Part II – Installation Instructions  
Introduction ...................................... Inside Front Cover  
Read This Manual Thoroughly................................IFC  
Contents .................................................................IFC  
Operation and Maintenance....................................IFC  
How to Obtain Service ............................................IFC  
Authorized Service Dealer Locator Number .............. IFC  
Safety Rules .................................................................... 18  
Section 1 – General Information...............................20  
1.1 Purpose and Scope of the Manual..................... 20  
1.2 Safety................................................................. 20  
1.3 Standards Booklets........................................... 20  
1.4 Equipment Description ..................................... 20  
1.5 Generator Engine Operating Speed................... 20  
1.6 Generator AC Connection System ..................... 20  
Safety Rules ...................................................................... 2  
Section 1 – General Information................................. 4  
1.1 Generator Identification ...................................... 4  
1.2 Generator Applicability ....................................... 5  
1.3 Safety................................................................... 5  
1.4 Generator AC Connection System ....................... 5  
1.5 Specifications...................................................... 5  
Section 2 – Operation .................................................... 7  
2.1 Generator Control Panel....................................... 7  
2.2 Optional Remote Start/Stop Panel........................ 7  
2.3 Automatic Choke.................................................. 7  
2.4 Before Starting the Engine ................................... 7  
2.5 Starting the Generator ......................................... 8  
2.6 Stopping the Generator........................................ 9  
2.7 Applying Loads to Generator................................ 9  
2.8 Do Not Overload the Generator............................ 9  
2.9 Protection Systems............................................... 9  
2.10 Additional Information....................................... 10  
Section 3 – Maintenance.............................................. 11  
3.1 Checking the Engine Oil Level............................ 11  
3.2 Changing the Engine Oil and/or Oil Filter .......... 11  
3.3 Maintaining the Engine Air Cleaner.................... 12  
3.4 Clean Air Intake ................................................. 13  
3.5 Checking the Engine Spark Plug........................ 13  
3.6 Fuel Filter........................................................... 13  
3.7 Spark Arrestor Service....................................... 13  
3.8 Cleaning the Generator ...................................... 14  
3.9 Battery Maintenance........................................... 14  
3.10 Major Service Manual......................................... 15  
3.11 Exercising the Generator.................................... 15  
3.12 Out of Service Procedure.................................... 15  
3.13 Adjusting Valve Clearance................................... 15  
3.14 RV Generator Service Interval............................ 16  
Section 2 – Installation................................................22  
2.1 Location and Support ....................................... 22  
2.2 Generator Compartments ................................. 23  
2.3 Cooling and Ventilating Air................................ 26  
2.4 Gasoline Fuel System........................................ 26  
2.5 Exhaust System................................................. 27  
2.6 Electrical Connections....................................... 28  
2.7 Battery Installation............................................ 31  
2.8 Optional Accessories......................................... 31  
Section 3 – Post-installation Start-up  
Adjustments..............................................32  
3.1 Post Installation Tests ....................................... 32  
3.2 Before Initial Start-up........................................ 32  
3.3 Initial Start........................................................ 32  
3.4 Testing Under Load........................................... 32  
3.5 Installation Checklist......................................... 33  
Appendix 1 – Notes ......................................................34  
Appendix 2 – Troubleshooting...................................35  
Appendix 3 – Electrical Data......................................36  
Appendix 4 – Exploded Views and Parts Lists.......38  
Appendix 5 – Warranty ................................................48  
1
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Safety Rules  
Recreational Vehicle Generator  
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe  
operation be copied and posted in potential hazard areas of the recreational vehicle.  
Safety should be stressed to all operators and potential operators of this equipment.  
• The generator engine releases DEADLY carbon  
monoxide gas through its exhaust system. This  
dangerous gas, if breathed in sufficient concentra-  
tions, can cause unconsciousness or even death.  
Never operate the generator set with the vehicle  
inside any garage or other enclosed area. DO NOT  
OPERATE THE GENERATOR IF THE EXHAUST  
SYSTEM IS LEAKING OR HAS BEEN DAMAGED.  
SYMPTOMS OF CARBON MONOXIDE POISONING  
ARE (a) inability to think coherently, (b) nausea,  
(c) vomiting, (d) twitching muscles, (e) throbbing  
temples, (f) dizziness, (g) headaches, (h) 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.  
• Never sleep in the vehicle while the genset is run-  
ning unless the vehicle has a working carbon  
monoxide detector. The exhaust system must be  
installed in accordance with the genset installation  
manual. Make sure there is ample fresh air when  
operating the genset in a confined area.  
• The engine exhaust fumes contain carbon monox-  
ide, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. This exhaust  
system must be installed properly, in strict com-  
pliance with applicable codes and standards.  
Following installation, do nothing that might ren-  
der the system unsafe or in noncompliance with  
such codes and standards. The generator com-  
partment 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.  
WARNING:  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
The engine exhaust from this product  
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
Study these SAFETY RULES carefully before install-  
ing, operating or servicing this equipment. Become  
familiar with this manual and with the unit. The gen-  
erator can operate safely, efficiently and reliably only  
if it is properly installed, operated and maintained.  
Many accidents are caused by failing to follow simple  
and fundamental rules or precautions.  
The manufacturer cannot anticipate every possible  
circumstance that might involve a hazard. The warn-  
ings 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 uti-  
lized does not render the generator unsafe.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting  
its maintenance or being careless can cause  
possible injury or death. Permit only responsible  
and capable persons to operate or maintain this  
equipment.  
• 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 ven-  
tilating air is critical to correct generator opera-  
tion and is required to expel toxic fumes and fuel  
vapors from the generator compartment. Without  
sufficient cooling airflow, the engine/generator  
quickly overheats, which causes serious damage  
to the generator. Do not alter the installation or  
permit even partial blockage of ventilation provi-  
sions, as this can seriously affect safe operation of  
the generator.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
GENERAL HAZARDS  
For safety reasons, the manufacturer recommends  
that the installation, initial start-up and main-  
tenance of this equipment is carried out by an  
Authorized Service Dealer.  
2
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Safety Rules  
Recreational Vehicle Generator  
• When working on this equipment, remain alert  
at all times. Never work on the equipment when  
physically or mentally fatigued.  
• Inspect the generator regularly, and contact the  
nearest Authorized Service Dealer immediately for  
parts needing repair or replacement.  
• Before performing any maintenance on the gen-  
erator, disconnect its battery cables to prevent  
accidental start up. Disconnect the cable from the  
battery post indicated by a NEGATIVE, NEG or (–)  
first. Reconnect that cable last.  
• Never use the generator or any of its parts as a  
step. Stepping on the unit can stress and break  
parts, and may result in dangerous operating con-  
ditions from leaking exhaust gases, fuel leakage,  
oil leakage, etc.  
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 installa-  
tion, do nothing that might alter a safe installation  
and render the unit in noncompliance with the  
aforementioned codes, standards, laws and regula-  
tions.  
• 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 sys-  
tem. Keep the extinguisher properly charged and  
be familiar with its use. If there are any questions  
pertaining to fire extinguishers, consult the local fire  
department.  
ELECTRICAL HAZARDS  
• The generator covered by this manual produces  
dangerous electrical voltages and can cause fatal  
electrical shock. Avoid contact with bare wires, ter-  
minals, connections, etc., while the unit is running.  
Ensure all appropriate covers, guards and barriers  
are in place before operating the generator. If work  
must be done around an operating unit, stand on  
an insulated, dry surface to reduce shock hazard.  
• Do not handle any kind of electrical device while  
standing in water, while barefoot, or while hands or  
feet are wet. DANGEROUS ELECTRICAL SHOCK  
MAY RESULT.  
• During installation onto the vehicle, have the  
generator properly grounded (bonded) either by  
solid mounting to the vehicle frame or chassis,  
or by means of an approved bonding conductor.  
DO NOT disconnect the bonding conductor, if so  
equipped. DO NOT reconnect the bonding conduc-  
tor 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.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any  
fuel or oil spills immediately. Ensure that no com-  
bustible materials are left in the generator com-  
partment, or on or near the generator, as FIRE or  
EXPLOSION may result. Keep the area surround-  
ing the generator clean and free from debris.  
• Gasoline is extremely FLAMMABLE and its vapors  
are EXPLOSIVE. Do not permit smoking, open  
flame, sparks or any source of heat in the vicinity  
while handling gasoline. Comply with all laws gov-  
erning the storage and handling of gasoline.  
• In case of accident caused by electric shock, imme-  
diately shut down the source of electrical power.  
If this is not possible, attempt to free the victim  
from the live conductor. AVOID DIRECT CONTACT  
WITH THE VICTIM. Use a nonconducting imple-  
ment, such as a rope or board, to free the victim  
from the live conductor. If the victim is uncon-  
scious, apply first aid and get immediate medical  
help.  
• Never wear jewelry when working on this equip-  
ment. Jewelry can conduct electricity resulting in  
electric shock, or may get caught in moving com-  
ponents causing injury.  
3
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Section 1 – General Information  
Recreational Vehicle Generator  
1.1 GENERATOR IDENTIFICATION  
Please record the following information from the generator DATA DECAL or information decal.  
1. Model Number _____________________  
3. kW Rating _________________________  
2. Serial Number __________________  
4. Rated Voltage __________________  
Model: 004700-0  
1. Generator Air Intake  
2. Engine Start/Stop Switch  
3. Fuse  
4. Optional Remote Panel Receptacle (Side View)  
5. Generator AC Output Leads (Side View)  
6. Fuel Primer Switch  
11. Fuel Filter (Side View)  
12. Oil Filter  
13. Oil Drain Cap  
14. Oil Dipstick  
15. Air Filter (Behind Access Panel)  
16. Oil Fill  
7. Circuit Breaker  
17. Spark Plug  
8. Starter Contactor  
9. Fuel Inlet  
10. Fuel Pump (Behind Access Panel)  
17  
8
2 6  
14,16  
CONTROL CENTER  
7
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AIR FILTER LOCATED BEHIND PANEL.  
MAINTENANCE SCHEDULE  
OIL LEVEL:  
AIR FILTER:  
CHECK DAILY  
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)  
AC  
CHANGE EVERY 400  
HOURS. (OR ANNUALLY)  
D
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  
30  
15W-40  
10W-30  
5W-30  
RAC OHVI INDU
-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.  
PACT
RV SERVICE LOCATOR:  
9/11  
13  
1
12  
4
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Section 1 – General Information  
Recreational Vehicle Generator  
1.2 GENERATOR APPLICABILITY  
1.4 GENERATOR AC  
These generators have been designed and manufac-  
tured for supplying electrical power for recreational  
vehicles. Do not modify the generator or use it for  
any application other than for what it was designed. If  
there are any questions pertaining to its application,  
contact an Authorized Service Dealer. Do not use the  
unit until advised by a competent authority.  
CONNECTION SYSTEM  
This generator set is equipped with dual stator AC  
power windings. These two-stator windings sup-  
ply electrical power to customer electrical loads by  
means of a two-wire connection system. Note, how-  
ever, that the neutral is bonded to the frame of the  
engine-generator.  
