Owner’s Manual and
Installation Instructions
Air-cooled Recreational
Vehicle Generators
• Model: 02010-2
PRIMEPACT 50
• Model: 04164-3
PRIMEPACT 50LP
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Table of Contents
Recreational Vehicle Generator
Part I – Owner’s Manual
Part II – Installation Instructions
Safety Rules ......................................................................18
Section 1 – General Information.................................20
1.1 Purpose and Scope of the Manual.......................20
1.2 Safety ..................................................................20
1.3 Standards Booklets.............................................20
1.4 Equipment Description .......................................20
1.5 Generator Engine Operating Speed.....................20
1.6 Generator AC Connection System .......................20
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..........................................27
2.5 LP Gas Fuel System ............................................28
2.6 Exhaust System...................................................30
2.7 Electrical Connections.........................................31
2.8 Battery Installation..............................................34
2.9 Optional Accessories...........................................34
Introduction ........................................ Inside Front Cover
Read This Manual Thoroughly................................. IFC
Contents .................................................................. IFC
Operation and Maintenance..................................... IFC
How to Obtain Service ............................................. IFC
Authorized Service Dealer Locator Number............. IFC
Safety Rules ........................................................................ 2
Section 1 – General Information................................... 4
1.1 Generator Identification ........................................4
1.2 Generator Applicability .........................................5
1.3 Safety ....................................................................5
1.4 Generator AC Connection System .........................5
1.5 Specifications........................................................5
Section 2 – Operation ...................................................... 7
2.1 Generator Control Panel........................................7
2.2 Optional Remote Start/Stop Panel.........................7
2.3 Automatic Choke (Gasoline Only)..........................7
2.4 Before Starting the Engine ....................................8
2.5 Starting the Generator ..........................................8
2.6 Stopping the Generator.........................................9
2.7 Applying Loads to Generator.................................9
2.8 Summer/Winter Heat Riser System.......................9
2.9 Protection Systems..............................................10
2.10 Additional Information........................................11
Section 3 – Maintenance...............................................11
3.1 Checking the Engine Oil Level.............................11
3.2 Changing the Engine Oil and/or Oil Filter ...........12
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 (Gasoline Only)...................................14
3.7 Spark Arrestor Muffler........................................14
3.8 Cleaning the Generator .......................................14
3.9 Battery Maintenance............................................14
3.10 Major Service Manual..........................................15
3.11 Drive Belt............................................................15
3.12 Exercising the Generator.....................................15
3.13 Out of Service Procedure.....................................15
Section 3 – Post-installation Start-up
Adjustments................................................35
3.1 Post Installation Tests .........................................35
3.2 Before Initial Start-up..........................................35
3.3 Initial Start..........................................................35
3.4 Testing Under Load.............................................35
3.5 Installation Checklist...........................................36
Section 4 – Troubleshooting.........................................37
Section 5 – Electrical Data............................................38
Section 6 – Exploded Views and Parts Lists.............40
Section 7 – Warranty ......................................................52
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.
• WARNING:
GENERAL HAZARDS
• The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects or other reproductive harm.
• 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 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.
• 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,
ensurethat it is safe for others. Also make sure the
procedure, work method or operating technique utl-
ized does not render the generator unsafe.
• 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.
DANGER
• The engine exhaust fumes contain carbon mon-
oxide, which can be DEADLY. This dangerous
gas, if breathed in sufficient concentrations, can
cause unconsciousness or even death. Thus, the
exhaust system must be installed properly, in strict
compliance with applicable codes and standards.
Following installation, do nothing that might 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.
Despite the safe design of this generator, operat-
ing this equipment imprudently, neglecting its
maintenance or being careless can cause pos-
sible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to ren-
der 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.
• 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.
2
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Safety Rules
Recreational Vehicle Generator
• 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.
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.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
FIRE HAZARDS
• 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.
• 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 regu-
lations.
• 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.
• This generator may use liquid propane (LP) gas
as a fuel. LP gas is highly EXPLOSIVE. The gas is
heavier than air and tends to settle in low areas
where even the slightest spark can ignite the gas
and cause an explosion.