DANGER  
The generator may have been installed so that it pow-  
ers 120-volt AC loads (Figure 1.1). It can be wired to  
connect 120-volt AC electrical loads. This procedure  
should be done by an Authorized Service Dealer or  
other qualified installer.  
For fire safety, the generator must have been  
properly installed in compliance with ANSI  
119.2-1975/NFPA 501C-1974, “Standard for  
Recreational Vehicles, Part III – Installation of  
Electrical Systems.” The generator also must  
have been installed in strict compliance with the  
manufacturer’s detailed installation instructions.  
After installation, do nothing that might render  
the unit in noncompliance with such codes, stan-  
dards 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 electri-  
cal 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 installa-  
tions may require that electrical loads be alter-  
nated to avoid overloading. Applying excessively  
high electrical loads may damage the generator  
and may shorten its life. Add up the rated watts  
of all electrical lighting, appliance, tool and  
motor loads the generator will power at one  
time. This total should not be greater than the  
wattage capacity of the generator. If an electri-  
cal device nameplate gives only volts and amps,  
multiply volts times amps to obtain watts (volts  
x amps = watts). Some electric motors require  
more watts of power (or amps of current) for  
starting than for continuous operation.  
1.5 SPECIFICATIONS  
1.5.1 FUEL REQUIREMENTS  
This generator is equipped with a gasoline fuel sys-  
tem. Depending on the installation, the generator may  
have either a separate fuel tank, or it may “share” the  
vehicle engine’s fuel tank.  
NOTE:  
Some installations using a “shared” fuel tank may  
have a generator fuel pickup tube that is shorter  
than the vehicle engine’s pickup tube. Such an  
arrangement causes the generator engine to “run  
out of gas” while adequate fuel for the vehicle  
remains in the tank.  
1.3 SAFETY  
Before attempting to use the generator set, care-  
fully read the “Safety Rules” section of this manual.  
Comply strictly with these rules to prevent accidents  
and damage to equipment and/or property. We sug-  
gest copying and posting the “Safety Rules” in poten-  
tial hazard areas of the vehicle. Stress safety to all  
operators and potential operators of this equipment.  
To reduce lead and carbon deposits use high qual-  
ity UNLEADED gasoline with the generator. Leaded  
REGULAR grade gasoline is an acceptable substitute.  
NOTE:  
Using unleaded gasoline contributes to longer  
engine valve life by reducing lead and carbon  
deposits.  
5
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Section 1 – General Information  
Recreational Vehicle Generator  
1.5.5 GENERATOR  
Rated Maximum Continuous  
AC Output (Gasoline)...........................3,600 Watts (3.6 kW)  
Rated Voltage.......................................................120 Volts AC  
Rated Maximum Continuous  
AC Current (Gasoline) ....................................... 30 Amperes  
The manufacturer does not recommend using  
any gasoline containing alcohol (such as “gaso-  
hol”). If using any gasoline containing alcohol, it  
must not contain more than 10 percent ethanol,  
and it must be removed from the generator dur-  
ing storage. Do NOT use any gasoline  
containing methanol. If using gasoline with alco-  
hol, inspect more frequently for fuel leaks and  
other abnormalities.  
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  
004700-0  
No Load  
1/2 Load  
Full Load  
0.24  
0.35  
0.55  
Fuel consumption is in gal/hr.  
1.5.6 EMISSIONS COMPLIANCE PERIOD  
1.5.3 ENGINE OIL REQUIREMENTS  
For non-handheld engines the Emissions Compliance  
Period referred to on the Emissions Compliance  
Label indicates the number of operating hours for  
which the engine has been shown to meet Federal  
emission requirements.  
Use only high quality detergent oil rated with American  
Petroleum Institute (API) Service Classification SF,  
SG or SH. The recommended oil weights include the  
following:  
• During summer months: SAE 30. An acceptable  
substitute is SAE 10W-30.  
For engines less than 225 cc displacement, Category  
C=125 hours, B=250 hours, and A=500 hours.  
For engines of 225 cc or more, Category C=250  
hours, B=500 hours, and A=1000 hours.  
• During winter months: SAE 5W-30. DO NOT USE  
SAE 10-W40.  
Crankcase and oil filter capacity is approximately  
800 mL or .84 U.S. quarts. Do NOT use special addi-  
tives. See Sections 3.1 and 3.2 for oil level check and  
fill procedures.  
1.5.4 ENGINE  
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  
6
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Section 2 – Operation  
Recreational Vehicle Generator  
2.1 GENERATOR CONTROL PANEL  
The following features are mounted on the generator  
control panel (Figure 2.1):  
2.2 OPTIONAL REMOTE  
START/STOP PANEL  
A remote mounted Start/Stop Panel is available that  
allows starting and stopping the generator engine  
conveniently from inside the vehicle.  
Figure 2.1 – Generator Control Panel  
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.  
CONTROL CENTER  
C
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A
2.3 AUTOMATIC CHOKE  
The engine is equipped with an automatic choke that  
consists of two main components: a choke solenoid  
and prechoke.  
2.1.1 FUEL PRIMER  
2.3.1 CHOKE SOLENOID  
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.  
During engine cranking (Start/Stop switch at START),  
a solid-state choke module signals the choke sole-  
noid to activate and cycle (choke on/choke off) until  
the engine starts. The choke solenoid thus opens  
and closes the carburetor choke valve only when the  
engine is cranking. When the engine starts, the choke  
stops cycling.  
2.1.2 START/STOP SWITCH  
2.3.2 PRECHOKE  
To crank and start the engine, hold this switch in the  
START position. Release the switch when the engine  
starts. To stop an operating engine, press and hold  
the switch in the STOP position until the engine shuts  
off. The switch center position is the RUN position.  
The choke system also has a temperature-sensitive  
metal strip that adjusts choke valve angle according  
to ambient temperatures (i.e., in cold ambient tem-  
peratures, 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.  
2.1.3 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 BEFORE STARTING THE ENGINE  
NOTE:  
Instructions and information in this manual  
assume the generator has been properly installed,  
connected, serviced, tested and adjusted by a  
qualified installation technician or installation  
contractor.  
2.1.4 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.  
2.4.1 INSTALLATION  
Generator installation must have been properly com-  
pleted so it complies with all applicable codes, stan-  
dards and regulations and with the manufacturer's  
recommendations.  
7
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Section 2 – Operation  
Recreational Vehicle Generator  
2.4.2 ENGINE LUBRICATION  
DANGER  
Have the engine crankcase properly serviced with the  
recommended oil before starting. Refer to Section  
1.5.4, and Sections 3.1 and 3.2 for oil servicing proce-  
dures and recommendations.  
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 installa-  
tion manual. Make sure there is ample fresh air  
when operating the genset in a confined area.  
Any attempt to crank or start the engine before  
it has been properly serviced with the recom-  
mended oil may result in an engine failure.  
2.5 STARTING THE GENERATOR  
NOTE:  
Read the vehicle manufacturer’s instructions.  
The owner/operator should become familiar with  
the vehicle in which this generator is installed.  
Differences exist between vehicles. For example,  
some vehicles may use a transfer switch to isolate  
dockside power from the generator, while other  
vehicles may use an isolating receptacle. Some  
vehicles may be equipped with a DC converter,  
which allows the generator to power certain DC  
lighting and other DC loads.  
2.4.3 FUEL SUPPLY  
The engine must have an adequate supply of proper  
fuel to operate. Before starting it, check that suffi-  
cient fuel is available.  
NOTE:  
Depending on the installation, the generator may  
have either a separate fuel tank, or it may “share”  
the vehicle engine’s fuel tank.  
To start the generator from either the generator con-  
trol panel or from the optional remote panel, proceed  
as follows:  
2.4.4 COOLING AND VENTILATING AIR  
Air inlet and outlet openings in the generator com-  
partment must be open and unobstructed for con-  
tinued proper operation. Without sufficient cooling  
and ventilating airflow, the engine/generator quickly  
overheats, which causes it to shut down and may  
damage the generator.  
1. Turn OFF electrical loads using the means pro-  
vided in the vehicle (such as a main line circuit  
breaker or transfer switch).  
NOTE:  
If starting from the generator control panel, turn  
OFF loads by setting the generator’s main circuit  
breaker to the OFF (or open) position. If starting  
from a remote panel, turn OFF loads using the  
means provided in the vehicle (such as a main  
circuit breaker). Electrical load circuits will be  
turned ON after the generator has started, stabi-  
lized and warmed up.  
2.4.5 ENGINE EXHAUST GAS  
Before starting the generator engine, be sure there is  
no way for exhaust gases to enter the vehicle interior  
and endanger people or animals. Close windows,  
doors and other openings in the vehicle that, if open,  
might permit exhaust gases to enter the vehicle.  
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.  
3. Hold the engine Start/Stop switch in the START  
position to crank the engine. Release the switch  
when the engine starts.  
DANGER  
The generator engine releases DEADLY carbon  
monoxide gas through its exhaust system. This  
dangerous gas, if breathed in sufficient con-  
centrations, 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 coher-  
ently, (b) nausea, (c) vomiting, (d) twitching  
muscles, (e) throbbing temples, (f) dizziness,  
(g) headaches, (h) weakness, and (i) sleepiness.  
IF EXPERIENCING ANY OF THESE SYMPTOMS,  
MOVE INTO FRESH AIR IMMEDIATELY. IF  
If the engine does not start after it has been  
cranking for 15 seconds, release the Start/Stop  
switch, wait one minute and try again. Holding  
the switch for longer than 15 seconds can dam-  
age the starter motor.  
SYMPTOMS PERSIST, GET MEDICAL HELP. Shut  
down the generator and do not operate it until  
it has been inspected and repaired.  
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 pro-  
vided (such as a main circuit breaker or transfer  
switch).  
8
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Section 2 – Operation  
Recreational Vehicle Generator  
• Induction type motors (such as those that run the  
vehicle’s furnace fan, refrigerator, air conditioner,  
etc.) need about 2-1/2 time more watts of power for  
starting than for running (for a few seconds during  
motor starting). Be sure to allow for this when con-  
necting electrical loads to the generator. First, fig-  
ure the watts needed to start electric motors in the  
system. To that figure, add the running wattages of  
other items that will be operated by the generator.  
• Do not apply heavy electrical loads for the first two  
or three hours of operation.  
2.6 STOPPING THE GENERATOR  
1. Turn OFF all electrical loads using the means  
provided (such as a main circuit breaker or  
transfer switch).  
2. Let generator run at no-load for a few minutes, to  
stabilize internal engine generator temperatures.  
3. Place the Start/Stop switch in its STOP position.  
2.7 APPLYING LOADS TO GENERATOR  
When applying electrical loads to the generator,  
observe these guidelines:  
• Before applying electrical loads, let the generator  
stabilize and warm up for a minute or two.  
• DO NOT overload the generator.  
2.9 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 dur-  
ing 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.  
2.7.1 LETTING THE ENGINE STABILIZE  
The generator supplies correct rated voltage only at  
the proper governed speed. Some electrical appli-  
ances may be extremely sensitive to voltage. Incorrect  
voltages can damage such appliances.  
If electrical loads are applied at reduced operating  
speeds, such loads imposed on the engine when suf-  
ficient 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.  
2.9.2 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 284º F (140º C), initiating an engine  
shutdown.  
2.8 DO NOT OVERLOAD THE  
GENERATOR  
Figure 2.2 – Low Oil Pressure and  
High Temperature Switches  
High Temperature Switch  
Read the rated wattage/amperage capacity of the gen-  
erator on the generator data label (see Section 1.1).  
Applying electrical loads in excess of the unit’s rated  
capacity will cause the engine/generator to automati-  
cally shut down.  
Low Oil Pressure  
Switch  
To avoid overloading, add up the wattage of all con-  
nected electrical lighting, appliance, tool and motor  
loads. This total should not be greater than the  
generator’s rated wattage capacity.  
• Most lighting, appliance, tool and motor loads  
indicate their required watts on their nameplate or  
data plate. For light bulbs, simply note the wattage  
rating of the bulb.  
• If a load does not show its rated wattage, multiply  
that load’s rated VOLTS times AMPS to obtain  
WATTS.  
9
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Section 2 – Operation  
Recreational Vehicle Generator  
The voltage regulator also incorporates a “voltage  
surge protection circuit.” This circuit prevents trou-  
blesome surges in the generator AC output voltage.  
Voltage surge is a common cause of damage to elec-  
tronic equipment.  
2.9.3 FIELD BOOST  
The Controller Circuit Board houses a field boost  
diode and resistor that are not part of the automatic  
choke circuit. These two components are part of  
a “field boost” circuit (Figure 2.3). 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.  
2.10 ADDITIONAL INFORMATION  
2.10.1 25-HOUR BREAK-IN PERIOD  
The first 25 hours of operation is the break-in period  
for the generator. Properly breaking in the genera-  
tor is essential to minimize fuel consumption and  
provide maximum engine performance. During this  
25-hour break-in period, follow this procedure:  
Figure 2.3 – Field Boost Circuit  
• Run the unit at varying electrical loads to help seat  
the engine piston rings properly.  
• Check the engine oil level frequently. Add oil if  
needed. It is normal for the generator engine to  
consume more oil than is normal until the piston  
rings have properly seated.  
For the 75-hour operation following the break-in  
period, avoid light electrical loads. Load the gen-  
erator at 50 percent (or more) of its rated watt-  
age capacity. Repeated light loads during these 75  
hours can cause improper seating of engine piston  
rings, resulting in blowby and high oil consump-  
tion.  
• After operating the unit for 25 hours, complete the  
tasks recommended under Section 2.10.2.  
2.9.4 OVERVOLTAGE PROTECTION  
2.10.2 25-HOUR CHECK-UP  
A solid-state voltage regulator (Figure 2.4) controls  
the generator’s AC output voltage. This regulator sup-  
plies an excitation current to the rotor. By regulating  
the rotor’s excitation current, the strength of its mag-  
netic field is regulated and, in turn, the voltage deliv-  
ered 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).  
After the 25-hour break-in period, contact an  
Authorized Service Dealer for the following main-  
tenance. The vehicle owner is responsible for any  
charges:  
• Change the engine crankcase oil and oil filter.  
• Check the oil level.  
• Inspect the cooling and ventilation openings.  
• Check the engine carburetor adjustments.  
• Check the engine ignition system.  
• Inspect the entire electrical system.  
• Inspect the engine exhaust system.  
Figure 2.4 – Solid State Voltage Regulator  
2.10.3 ATTENTION REQUIRED  
AFTER SUBMERSION  
If the recreational vehicle generator has been sub-  
merged in water, it MUST NOT be started and oper-  
ated. Following any submersion in water, have an  
Authorized Service Dealer thoroughly clean and dry  
the generator.  
10  
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Section 3 – Maintenance  
Recreational Vehicle Generator  
2.10.4 OPERATION IN HIGH GRASS  
OR BRUSH  
3.1 CHECKING THE ENGINE OIL  
LEVEL  
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.  
For oil capacities and requirements, see “Engine  
Oil Requirements,” Section 1.5.4. Check the engine  
crankcase oil level at least every eight hours of opera-  
tion, or before each use. To check the engine oil level,  
proceed as follows (see Figure 3.1):  
1. Be sure the generator is as level as possible.  
2. Remove the dipstick and wipe it dry with a clean,  
lint-free cloth.  
3. Install and tighten the dipstick cap; then, remove  
it again. The oil level should be at the dipstick  
Full” mark.  
4. If necessary, remove the oil fill cap on the rocker  
cover and slowly add oil until it reaches the dip-  
stick “Full” mark. DO NOT FILL ABOVE THE  
“FULLMARK.  
2.10.5 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 mois-  
ture 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.  
Never operate the engine with the oil level  
this could damage the engine.  
5. Install and tighten the oil fill cap and the dipstick  
before operating the engine.  
below the “Add” mark on the dipstick. Doing  
3.2 CHANGING THE ENGINE OIL  
AND/OR OIL FILTER  
• Change the engine oil after the first 25 hours of  
operation (after the 25-hour break-in period, see  
Section 2.10.1). Thereafter, change the oil every  
100 operating hours. Change the oil more fre-  
quently if operating consistently under heavy load  
or at high ambient temperatures.  
Figure 3.1 – Oil Maintenance Features  
CONTROL CENTER  
C
3
.
0
B
A
.
S
T
A
R
T
F
U
E
L
S
T
O
P
P
R
I
M
E
F
U
S
A
E
7.5  
S
E
R
V
IC  
E
A
C
C
E
S
S
P
A
N
E
L
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)  
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  
30  
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.  
Oil Drain  
Oil Filter  
Oil Dipstick/Oil Fill  
11  
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Section 3 – Maintenance  
Recreational Vehicle Generator  
• Change the engine oil filter after the first 25 hours  
of operation, and every 100 operating hours there-  
after.  
4. Wash the foam precleaner in liquid detergent and  
water.  
5. Wrap the foam precleaner in a clean cloth and  
To change the oil and/or oil filter, proceed as follows  
gently squeeze it dry.  
(see Figure 3.1):  
6. Saturate the foam precleaner in clean engine  
oil. Gently squeeze it in a clean cloth to remove  
excess oil and to distribute oil (DO NOT TWIST).  
7. Install the foam precleaner into the cover, fol-  
lowed by the paper filter.  
8. Install the cover, foam precleaner and paper filter.  
9. Tighten the two screws to retain the filter in place.  
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.  
3. After the oil has drained, replace the plug onto the  
end of the oil drain tube. Retain the cover in the  
base.  
Figure 3.2 – Engine Air Cleaner  
4. With the oil drained, remove the old oil filter by  
turning it counterclockwise. Place a towel under-  
neath to catch excess oil.  
5. Apply a light coating of clean engine oil to the gas-  
ket 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.  
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 recom-  
mended oil (see Section 1.5.4). 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.  
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):  
9. Install and tighten the oil fill cap and the dipstick  
before operating the engine.  
10. Start the engine and check for leaks.  
NOTE:  
1. Follow steps 1-3 in Section 3.3.1; service the  
foam precleaner if necessary.  
2. Remove the paper filter.  
Check the oil level and fill to the “FULLmark  
after checking for leaks. The filter will retain some  
oil.  
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 fol-  
lowing steps 7-9 in Section 3.3.1.  
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 fre-  
quently 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.  
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Section 3 – Maintenance  
Recreational Vehicle Generator  
3.4 CLEAN AIR INTAKE  
3.6 FUEL FILTER  
Clean all foreign material from the air intake (Figure  
3.3) at least once every 100 hours of operation. Clean  
more often if necessary.  
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.  
Inspect the area around the generator exhaust muf-  
fler periodically and remove all grass, leaves, dirt,  
etc., from this area.  
Figure 3.5 – Fuel Filter  
Figure 3.3 – Cleaning Air Intake  
POS  
FUEL  
NEG  
USTC  
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.  
3.5 CHECKING THE ENGINE  
SPARK PLUG  
Clean the spark plug and reset the spark plug gap  
every 100 hours of operation.  
NOTE:  
If using the generator on any forest-covered,  
brush-covered or grass-covered unimproved land,  
it must equipped with a spark arrestor. The spark  
arrestor must be maintained in good condition by  
the owner/operator.  
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 question-  
able.  
2. Clean spark plug by scraping or washing using a  
wire brush and commercial solvent. Do not blast  
the spark plug to clean.  
Clean and inspect the spark arrestor as follows:  
• Remove the screen retaining bracket by removing  
the screw.  
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).  
• 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 com-  
mercial solvent.  
Figure 3.4 – Setting the Spark Plug Gap  
• Replace the screen and the retaining bracket.  
Figure 3.6 - Spark Arrestor  
TAILPIPE  
P/N 0E0683  
SPARK ARRRESTOR  
SCREEN P/N 089680  
Sparking can occur if the wire terminal does not  
fit firmly on the spark plug terminal end. If nec-  
essary, re-form the wire terminal to obtain a  
tight fit.  
RETAINING  
SCREW P/N 056892  
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Section 3 – Maintenance  
Recreational Vehicle Generator  
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 mois-  
ture to accumulate on generator windings will have  
an adverse effect on the insulation resistance of those  
windings.  
DANGER  
Do not dispose of the battery in a fire. The  
battery is capable of exploding. Storage batter-  
ies 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 explo-  
sion. 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 equip-  
ment near the battery. Discharge static electric-  
ity from body before touching the battery by  
first touching a grounded metal surface.  
When moisture is allowed to remain in contact with  
windings, some of the moisture will be retained in  
voids and cracks in the insulation. This causes a  
reduced insulation resistance and will eventually  
cause problems. Dirt will make the problem worse,  
since dirt tends to hold moisture in contact with  
windings. Salt (as from sea air) also will worsen the  
problem since it tends to absorb moisture from the  
air. Salt and moisture, when combined, form a good  
electrical conductor which can be damaging to the  
generator windings.  
A battery presents a risk of electrical shock  
and high short circuit current. The following pre-  
cautions are to be observed when working on  
batteries:  
• Remove watches, rings or other metal objects;  
• Use tools with insulated handles;  
• Wear rubber gloves and boots;  
• Do not lay tools or metal parts on top of the  
battery;  
Do NOT use a forceful spray of water to clean  
the generator. Water will enter the generator  
interior and cause problems, and may also con-  
taminate the generator fuel system.  
• Disconnect any charging source prior to connecting  
or disconnecting battery terminals; and  
• Do not use any jumper cables or booster battery to  
crank and start the generator engine. If any battery  
has discharged, remove it for recharging.  
3.9 BATTERY MAINTENANCE  
All lead-acid batteries will discharge when not in  
use. The generator battery should be inspected as  
follows:  
3.9.1 WEEKLY  
Do not open or mutilate the battery. Released  
• Inspect the battery posts and cables for tightness  
and corrosion. Tighten and clean as necessary.  
• Check the battery fluid level of unsealed batteries  
and, if necessary, fill with Distilled Water Only. Do  
not use tap water in batteries.  
electrolyte has been known to be harmful to the  
skin and eyes, and to be toxic.  