• 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
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: 02010-2
1. Generator Air Intake
2. Engine Start/Stop Switch
3. Fuse
4. Optional Remote Panel
Receptacle (behind
PRIMEPACT
E
v
ery
8
hours
Ev
ery 25 hours
E
v
ery 100 hours
M
aintenance Schedule
heck engine oil level
hange oil
hange oil filter
or before use or
3
m
onths or once ear
a
y
C
•
C
•
•
control panel)
5. Generator AC Output Leads
(behind control panel)
6. Fuel Primer Switch
7. Circuit Breaker
8. Circuit Breaker
9. Starter Contactor
10. Fuel Inlet
C
Clean & re-oil foam pre cleaner
Clean air intake
•
•
•
•
Clean & reset spark plugs
R
eplace fuel filter
Inspect battery posts & cables
“E ercise” generator
V Service ocator 1-800-333-1322
•
•
x
R
L
•
www.guardiangenerators.com
18
11. Fuel Pump
12. Fuel Filter
13. Oil Filter
14. Oil Drain Cap
15. Oil Dipstick
16. Data Decal
17. Oil Fill
18. Spark Plug
Model: 04164-3
1. Generator Air Intake
2. Engine Start/Stop Switch
3. Fuse
4. Optional Remote Panel
Receptacle (behind
control panel)
PRIMEPACT
E
v
ery
8
hours
Ev
ery 25 hours
E
v
ery 100 hours
M
aintenance Schedule
heck engine oil level
hange oil
hange oil filter
Clean & re-oil foam pre cleaner
or before use or
3
m
onths or once ear
a
y
C
•
C
•
•
C
•
Clean air intake
•
•
•
Clean & reset spark plugs
R
eplace fuel filter
Inspect battery posts & cables
“E ercise” generator
V Service ocator 1-800-333-1322
•
•
x
5. Generator AC Output Leads
(behind control panel)
6. Fuel Primer Switch
7. Circuit Breaker
8. Circuit Breaker
9. Starter Contactor
10. Fuel Solenoid
11. Demand Regulator
12. Oil Filter
R
L
•
www.guardiangenerators.com
17
13. Oil Drain Cap
14. Oil Dipstick
15. Data Decal
16. Oil Fill
17. Spark Plug
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 applica-
tion, write or call the factory. 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 dual two-wire connection system. Note,
however, that the neutral is grounded.
The generator may have been installed so that it pow-
ers 120-volt AC loads (Figure 1.1). It can be wired to
connect both 120- and/or 240-volt AC electrical loads.
This procedure should be done by an Authorized
Service Dealer or other qualified installer.
DANGER
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 120/240-volt, single-phase, 60 Hertz, AC
electrical loads. These loads can require up to 4,800
watts (4.8 kW) of power, but cannot exceed 40 AC
amperes of current at 120 volts, or 20 AC amperes
at 240 volts for model 02010-2. For model 04164-3,
the loads can require up to 4,500 watts (4.5 kW) of
power, but cannot exceed 37.5 amperes of current at
120 volts, or 18.8 amperes at 240 volts.
1.5 SPECIFICATIONS
‹
1.5.1 FUEL REQUIREMENTS
Do not overload the generator. Some installa-
tions may require that electrical loads be alter-
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.
nated to avoid overloading. Applying excessively
high electrical loads may damage the genera-
tor 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.
NOTE:
Some installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter
than the vehicle engine’s pickup tube. Such an
arrangement causes the generator engine to “run
out of gas” while adequate fuel for the vehicle
remains in the tank.
To reduce lead and carbon deposits use high qual-
ity UNLEADED gasoline with the generator. Leaded
REGULAR grade gasoline is an acceptable substi-
tute.
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.
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 ENGINE
Type of Engine................................... GN-410, Single-cylinder
Cooling Method........................................................Air-cooled
Rated Horsepower ........................................15 @ 4,200 rpm
Displacement.................................................................. 407cc
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
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 alcohol, inspect
more frequently for fuel leaks and other abnor-
malities.
Champion ................................................................ RC14YC
AC..................................................................................R45S
Fram Autolite .....................................................................65
Spark Plug Gap....................................... 0.030 inch (76 mm)
Recommended Minimum Battery..............400 Cold-cranking
Amperes
‹
1.5.2 OPTIONAL PROPANE FUEL SYSTEM
This generator is equipped with a liquid propane (LP)
gas fuel system. LP gas is usually supplied as a liquid
in pressure tanks.
The generator requires a vapor withdrawal type fuel
system. This type of gaseous fuel system uses the
vapors forming above the liquid fuel in the storage
tank. Air temperature around the storage tank must
be high enough to sustain adequate fuel vaporization.
In colder climates, it may be necessary to use an inde-
pendent heat source to be sure the fuel sufficiently
vaporizes in the storage tank.
‹
1.5.6 GENERATOR
Rated Maximum Continuous
AC Output (Gasoline)...........................4,800 Watts (4.8 kW)
AC Output (LP Fuel).............................4,500 Watts (4.5 kW)
Rated Voltage..................................................... 120 Volts AC*
Rated Maximum Continuous
AC Current (Gasoline) ....................................40 Amperes**
AC Current (LP Fuel) ...................................37.5 Amperes**
Phase.............................................................................. Single
Rotor RPM.......................................................................3,600
Number of Rotor Poles...........................................................2
Engine RPM.....................................................................2,571
Rated AC Frequency....................................................... 60 Hz
Battery Charge Voltage..........................................14 Volts DC
Battery Charge Current................................2 Amperes (max)
LP gas may consist of propane, butane or a mixture of
the two gases. Propane vaporizes at temperatures as
low as -20° F (-29° C), but butane returns to its liquid
state when the temperature drops below about 32° F
(0° C). For that reason, a higher ratio of propane is
desired in the gas mixture when temperatures drop
below freezing.