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically  
conductive and corrosive. The following  
procedures are to be observed:  
3.9.2 EVERY SIX MONTHS  
• Have the state of charge and condition checked.  
This should be done with an automotive-type bat-  
tery hydrometer.  
• Wear full eye protection and protective clothing;  
• Where electrolyte contacts the skin, wash it off  
immediately with water;  
• Where electrolyte contacts the eyes, flush  
thoroughly and immediately with water and seek  
medical attention; and  
• Spilled electrolyte is to be washed down with an  
acid neutralizing agent. A common practice is to  
use a solution of 1 pound (500 grams) bicarbonate  
of soda to 1 gallon (4 liters) or water. The bicar-  
bonate of soda solution is to be added until the  
evidence of reaction (foaming) has ceased. The  
resulting liquid is to be flushed with water and the  
area dried.  
NOTE:  
Servicing of the battery is to be performed or  
supervised by personnel knowledgeable of batter-  
ies and the required precautions. Keep unauthor-  
ized personnel away from batteries.  
Damage will result if the battery connections are  
made in reverse.  
14  
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Section 3 – Maintenance  
Recreational Vehicle Generator  
4. Reconnect the battery. Observe battery polarity.  
Damage may occur if the battery is connected  
incorrectly.  
3.10 MAJOR SERVICE MANUAL  
To obtain a service manual for the generator, contact  
the nearest Authorized Service Dealer. Make sure to  
identify the MODEL NUMBER and SERIES.  
5. Turn OFF all electrical loads. Add fuel if neces-  
sary and then start the engine.  
6. Allow the unit to run for several minutes to warm  
up.  
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.  
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.  
3.12 OUT OF SERVICE PROCEDURE  
3.13 ADJUSTING VALVE 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, pre-  
pare 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.  
Note:  
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).  
Using a fuel additive such as STA-BIL fuel stabi-  
lizer, 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 completely. 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 classification of the oil in the crankcase.  
5. Remove the spark plug and pour two or three  
tablespoons of clean, fresh engine oil into the  
spark plug threaded openings. Reinstall and  
tighten the spark plug.  
6. Remove the battery and store it in a cool, dry  
room on a wooden board. Never store the battery  
on any concrete or earthen floor.  
7. Clean and wipe the entire generator.  
3.12.2 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 recommend-  
ed oil is used in the engine (see Section 1.5.4). 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 dis-  
tilled water. DO NOT USE TAP WATER IN THE  
BATTERY. Recharge the battery to 100 percent  
state of charge, or, if defective, replace the battery.  
3. Clean and wipe the entire generator.  
15  
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Section 3 – Maintenance  
Recreational Vehicle Generator  
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).  
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  
Figure 3.8 — Tightening Jam Nut  
every 500 Hrs. ..........................Adjust Valve Lash  
16  
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PART II –  
INSTALLATION  
INSTRUCTIONS  
DANGER  
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS  
SHOULD ATTEMPT INSTALLATION!!  
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Safety Rules  
Recreational Vehicle Generator  
DANGER: For fire safety, installation of a generator into a recreational vehicle must comply  
strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard  
for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation  
must comply with the manufacturer’s instructions and recommendations.  
NOTICE TO INSTALLER  
These Installation Instructions have been published  
by the manufacturer to aid in the installation of the  
products described in this manual. The manufac-  
turer 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 sup-  
pliers.  
GENERAL HAZARDS  
For safety reasons, the manufacturer recommends  
that the installation, initial start-up and main-  
tenance of this equipment is carried out by an  
Authorized Service Dealer.  
• The engine exhaust fumes contain carbon monox-  
ide, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. This exhaust  
system must be installed properly, in strict com-  
pliance with applicable codes and standards.  
Following installation, do nothing that might ren-  
der the system unsafe or in noncompliance with  
such codes and standards. The generator com-  
partment must be completely vapor sealed from  
the vehicle interior. There must be no possibility of  
exhaust fumes entering the vehicle interior. Never  
operate this equipment with a leaking or defective  
exhaust system.  
• Keep hands, feet, clothing, etc., away from drive  
belts, fans, and other moving or hot parts. Never  
remove any drive belt or fan guard while the unit  
is operating.  
• Adequate, unobstructed flow of cooling and ven-  
tilating air is critical to correct generator opera-  
tion and is required to expel toxic fumes and fuel  
vapors from the generator compartment. Without  
sufficient cooling airflow, the engine/generator  
quickly overheats, which causes serious damage  
to the generator. Do not alter the installation or  
permit even partial blockage of ventilation provi-  
sions, as this can seriously affect safe operation of  
the generator.  
The manufacturer cannot possibly know of and  
advise the recreational vehicle trade of all conceiv-  
able methods, procedures or techniques by which to  
perform an installation. Nor can we anticipate every  
possible hazard that might result from each installa-  
tion method, procedure or technique. The manufac-  
turer has not undertaken any such wide evaluation.  
Therefore, people who use a method, procedure or  
technique that the manufacturer does not specifically  
recommend must first completely satisfy themselves  
that their safety, the safety of the vehicle's occupants  
and the product's safety is not endangered by the  
method, procedure or technique selected.  
Information, illustrations, specifications, etc., con-  
tained in these Installation Instructions are based on  
the latest information available at the time of publica-  
tion. 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.  
DANGER  
• When working on this equipment, remain alert  
at all times. Never work on the equipment when  
physically or mentally fatigued.  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting  
its maintenance or being careless can cause  
possible injury or death. Permit only responsible  
and capable persons to operate or maintain this  
equipment.  
• Before performing any maintenance on the gen-  
erator, disconnect its battery cables to prevent  
accidental start up. Disconnect the cable from the  
battery post indicated by a NEGATIVE, NEG or (–)  
first. Reconnect that cable last.  
• Never use the generator or any of its parts as a  
step. Stepping on the unit can stress and break  
parts, and may result in dangerous operating con-  
ditions from leaking exhaust gases, fuel leakage,  
oil leakage, etc.  
• Never insert any tool or other object through open-  
ings in the generator interior, even if the unit is not  
running. Serious injury or damage to the equip-  
ment may occur.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
18  
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Safety Rules  
Recreational Vehicle Generator  
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, ter-  
minals, connections, etc., while the unit is running.  
Ensure all appropriate covers, guards and barriers  
are in place before operating the generator. If work  
must be done around an operating unit, stand on  
an insulated, dry surface to reduce shock hazard.  
• Do not handle any kind of electrical device while  
standing in water, while barefoot, or while hands or  
feet are wet. DANGEROUS ELECTRICAL SHOCK  
MAY RESULT.  
• During installation onto the vehicle, properly  
ground (bond) the generator either by solid mount-  
ing to the vehicle frame or chassis, or by means of  
an approved bonding conductor. DO NOT connect  
the bonding conductor to any generator part that  
might be removed or disassembled during routine  
maintenance. If the grounding conductor must be  
replaced, use only a flexible conductor that is of  
No. 8 American Wire Gauge (AWG) copper wire  
minimum.  
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 installa-  
tion, do nothing that might alter a safe installation  
and render the unit in noncompliance with the  
aforementioned codes, standards, laws and regula-  
tions.  
• 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 sys-  
tem. Keep the extinguisher properly charged and  
be familiar with its use. If there are any questions  
pertaining to fire extinguishers, consult the local fire  
department.  
• 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 vehi-  
cle circuits at the same time. The dockside (utility)  
power source must be positively isolated from the  
vehicle circuits whenever the generator is operat-  
ing. 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, imme-  
diately shut down the source of electrical power.  
If this is not possible, attempt to free the victim  
from the live conductor. AVOID DIRECT CONTACT  
WITH THE VICTIM. Use a nonconducting imple-  
ment, such as a rope or board, to free the victim  
from the live conductor. If the victim is uncon-  
scious, 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 com-  
bustible materials are left in the generator com-  
partment, or on or near the generator, as FIRE or  
EXPLOSION may result. Keep the area surround-  
ing the generator clean and free from debris.  
• Gasoline is extremely FLAMMABLE and its vapors  
are EXPLOSIVE. Do not permit smoking, open  
flame, sparks or any source of heat in the vicinity  
while handling gasoline. Comply with all laws gov-  
erning 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, non-  
conductive fuel line between the generator fuel con-  
nection point and rigid fuel lines.  
• Never wear jewelry when working on this equip-  
ment. Jewelry can conduct electricity resulting in  
electric shock, or may get caught in moving com-  
ponents causing injury.  
19  
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Section 1 – General Information  
Recreational Vehicle Generator  
6. CSA Electrical Bulletin 946, available from the  
Canadian Standards Association, Housing and  
Constructions Materials Section, 178 Rexdale  
Boulevard, Rexdale, Ontario, Canada, M9W 1R3.  
1.1 PURPOSE AND SCOPE  
OF THE MANUAL  
These Installation Instructions have been prepared  
especially for the purpose of familiarizing installers  
and owners of the applicable equipment with the  
product's installation requirements. Give serious  
consideration to all information and instructions in  
the manual, both for safety and for continued reliable  
operation of the equipment.  
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.  
Because of the different recreational vehicle mod-  
els and the variations between the models, it would  
be extremely difficult, if not impractical, to provide  
detailed instructions for every possible installation.  
For that reason, instructions and illustrations in this  
manual are general in nature. Illustrations are not  
intended to serve as detailed installation blueprints.  
1.5 GENERATOR ENGINE  
OPERATING SPEED  
The generator’s revolving field (rotor) is driven by a  
single-cylinder, four-cycle engine. The generator sup-  
plies 120 volts AC at 60 Hertz when the rotor is oper-  
ating at 3,600 rpm.  
The installation should comply strictly with all appli-  
cable 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 prece-  
dence over the manual.  
1.6 GENERATOR AC  
CONNECTION SYSTEM  
The generator is equipped with dual stator power  
windings as shown in Figure 1.1.  
1.2 SAFETY  
Figure 1.1 – 120-volt Single Voltage Connection  
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 equip-  
ment and/or property. Stress safety to all installers,  
operators and service technicians who work on this  
equipment.  
BLACK  
1.3 STANDARDS BOOKLETS  
Installation, use and servicing of this equipment  
should comply strictly with published standards, as  
well as the manufacturer's recommendations. The  
following standards booklets (latest revision) are  
available from the sources indicated:  
1. NFPA Standard 501C, “Standard for Recreational  
Vehicles,” available from the National Fire  
Protection Association, Batterymarch Park,  
Quincy, MA 02269.  
• The AC connection system on air-cooled genera-  
tors uses a GROUNDED neutral.  
• A separate green ground wire is connected to the  
recreational vehicle’s junction box.  
NOTE:  
2. NFPA 70, “NFPA Handbook of the National  
Electric Code,” available same as Item 1.  
3. ANSI C1-1975 and ANSI 119.2-1975, available  
from the American National Standards Institute,  
1430 Broadway, New York, NY 10018.  
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.  
20  
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Section 1 – General Information  
Recreational Vehicle Generator  
Figure 1.2 – Major Features and Dimensions (Drawing No. 0D8716-G)  
21  
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Section 2 – Installation  
Recreational Vehicle Generator  
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 genera-  
tor below the horizontal support tubing by means of  
suitable, structurally sound metal framework. The  
following general rules apply:  
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 rein-  
force.  
Vehicle construction MUST be capable of support-  
ing the weight of the generator.  
• Whether the generator is mounted above the hori-  
zontal support tubing or suspended below the tub-  
ing, the supporting frame used must be structur-  
ally sound.  
• If the generator cannot be bolted directly to the  
supporting frame or support tubing, consider  
using additional tubing, angle brackets or other  
supports to give the supporting frame sufficient  
strength.  
Many recreational vehicles have been factory equipped  
with an area for the generator set. Some vehicles may  
even have a generator compartment provided by the  
vehicle manufacturer.  
Plan the generator location based on the following:  
• The generator set must be installed on a frame-  
work that is part of the recreational vehicle, as  
outlined in Section 2.1.2.  
• The location must provide an access opening  
that is large enough to permit generator removal  
(unless the generator is to be removed from under-  
neath the supporting framework).  
Figure 2.1 – Typical Horizontal Support Frame  
• The location must provide easy access to frequent-  
ly 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 Section 2.2. If  
sound insulation is to be used on the compartment  
walls and ceiling, the minimum recommended  
applies to the space between the generator and  
such insulation.  
• The location must provide adequate cooling and  
ventilating airflow for the generator without a great  
deal of work and expense.  
• If mounting the generator in an enclosed compart-  
ment, 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 sur-  
rounding bodywork. If the unit is mounted higher  
in the structure, heated air may recirculate into the  
generator causing it to overheat.  
2.1.3 SUSPENDED MOUNTING  
If the generator will be suspended below the hori-  
zontal support tubing, the suspension method used  
with the vehicle frame members must (a) be able to  
support the weight of the generator AND (b) provide  
sufficient restraint for the generator. One typical 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:  
• 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.  
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 tub-  
ing OR (b) 1-1/2-inch, 11-gauge angle iron. A typical  
supporting frame with horizontal support tubing, is  
shown in Figure 2.1.  
Figure 2.2 – Typical Suspended Mounting System  
GENERATOR  
SUPPORT FRAME  
(MODEL 004718-0)  
GENERATOR MOUNTING  
HOLES FOR 5/16" - 18  
BOLTS (6 PLACES)  
22  
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Section 2 – Installation  
Recreational Vehicle Generator  
• The installer must make certain that the selected  
location will permit adequate cooling and ventilat-  
ing airflow to be supplied.  
NOTE:  
Refer to “Figure 1.2 – Major Features and  
Dimensions”.  
2.1.4 GENERATOR RESTRAINT  
2.2.2 COMPARTMENT CONSTRUCTION  
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 support-  
ing framework (Figure 2.3). All bolts must be long  
enough so that when tight, at least three threads are  
visible past the retaining lock nuts. Refer to Section  
2.2 for the location of the generator mounting holes.  
• The generator compartment should be either con-  
structed of, or lined with, 26-gauge galvanized  
steel.  
NOTE:  
Aluminum is NOT an acceptable alternative to  
galvanized steel due to aluminum’s low melting  
point.  
• If the compartment is lined with galvanized steel,  
it may be constructed of any material. The manu-  
facturer recommends that the compartment be  
constructed of 1/2-inch thick plywood (not strand-  
board), 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 compartment that the installer  
constructs, the compartment must meet certain spec-  
ifications as outlined in the following sections:  
2.2.1 COMPARTMENT SIZE  
Plan the compartment size carefully. Provide a mini-  
mum clearance of 1/2 inch (13 mm) on the front and  
top, 1/2 inch (25 mm) on the sides, and 1/2 inch (13  
mm) from the back for air circulation AFTER the  
compartment has been lined with metal and sound  
insulation (Figure 2.4).  
• If constructing a compartment, line the exterior  
(underside) of the compartment floor with 26-  
gauge galvanized steel.  
Figure 2.4 – Clearances  
Plywood  
Compartment  
• All seams, splices and joints of the compartment  
walls (unless vapor tight by design) should be  
caulked to prevent poisonous, flammable or explo-  
sive vapors from entering the vehicle interior.  
NOTE:  
1/2" Clearance on Top  
1" Clearance  
in Back  
Caulking must be done so that the caulking mate-  
rial 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  
23  
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Section 2 – Installation  
Recreational Vehicle Generator  
• Holes and openings made in the compartment  
walls to allow for the passage of electrical conduit,  
conductors, hoses, cables, etc., into the vehicle liv-  
ing 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:  
mable type. One excellent insulating material is a 1-  
inch (25 mm) thick fiberglass having a 2-pound den-  
sity. When fiberglass is used, its coated side should  
face toward the compartment interior.  
DANGER  
Do not install sound insulation or any absorbent  
material on the compartment floor interior. Such  
materials will become soaked with combustible  
or explosive vapors and  
liquids and will become a fire hazard.  
Flexible metal conduit, due to its unique construc-  
tion, is NOT vapor tight along its entire length.  
• Seams and joints of the galvanized steel (whether  
used as a liner or for the compartment itself) must  
be lapped and mechanically secured. Such seams  
may be manufactured, welded, bolted, riveted or  
screwed. Manufactured lock seams are shown in  
Figure 2.6. Installer constructed compartments  
typically utilize a standard lap joint.  
Using a combination of sound insulating materials  
can often reduce noise more effectively than a single  
material. For example, a sheet of lead or visco-elastic  
material, along with a layer of other acoustical mate-  
rial, is more effective than when a single material is  
used.  
2.2.4 ACOUSTICS  
Figure 2.6 – Types of Lock Seams  
For additional noise abatement, the installer may  
wish to consider the following:  
• Using special sound insulating materials.  
• Construction of a special noise abatement com-  
partment.  
NOTE:  
Any method used to reduce noise must not  
adversely affect the flow of cooling and ventilating  
air into or out of the compartment.  
In addition to the effective use of sound insulating  
materials, construction of a special noise abatement  
compartment might be considered to reduce noise  
levels. Such a compartment might be constructed as  
follows (Figure 2.7):  
• 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 Section 2.2.3.  
• Use 5/8-inch thick or 3/4-inch thick plywood in the  
compartment.  
• Construct the compartment floor of a double thick-  
ness of 5/8-inch or 3/4-inch plywood.  
• Line the compartment interior walls and floor, as  
well as the underside of the floor, with 26-gauge  
galvanized steel.  
DANGER  
Do not install any flammable material directly  
above or around the compartment. Heat, trans-  
ferred through the compartment structure, may  
be sufficient to ignite, char or discolor seat cush-  
ions, fiberboard and other flammable materials.  
Use approved nonflammable insulating materi-  
als in high temperature areas.  
Vapor seal all compartment seams and joints.  
• Over the galvanized steel lining, install a combi-  
nation of acoustical materials as mentioned in  
Section 2.2.3.  
DANGER  
2.2.3 SOUND INSULATING MATERIALS  
To prevent fire or explosion, do not install any  
Once installers have determined that a compartment  
is properly constructed and metal lined, they can add  
acoustical material. This may include additional seal-  
ant or insulating material, to reflect noise away from  
the vehicle interior.  
insulation or other absorbent materials on the  
interior or underside of the compartment floor.  
• Seal all compartment door edges to prevent noise  
leakage around the door perimeter.  
Sound insulating materials should be of a nonflam-  
24  
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Section 2 – Installation  
Recreational Vehicle Generator  
• 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).  
2.2.5 COMPARTMENT FLOOR CUTOUTS  
Provide openings in the generator compartment for  
the following items (Figure 1.2):  
• Engine exhaust and cooling air outlets  
• Generator cooling air inlet  
Figure 2.7 – Typical Noise Abatement  
Four holes for passage of generator mounting  
bolts. See Section 2.1.4.  
DANGER  
Fuel lines and exhaust piping must not pen-  
etrate into the vehicle living area.  
Figure 2.8 – Compartment Floor Cutout (Drawing 0D8716-G)  
VIEW FROM TOP  
717.7  
[ 28 1/4"]  
423.2  
[ 16 11/16"]  
TYP.  
6.7  
5/16"-18 WELDNUTS  
(6 PLACES)  
343.4  
[ 13 1/2"]  
[ 1/4"]  
82.5  
[ 3 1/4"]  
50.8  
[2"]  
60  
[ 2 3/8"]  
476.4  
[ 18 3/4"]  
118  
[ 4 5/8"]  
210  
[ 8 1/4"]  
170  
[ 6 11/16"]  
HOT AIR  
EXHAUST  
414.5  
[ 16 5/16"]  
416  
[ 16 3/8"]  
429.5  
[ 16 15/16"]  
AIR  
INTAKE  
360.5  
[ 14 3/16"]  
TAIL PIPE  
EXIT  
79  
[ 3 1/8"]  
376.5  
[ 14 13/16"]  
101  
[ 4"]  
83.5  
[ 3 5/16"]  
223.5  
[ 8 13/16"]  
176.6  
[ 6 15/16"]  
36.5 [ 1 7/16"]  
55.5  
[ 2 3/16"]  
48.1  
[ 1 7/8"]  
63.5  
[ 2 1/2"]  
222.7  
[ 8 3/4"]  
29  
[ 1 1/8"]  
300.7  
[ 11 13/16"]  
OIL DRAIN  
369.7  
[ 14 9/16"]  
688.3  
[ 27 1/8"]  
736.4  
[ 29"]  
All measurements are in millimeters, 25.4 mm = 1”.  
25  
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Section 2 – Installation  
Recreational Vehicle Generator  
2.3.2 TESTING THE INSTALLATION  
2.3 COOLING AND VENTILATING AIR  
It is absolutely essential that an adequate flow of  
air for cooling, ventilating and engine combustion  
be supplied to the generator set. Without sufficient  
airflow, the engine/generator quickly overheats. Such  
overheating can cause serious operating difficulties  
and also may cause fire and personal injury. The  
installer must make sure that sufficient air is avail-  
able to the generator for cooling, ventilating and  
combustion. The installer also must provide for a  
path for exhausting the cooling air to the exterior of a  
compartment, if so equipped.  
The manufacturer recommends testing the installa-  
tion to be sure adequate cooling airflow is available to  
the unit before placing the unit into service. If the unit  
shows signs of overheating, enlarge the air openings.  
Never place a unit into service until absolutely certain  
that cooling and ventilation is adequate.  
NOTE:  
Test the installation, especially if bringing in air  
from below the generator set.  
2.4 GASOLINE FUEL SYSTEM  
DANGER  
The installation of a gasoline fuel system (Figure  
2.10) for a recreational vehicle generator set must  
comply with applicable codes, standards and regula-  
tions. The entire fuel system must be completely free  
of leaks. There must be no possibility of gasoline  
vapors entering the vehicle interior.  
Never use discharged cooling air for heating or  
permit such air to enter the vehicle interior. This  
air contains deadly carbon monoxide gas and  
other poisonous, flammable or explosive gases.  
2.3.1 GENERATOR AIRFLOW  
Figure 2.10 – Generator Fuel System  
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 collector 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.  
CONTROL CENTER  
C
.
B
.
S
T
A
R
T
F
U
E
L
3
0
A
S
T
O
P
P
R
I
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E
F
U
S
A
E
7.5  
S
E
R
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IC  
E
A
C
C
E
S
S
P
A
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E
L
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)  
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  
30  
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.  
Figure 2.9 – Airflow Through Engine/Generator  
Fuel Pump & Fuel Filter  
(Behind Access Panel & Air Filter)  
DANGER  
Gasoline is highly flammable, and its vapors are  
explosive. Comply with all codes, standards 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.  
26  
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Section 2 – Installation  
Recreational Vehicle Generator  
2.4.1 FUEL TANK  
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 follow-  
ing rules apply:  
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 regula-  
tions.  
• The flexible hose must comply with SAE J30B,  
“Standard for Fuel and Oil Hose.” It must be  
approved for use with gasoline.  
• 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.  
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.  
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.  
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 run-  
ning, generator operation may drain the vehicle  
engine supply line, making it difficult to start  
the vehicle engine.  
DANGER  
The generator engine gives off DEADLY carbon  
monoxide gas through its exhaust system. This  
dangerous gas, if breathed in sufficient con-  
centrations, 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 coher-  
ently; (b) vomiting; (c) twitching 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.  
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, stan-  
dards and regulations. The following general rules  
apply to rigid fuel lines:  
• Rigid lines should be of annealed, seamless, drawn  
aluminum or steel.  
• Lines and fittings must comply with SAE J512F,  
“Standard Automotive Fittings,” or with ANSI  
B126.26 (latest edition).  
• Route the fuel line so that at least 2 inches (51 mm)  
of clearance is maintained between the line and  
any exhaust system parts.  
• Do not attach electrical wiring to fuel lines. Route  
the wiring so it cannot come into contact with any  
fuel line.  
• Route fuel lines so if they leak, fuel does not drip  
onto any electrical or exhaust system parts.  
• Use nonferrous metal straps without sharp edges  
to secure fuel lines.  
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 dam-  
age the other engine.  
27  
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Section 2 – Installation  
Recreational Vehicle Generator  
2.5.1 SPARK ARRESTOR  
2.5.2 EXHAUST SYSTEM SAFETY  
This spark arrestor assembly meets code and stan-  
dard requirements of the U.S. Forest Service. Use  
only mufflers and parts approved by the manufactur-  
er. Any person(s) installing an unapproved muffler, or  
an unapproved exhaust system part, or modifying an  
exhaust system in any way that might cause a hazard,  
is liable for any damage, injury or warranty expense  
that might be caused by such unapproved installation  
or modification.  
• Maintain a clearance of at least 3 inches (76 mm)  
between exhaust system parts and any combus-  
tible 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 tempera-  
ture of any combustible material is not raised  
more than 117° F (65° C) above the ambient air  
temperature.  
• Extend the exhaust system at least 1 inch (25 mm)  
past the outer edge of the vehicle. Do not terminate  
the exhaust system under the vehicle.  
Terminate the exhaust tailpipe such that exhaust  
gases will not be drawn back into the generator  
compartment and recirculated.  
• If there is any possibility of the tailpipe or muffler  
being damaged, protect these damage-prone areas  
by means of a protective device (such as a skid  
bar).  
Failure to provide and maintain a spark arrestor may  
be in violation of the law. If this generator is used on  
any forest covered, brush covered or grass covered  
unimproved land, provide a spark arrestor. The vehi-  
cle owner or operator must maintain this device in  
good condition. In the state of California, the preced-  
ing is required by law (Section 4442 of the California  
Public Resources Code). Other states may have simi-  
lar laws. Federal laws apply on federal lands.  
When installing/replacing the tailpipe or spark arres-  
tor components, 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.  
• Install the generator exhaust system according to  
safe automotive practices.  
• Use enough exhaust system hangers to prevent any  
part of the system from being dislocated.  
• Use exhaust system parts recommended by the  
manufacturer. Using unapproved exhaust mufflers  
and exhaust system parts is the responsibility of  
the person(s) installing such unauthorized parts.  
• Do not terminate the exhaust system under any  
opening, window or vent that can be opened or is  
not permanently sealed from the vehicle interior.  
• Exhaust piping must be large enough to prevent  
excessive back pressure on the generator engine.  
• Never tee the generator engine exhaust pipe into  
the vehicle engine exhaust piping. This causes  
excessive back pressure on the generator engine.  
Also, water from one engine can damage the other  
engine.  
Figure 2.11 - Spark Arrestor  
TAILPIPE  
P/N 0E0683  
SPARK ARRRESTOR  
SCREEN P/N 089680  
• Plan exhaust system installation carefully. Comply  
with all applicable codes, standards and regula-  
tions.  
RETAINING  
SCREW P/N 056892  
2.6 ELECTRICAL CONNECTIONS  
Figure 2.12 — Spark Arrestor Installation  
Be sure to read Section 1.6.  
The following general rules apply to electrical connec-  
tions in a recreational vehicle:  
• Qualified electricians who are familiar with appli-  
cable codes, standards and regulations should  
install electrical wiring.  
• The wiring should comply with codes, standards  
and regulations. The National Electrical Code  
(NFPA 70), and state and local codes apply.  
• Switches and circuit breakers should be of a type  
approved for use in recreational vehicles and must  
be mounted and installed to prevent damage from  
road shock.  
27.4 [1.08"] I.D.  
5.5 [7/32"] DRILL  
40 [1.58"]  
BOTTOM SIDE ONLY  
28  
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Section 2 – Installation  
Recreational Vehicle Generator  
• Wiring must be of adequate size, have approved  
insulative qualities and be properly supported.  
• Conduit and wire openings into the generator com-  
partment (if used) must be vapor-sealed to prevent  
entry of flammable, explosive or poisonous gases  
into the vehicle.  
Figure 2.13 – Generator AC Output Leads  
483.1  
REMOTE PANEL  
CONNECTOR  
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 installation of the generator  
(NOT on the generator). Route the generator's AC  
output leads into this junction box through approved  
flexible conduit. This is the point of first termination  
for generator AC output leads.  
AC OUTPUT  
HARNESS  
FUEL FILTER  
BATTERY  
CONNECTIONS  
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.  
Leads BLACK to WHITE are protected against over-  
load 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.  
• 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 elec-  
trical junction box on the compartment wall.  
If flexible metal conduit is used between the gen-  
erator and the compartment junction box, the con-  
duit end that terminates the compartment junction  
box must be vapor-sealed. Flexible metal conduit  
is NOT vapor tight along its entire length.  
• From the junction box, route power supply wires  
through approved conduit to either (a) double-pole,  
double-throw transfer switch, or (b) approved iso-  
lation receptacle. Connecting to a transfer switch  
or isolation receptacle must prevent vehicle electri-  
cal circuits from being connected to two different  
power supplies at the same time (such as genera-  
tor and dockside power).  
Do NOT connect electrical loads in excess of any  
circuit breaker rating or problems will develop  
with circuit breaker tripping, which causes a loss  
of AC output. Also, do NOT exceed the gener-  
ator's rated wattage capacity. Add the watts  
or amperes of all lighting, appliance, tool and  
motor loads the generator will operate at one  
time. This total should be less than the unit's  
rated wattage/amperage capacity.  
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 junction box connections.  
• Carefully prepare conduit ends to prevent sharp  
edges from cutting through wiring insulation.  
• Route conduit so it does not interfere with genera-  
tor movement.  
• If using metallic conduit, vapor seal the end of the  
conduit where it enters the junction box. Do this  
because flexible metallic conduit is not vaporproof  
along its entire length.  
• Conductors must be rated 221° F (105° C) or must  
be of a larger conductor size.  
2.6.3 GENERATOR AC CONNECTIONS  
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.  
29  
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Section 2 – Installation  
Recreational Vehicle Generator  
2.6.5 ISOLATING DIFFERENT POWER  
SOURCES  
2.6.6 POWER SUPPLY CORD  
The power supply cord must comply with all appli-  
cable codes, standards and regulations. It must be  
large enough to handle the full amperage to which it  
will be subjected.  
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 isolating receptacle  
(Figure 2.15). Whichever method is used, be certain  
that both power sources are NOT connected at the  
same time.  
Figure 2.14 – Transfer Switch Isolation Method  
GENERA  
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:
1
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3
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3
2
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Figure 2.15 – Installation With Isolation Receptacle  
G
EN  
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30  
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Section 2 – Installation  
Recreational Vehicle Generator  
2. Connect the battery cable from the battery post  
indicated by a NEGATIVE, NEG or (-) to the  
frame ground connection (Figure 2.16).  
3. Connect cables so the connectors are clean and  
tight.  
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 electri-  
cal receptacles. Contact the dealer for recommenda-  
tions.  
Figure 2.16 – Connecting Battery Cables  
POS  
2.7 BATTERY INSTALLATION  
FUEL  
2.7.1 RECOMMENDED BATTERY  
Install a battery that meets the following require-  
ments:  
NEG  
• The battery must be a 12-volt, automotive type  
storage battery.  
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.  
NOTE:  
2.7.4 BATTERY COMPARTMENT  
Install the generator battery in its own, vented com-  
partment. Place the battery compartment away from  
any source of heat, sparks or flame.  
Provide ventilation openings in the battery compart-  
ment. The minimum size of openings should be 2  
square inches at the top of the compartment. Mount  
the battery on a strong, rigid supporting structure,  
where leaks and spills of battery fluid will not cause  
damage.  
If the battery is to be used to power other vehicle  
accessories, as well as start the generator, a bat-  
tery with a larger capacity may be needed.  
2.7.2 BATTERY CABLES  
2.8 OPTIONAL ACCESSORIES  
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.  
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.  
These generators are rated at about 100 DC amperes  
of cranking current.  
Figure 2.17 – Remote Panel Plug-in Receptacle  
Select battery cables based on (a) cable length and  
(b) prevailing ambient temperatures. Generally, the  
longer the cable and the colder the weather, the larger  
the cable size must be, as shown in the chart.  
6
5
4
3
2
1
14A  
18  
14A  
18  
CABLE LENGTH  
in Feet (Meters)  
0 to 10 (0 to 3)  
15  
14  
0
15  
14  
0
CABLE SIZE  
2*  
17  
17  
11 to 15 (3.4 to 4.5)  
16 to 20 (4.5 to 6)  
0
000  
* For warm weather, use No. 2 cable up to 20 feet.  
12.00"  
WIRE  
No.  
WIRE  
COLOR  
2.7.3 BATTERY CABLE CONNECTIONS  
LENGTH (mm)  
FUNCTION  
GROUND  
1. Connect the battery cable from the battery post or  
terminal indicated by a POSITIVE, POS or (+) to  
the lug on the starter contactor (Figure 2.16).  
NOTE:  
0
14  
15  
17  
18  
WHITE  
RED  
ORANGE  
YELLOW  
BROWN  
BLUE  
12.0 (305)  
12.0 (305)  
12.0 (305)  
12.0 (305)  
12.0 (305)  
12.0 (305)  
ENGINE RUN SIGNAL  
12 VDC  
START  
STOP  
PRIME  
14A  
Check to be sure the battery cable boot for the  
starter cable has been installed.  
P/N: 0D9099-B  
31  
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Section 3 – Post-Installation Start-up Adjustments  
Recreational Vehicle Generator  
2.8.1 REMOTE START/STOP PANEL  
3.3 INITIAL START  
When absolutely certain that the unit has been prop-  
erly installed and prepared for use, start the engine  
as follows:  
A remote mounted Start/Stop panel (Figure 2.18) 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, hour-  
meter, 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.  
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, Section 2.5, “Starting the  
Generator”, for cranking and starting instruc-  
tions. 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).  
Figure 2.18 – Optional Remote Panel  
3. Let the engine warm up for about five minutes to  
allow internal temperatures to stabilize.  
4. Carefully inspect the engine/generator for fuel, oil  
and exhaust system leaks. Before proceeding to the  
next step, correct any leakage immediately.  
5. When all tests and adjustments at no-load are  
completed, apply electrical loads and check for  
proper operation under load. See Section 3.4.  
Run the unit at least 30 minutes with loads  
applied.  
FUEL  
RUN  
PRIME  
STOP  
6. Turn off all electrical loads by setting the gener-  
ator’s main circuit breakers to their “OFF” (or  
open) position.  
7. Let the unit run at no-load for a few minutes to  
stabilize internal engine/generator temperatures.  
Then, shut down the engine.  
3.1 POST INSTALLATION TESTS  
The air-cooled generator set was factory tested and  
adjusted. It should not be required to adjust the unit  
any further except under special circumstances.  
NOTE:  
The generator set was thoroughly tested and  
adjusted at the factory before shipping. No addi-  
tional adjustment should be necessary. Only quali-  
fied service technicians who have been trained  
should perform adjustments outlined in this  
manual.  
Do not make any unnecessary adjustments.  
Factory settings are correct for most applica-  
tions. When making adjustments, however, be  
careful to avoid overspeeding the engine.  
3.2 BEFORE INITIAL START-UP  
Before starting, complete the following:  
3.4 TESTING UNDER LOAD  
1. Check the engine crankcase oil level and, if nec-  
essary, fill to the dipstick “FULLmark (cross-  
hatched area) with the recommended oil. Do not  
fill above the FULL mark.  
2. Check the fuel supply. Gas fuel lines must have  
been properly purged and leak tested in accor-  
dance with applicable fuel codes. All fuel shutoff  
valves in the fuel supply lines must be open.  
Apply electrical loads equal to about 75 to 100 per-  
cent of the unit's rated wattage/amperage capacity.  
Let the unit run at least 30 minutes with load applied.  
During this part of the test, check that the unit is not  
running excessively hot and that adequate cooling  
airflow is available. Do not allow the unit to overheat  
during prolonged operation.  
NOTE:  
DANGER  
The generator engine is equipped with a high tem-  
perature 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.  
If a liquid propane (LP) gas fuel system has been  
installed, it must be properly tested for leaks  
before operating the system in compliance with  
ANSI A119.2/NFPA 501C. No leakage is permit-  
ted. Be sure that no gasoline fuel vapors enter  
the vehicle interior.  
THE MANUFACTURER RECOMMENDS THAT THE  
GENERATOR BE TESTED FOR ADEQUATE COOL-  
ING.  
32  
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Section 3 – Post-installation Start-up Adjustments  
Recreational Vehicle Generator  
EXHAUST SYSTEM  
3.5 INSTALLATION CHECKLIST  
Exhaust system complies with all applicable  
LOCATION AND SUPPORT  
codes.  
Generator is properly located.  
Generator is properly supported.  
Generator is properly restrained.  
Exhaust system is properly and safely installed.  
ELECTRICAL CONNECTIONS  
Connections comply with local code requirements  
and all National Electrical Codes.  
GENERATOR COMPARTMENT  
Junction box is properly installed.  
Wiring meets all standards.  
Compartment construction is proper.  
Holes/Openings are vapor-sealed.  
Compartment size is correct.  
All connections are correct.  
Conduit is properly installed and sealed.  
Generator is properly bonded to the vehicle.  
Compartment is vapor-sealed.  
Sound insulation is correct.  
Floor cutouts are properly completed.  
BATTERY INSTALLATION  
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  
Fuel system is properly installed and checked  
Check that remote start/stop panels (if used) are  
for leaks.  
installed properly.  
Check that hourmeter kit (if used) is installed  
OPTIONAL LP GAS FUEL SYSTEM  
properly.  
Fuel system is properly installed and checked  
Check that any other options and accessories (if  
for leaks.  
used) are installed properly.  
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_________________________________________________  
33  
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Appendix 1 – Notes  
Recreational Vehicle Generator  
34  
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Appendix 2 – Troubleshooting  
Recreational Vehicle Generator  
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  
battery cables  
as necessary.  
3. Defective engine Start/Stop  
switch  
3. Replace Start/Stop switch.  
4. Defective starter contactor  
5. Defective starter motor  
6. Low or defective battery  
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  
4. Flooded engine  
5. Defective spark plug(s)  
6. Fuel line shut-off closed  
7. Plugged fuel filter  
3. Check connections and.  
insulation of #14 wires.  
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.  
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  
2. Defective low oil  
pressure switch  
1. Check oil and add oil as needed.  
2. Replace pressure switch.  
3. Defective high temperature  
switch  
3. Replace temperature switch.  
4. Defective engine control board  
5. Overheated engine  
4. Replace control board.  
5. Check that the airflow  
openings are adequate.  
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  
1. Reset circuit breaker  
to ON (or closed).  
2. Fault with vehicle circuit  
breaker and/or fuses  
2. Reset and replace if necessary.  
3. Transfer switch set to NORMAL 3. Set switch to GENERATOR.  
4. Start switch not held long  
4. Stop, then restart the engine  
(Hold Start switch for at least  
2 seconds).  
enough to flash the field  
5. Generator internal failure  
5. Contact aN Authorized Service  
Dealer.  
35  
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Appendix 3 — Electrical Data  
Recreational Vehicle Generator  
Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D  
BATTERY  
RED  
RED  
BLK  
SC  
16  
SM  
FP  
13  
F1  
15  
14A  
14  
CH  
SW2  
14  
SC  
0
0
16  
FS  
PCB  
15  
J3  
J2  
J1-1  
J1-2  
J1-3  
J1-4  
J1-5  
J1-6  
J1-7  
J1-8  
J1-9  
56  
90  
CS  
0
14  
SP  
IM  
15  
18A  
17  
17  
(START)  
(STOP)  
0B  
SW1  
HTO  
4
85  
85  
0
J1-10  
J1-11  
J1-12  
J1-13  
J1-14  
J1-15  
66  
85  
0
LOP  
0
REMOTE  
PANEL  
66  
18  
18  
4
CONNECTOR  
17  
0I  
1
1
17  
14  
18  
15  
2
2
3
4
5
6
14  
3
4
5
6
BCR  
14 A  
66  
7
8
7
8
15  
15  
14 A  
14  
0
18  
17  
66  
77  
BATTERY CHARGE WINDING  
STOP  
55  
R1  
START  
0N  
4
L1  
POWER WINDING  
22S  
HM  
33  
0N  
11S  
FUEL  
PRIME  
44  
11P  
22P  
REMOTE PANEL  
(OPTIONAL)  
ELECTRONIC  
VOLTAGE  
CB1  
LEGEND  
REGULATOR  
0K  
BCR - BATTERY CHARGE RECTIFIER  
CB1 - CIRCUIT BREAKER, 30A  
CB3 - CIRCUIT BREAKER, 2.5A  
CH - CHOKE HEATER (GASOLINE ONLY)  
2A  
4
CS - CHOKE SOLENOID  
CB3  
F1 - FUSE, 7.5A  
0N  
T1  
FP - FUEL PUMP-OR-LPG SHUT OFF VALVE  
FS - FUEL SOLENOID (GASOLINE ONLY)  
GT - TERMINAL, GROUND 4-TAB  
HM - METER, HOUR (OPTIONAL)  
4
2
6
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  
0F  
4
FIELD  
BLACK  
WHITE  
T2  
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  
36  
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Appendix 3 — Electrical Data  
Recreational Vehicle Generator  
Electrical Schematic and Wiring Diagram – Drawing No. 0D8063-D  
SUPPLIED BY  
CUSTOMER  
SUPPLIED BY  
CUSTOMER  
12V  
BATTERY  
16  
SM  
SC  
4
0K  
11S  
6
2A  
ELECTRONIC  
VOLTAGE  
REGULATOR  
4
13  
22S  
STATOR  
2A  
16 56  
0
0
15  
J3  
J2  
15  
14  
56  
J1-1  
J1-2  
J1-3  
J1-4  
J1-5  
J1-6  
0
90  
2A  
22S  
11S  
6
18A  
2
17  
4
17  
4
PCB  
J1-7  
17  
17  
J1-8  
J1-9  
66  
33  
77  
CLOSEST TO BEARING  
11P  
22P  
66  
0
J1-10  
J1-11  
J1-12  
J1-13  
J1-14  
J1-15  
44  
90  
55  
14  
16  
2A  
15  
RED  
18  
4
4
0F  
2
FIELD  
85  
0
13  
CB3  
77  
18  
11P  
2
55  
BCR  
33  
22P  
2A  
2
66  
R1  
0F  
44  
0N  
17  
15  
66  
0
0K  
0N  
18  
0
0
18A  
0F  
1
CONN. 1  
PIN#  
0
0
85  
18  
0I  
0I  
17  
14  
8
0
2
1
2
3
0
GT  
14  
7
6
3
4
90  
14  
14A  
15  
14  
14  
14  
18  
1
2
5
17  
14  
14A  
REMOTE  
PANEL  
TC  
14  
0
CONN. 2  
PIN#  
SW1  
15  
SW2  
18  
CONNECTOR  
15  
11P  
0B  
FS  
FP  
GT  
33  
F1  
15  
0
14A  
11P  
18  
13  
90  
14A  
WHITE  
15  
BLACK  
18  
CB1  
14A  
14  
18  
14A  
18A  
85  
15  
15  
85  
FILTER MTG  
SCREW  
LOP  
HTO  
0
T2  
GREEN  
T1  
18A  
CUSTOMER  
AC CONNECTION  
0
GREEN  
BLACK  
WHITE  
SP1  
90  
14  
CS  
CH  
NEUTRAL CONNECTION  
BY CUSTOMER  
IM1  
37  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
Enclosure – Drawing No. 0D8352-G  
38  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
Enclosure – Drawing No. 0D8352-G  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
2
0D6822  
0D6942  
0D6939  
0D6943  
0D6941  
0D6940  
0D6945  
0D6944  
0D8254  
0C5644  
0D7513  
087769  
0D7613  
0D7614  
048031C  
047411  
022473  
023484S  
022097  
086729  
0D3700  
022129  
022259  
075763A  
0D7293  
064113  
0C7561  
0A4456  
049813  
022237  
022131  
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
2
2
1
2
1
24  
2
2
2
1
1
1
1
2
1
2
TRAY, ENCLOSURE  
33  
34  
35  
36  
37  
38  
39  
40  
41  
0C5443  
0C7423  
029451  
1
1
BLOCK, TERMINAL BATTERY POST  
STUD 3/8”-16 X 2”-1/4” BRASS  
TAPE FOAM 1/8” X ½”  
PANEL, ENCLOSURE SIDE  
PANEL, REAR DIVIDER  
PANEL, ENCLOSURE ROOF  
PANEL, ENCLOSURE BACK  
PANEL, FRONT DIVIDER  
COMPARTMENT, AIR INTAKE  
PANEL, ENCLOSURE DOOR  
SHIELD, MUFFLER  
3
2.1’  
4
4
074908  
SCREW HHTT M5-0.8 X 10  
CUSTOMER CONNECTION HARNESS  
FOAM, AIR OUT COMPARTMENT SIDE  
CABLE, STARTER  
5
0D8717  
0D9020  
0742600144  
0E0724  
0A7215  
1
6
1
7
1
8
1
18  
ASSEMBLY OIL DRAIN  
SCREW SW ¼”-20 X 5/8” WITH NYLON  
WASHER  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
30  
31  
32  
SLIDE LATCH, FLUSH  
PUMP, FUEL  
FILTER, FUEL  
42  
43  
44  
45  
46  
47  
48  
49  
50  
0742600143  
0D8595  
0D8627  
0D8628  
0D8628A  
0D8691  
0D7176  
0A2115  
1
1
2
1
1
1
4
1
1
CABLE, BATTERY CONNECTION  
MOUNT, FUEL FILTER SUPPORT  
FOAM, AIR INTAKE COMPARTMENT  
FOAM, ROOF AIR OUT COMPARTMENT  
FOAM, BACK COMPARTMENT  
FOAM, DOOR PANEL  
FUEL LINE, FILTER TO PUMP  
FUEL LINE, PUMP TO CARB  
CLAMP HOSE BAND ¼”  
SCREW HHC M6-1.0 X 16  
WASHER FLAT ¼”  
WASHER SELF LOCKING 1"  
WASHER NYLON .250”  
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  
0D9282  
HARDWARE CLOTH COMPARTMENT  
AIR OUT  
BUSHING, 0.50” SNAP  
51  
52  
53  
54  
55  
56  
57  
58  
59  
023484E  
0F9176  
0E0014  
0E0017  
0C7968  
0E0393  
0D8981  
029451A  
0D8628B  
1
8.5”  
1
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  
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  
1
4
1
1
8.75’ FOAM TAPE 1/16” X ½”  
1
FOAM, FRONT AIR OUT  
COMPARTMENT  
WASHER LOCK 3/8”  
WASHER FLAT 3/8-M10”  
39  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
Generator – Drawing No. 0D8353-H  
40  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
Generator – Drawing No. 0D8353-H  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
050322  
022129  
049451  
0C8096A  
0D8120  
066849  
066386  
0D4217  
073159  
0D4484H  
0D4430H  
0D4216  
048614  
0D2588A  
022131  
027028  
0D6832  
022145  
030231  
0C3168  
022259  
0C8565  
0D8048  
083512  
0D6831  
029451  
0D6918  
0D2558  
087680  
0D7530  
0D9723  
0D4511  
0D8451  
022097  
0D7440  
090388  
0D7441  
081105  
089476  
022531  
0D8981  
1
22  
1
SCREW IHHC 5/16"-24 X 9-3/4"  
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  
3
4
1
5
4
6
2
7
1
8
1
9
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
41  
42  
1
ROTOR  
STATOR  
ADAPTOR, ENGINE  
1
1
4
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"  
1
4
4
1
18  
3
SCREW HHC 5/16"-18 X 1-1/2"  
5/16" SPECIAL LOCK WASHER  
NUT HEX 5/16"-18  
1
10  
2
SCREW SHC M8-1.25 X 18MM  
VIBRATION MOUNT  
4
6
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  
1
2.14'  
1
1
2
1
STUD, M6-1.0 OFFSET  
ELEMENT, AIR FILTER  
PRECLEANER, AIR  
1
1
1
WASHER FLAT .281" I.D. X 1.50" O.D.  
WASHER LOCK M6-1/4"  
MUFFLER  
1
1
2
SCREW HHTT M6-1.0 X 12MM  
BOLT CARR 5/16"-18 X 2"  
NUT FLANG 5/16"-18 LOCK  
GASKET, EXHAUST  
2
2
1
1
SCREW HHC 5/16"-18 X 1-3/4"  
FILTER GASKET RV  
1
41  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
Control Panel – Drawing No. 0D8354-E  
3
26  
25  
24  
9
17  
21  
20  
23  
2
13  
16  
7
15  
17  
10  
12  
1
11  
31  
23  
39  
38  
30  
27  
8
4
17  
18  
5
6
37  
5
4
5
36  
29  
3
14  
19  
35  
28  
22  
42  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
Control Panel – Drawing No. 0D8354-E  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
0830490  
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  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
5
1
2
2
4
1
5
4
4
2
1
2
2
1
2
2
1
1
1
2
2
1
1
REGULATOR VOLTAGE  
TERMINAL BLOCK  
CONTROLLER P.C.B.  
BATTERY CHARGER RECTIFIER  
BUSHING SNAP 1"  
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.  
9
10  
11  
12  
13  
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  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
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  
43  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
GN-220 H/SH Engine – Drawing No. 0D8355-S Part 1  
44  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
GN-220 H/SH Engine – Drawing No. 0D8355-S Part 1  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0D8433  
0C1069  
090695F  
081810  
083312  
0D8400  
0C8917A  
0C8798A  
045756  
082774  
022129  
081990  
0D9004A  
0E7585  
022097  
082981  
081675  
0D7666A  
090051  
080316  
090948  
078631  
0D8332  
091846  
0D7558  
078643  
0D8372  
0C2756  
0D7458  
0C3979  
085953  
0D8739  
0D8398  
091638A  
083512  
082025  
092984  
094820  
089739  
091848  
0D8778  
0D8803  
0A8584  
070185B  
075281  
043182  
0C4739  
0D9689  
0A7095  
077091  
0D8397  
077075  
0C2824  
0A7094  
0D8590  
0D8591  
1
10  
1
1
1
1
1
1
9
1
2
2
1
1
2
2
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
2
1
1
1
2
2
1
1
GUARD, FAN  
SCREW, HHTT M6-1.0 X 8mm  
BLOWER HOUSING  
NUT, HEX M16-1.5  
3
4
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  
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
SPARK PLUG, CHAMPION RC14YC  
LOCKWASHER, ¼”- M6  
TAPTITE, M6-1.0 x 30mm  
ASSEMBLY, IGNITION COIL  
BREATHER TUBE  
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  
SPRING, ANTI LASH  
WASHER, CARB WEAR  
ASSEMBLY BRACKET GOVERNOR ADJUST  
ROD, CHOKE LINKAGE  
SPRING, GOVERNOR  
SCREW HHTT M8-1.2 x 16mm  
NUT, M5-0.8 LOCK  
TOP WRAPPER  
PLUG, EXPANSION  
LOWER WRAPPER  
GASKET, OIL PSI PAD  
ADAPTER, OIL FILTER  
SCREW SHC M6-1.0 X 22mm  
SWITCH, OIL- 10 PSI  
FILTER, OIL  
SWITCH, THERMAL 284F  
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  
45  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
GN-220 H/SH Engine – Drawing No. 0D8355-S Part 2  
46  
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Appendix 4 — Exploded Views and Parts Lists  
Recreational Vehicle Generator  
GN-220 H/SH Engine – Drawing No. 0D8355-S Part 2  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
N/A  
1
0E8804  
078621  
076389  
088411  
0A8897B  
077168  
088057  
076390  
0E8540A  
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  
1
1
1
1
1
5
1
2
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
4
1
6
1
2
2
2
1
1
4
1
1
1
2
2
1
1
2
2
2
1
1
1
1
4
1
1
LONG BLOCK ASSEMBLY  
CONNECTING ROD ASSEMBLY  
PISTON PIN  
2
3
PISTON RING SET  
4
GEAR COVER ASSEMBLY  
M8 x 56mm HEAD BOLT  
PISTON  
5
6
7
PIN RETAINER RING  
TAPERED CRANKSHAFT ASSEMBLY  
GOVERNOR “R” PIN  
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
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  
47  
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Appendix 5 – Warranty  
Recreational Vehicle Generator  
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 emission 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, dur-  
ing 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 unap-  
proved 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 ser-  
vice, 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 fol-  
lowing address:  
ATTENTION WARRANTY DEPARTMENT  
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 297  
WHITEWATER, WI 53190  
Part 1  
48  
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Appendix 5 – Warranty  
Recreational Vehicle Generator  
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 equipment 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 subsequent 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.  
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:  
(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:  
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  
*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  
Part 2  
49  
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Appendix 5 – Warranty  
Recreational Vehicle Generator  
GENERAC POWER SYSTEMSTHREE-YEAR LIMITED WARRANTY  
FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS  
NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period  
of 3 (three) years of operation from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or  
replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is  
found to be defective under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that  
the purchaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service  
Facility. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner.  
This warranty applies only to Generac generators sold and rated for “Recreational Vehicle” (RV) applications, as Generac has defined  
Recreational Vehicle generator applications. The factory recommends exercising the unit one half-hour every month.  
WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS  
YEAR ONE – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:  
• Engine All components  
• Alternator All components  
WARRANTY SCHEDULE – CONSUMER/PERSONAL APPLICATIONS  
YEARS ONE AND TWO – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:  
• Engine All components  
• Alternator All components  
YEAR THREE – 100% (one hundred percent) only on selected part(s) and labor listed [Any labor and part(s) not listed, and removal  
and reinstallation are the owner’s responsibility]:  
Rotor, Stator, Computer Control Board (part numbers 0A6060 and 0A3369) and inverter, (if applicable with regard to the generator)  
Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Valve, Valve Lifter(s), Intake and Exhaust Manifolds  
Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators  
manufactured after January 1, 1998, have a transferable warranty to the second owner ONLY for the remainder of the three-year  
limited warranty. Proof-of-purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the  
performance of any warranty service.  
All warranty expense allowances are subject to the conditions defined in Guardian’s Warranty Policies and Procedures Guide.  
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:  
• Generac Guardian generators that utilize non-Generac replacement parts.  
• Costs of normal maintenance, adjustments, installation and start-up.  
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by  
Generac Power Systems.  
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.  
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all  
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.  
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL  
GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT  
RESULT OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages,  
so the above limitation may not apply to you.  
This warranty gives you specific legal rights. You also have other rights from state to state.  
GENERAC® POWER SYSTEMS, INC.  
P.O. BOX 297  
WHITEWATER, WI 53190  
Revision 02.05  
Part No. 0D8351  
Revision R (02/22/06)  
Printed in U.S.A.  
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