Weight
‹
1.5.3 FUEL CONSUMPTION
Gasoline ..............................................................198 Pounds
LP Fuel ................................................................200 Pounds
Length...................................................25.5 inches (648 mm)
Width..................................................18.88 inches (479 mm)
Height.................................................16.75 inches (425 mm)
*All units are reconnectable to 120- and/or 240-volt, dual voltage
output. Units are no longer listed per RVIA/ANSI when recon-
nected for dual voltage output.
Model
No Load 1/2 Load Full Load
02010-2
04164-3
0.32
0.46
0.76
0.47/17.05 0.72/3.06 1.25/45.35
Gasoline is in gal/h.
LP is in gal/h and cf/h.
‹
1.5.4 ENGINE OIL REQUIREMENTS
**If reconnected for dual voltage, the ampere rating for 240 volts
is 20 AC amperes for model 02010-2, and 18.8 AC amperes for
model 04164-3.
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:
‹
1.5.7 EMISSIONS COMPLIANCE PERIOD
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.
• During summer months: SAE 30. An acceptable
substitute is SAE 10W-30.
• During winter months: SAE 5W-30. DO NOT USE
SAE 10-W40.
Crankcase and oil filter capacity is approximately
1,400 mL or 1.5 U.S. quarts. Do NOT use special
additives. See "Checking the Engine Oil Level" and
"Changing the Engine Oil and/or Oil Filter" sections
for oil level check and fill procedures.
• 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.
6
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Section 2 – Operation
Recreational Vehicle Generator
NOTE:
2.1 GENERATOR CONTROL PANEL
The following features are mounted on the generator
control panel (Figure 2.1):
If the generator has been reconnected for dual volt-
age AC output (120/240 volts), install line break-
ers having an amperage rating that is different
than that stated in the "Generator AC Connection
System" section. The replacement line breakers
consist of two separate breakers (one 20 amp, and
one 30 amp) with a connecting piece between the
breaker handles (so that both breakers will oper-
ate at the same time). If the unit is reconnected for
dual voltage, it is no longer RVIA listed.
Figure 2.1 – Generator Control Panel
2.2 OPTIONAL REMOTE
START/STOP PANEL
A remote mounted Start/Stop Panel (Figure 2.2) is
available that allows starting and stopping the gen-
erator engine conveniently from inside the vehicle.
The remote panel includes a Start/Stop switch, hour-
meter, generator run lamp and a wire harness.
Figure 2.2 — Optional Remote Panel
(Models 004057 and 004184)
‹
2.1.1 FUEL PRIMER
Before starting a cold engine (if it has not been started
in more than two weeks), this switch must be pressed
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.
It is not necessary to press the primer switch for LP
units.
2.3 AUTOMATIC CHOKE (GASOLINE ONLY)
The engine is equipped with an automatic choke that
consists of two main components: a choke solenoid
and prechoke.
‹
2.1.2 START/STOP SWITCH
To crank and start the engine, hold this switch in the
START position. Release the switch when the engine
starts. To stop an operating engine, press and hold
the switch in the STOP position until the engine shuts
off. The switch center position is the RUN position.
‹
2.3.1 CHOKE SOLENOID
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.
‹
2.1.3 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 replaxed, use only an
identical replacement.
‹
2.3.2 PRECHOKE
The choke system also has a temperature-sensitive
metal strip that adjusts choke valve angle according
to ambient temperatures (i.e., in cold ambient 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.
‹
2.1.4 MAIN BREAKER
The main breaker protects the generator’s AC output
circuit against overload and provides a method of
turning OFF the generator’s 120/240-volt AC output
to the vehicle circuits. The generator has one 20-amp
breaker and one 30-amp breaker.
7
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Section 2 – Operation
Recreational Vehicle Generator
‹
2.4.5 ENGINE EXHAUST GAS
2.4 BEFORE STARTING THE ENGINE
NOTE:
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.
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.
DANGER
‹
2.4.1 INSTALLATION
The generator engine releases DEADLY carbon
monoxide gas through its exhaust system. This
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.
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
NOTE
Be sure the installation complies with all stan-
dards and codes listed in the "Standards Booklets"
section of this manual.
‹
2.4.2 ENGINE LUBRICATION
Have the engine crankcase properly serviced with the
recommended oil before starting. Refer to the "Engine
Oil Requirements" section and "Checking the Engine
Oil Level" and "Changine the Engine Oil and/or Oil
Filter" sections for oil servicing procedures and rec-
ommendations.
SYMPTOMS PERSIST, GET MEDICAL HELP. Shut
down the generator and do not operate it until
it has been inspected and repaired.
DANGER
Never sleep in the vehicle while the genset is
running unless the vehicle has a working carbon
Any attempt to crank or start the engine before
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.
it hase been properly serviced with the recom-
mended oil may result in an engine failure.
‹
2.4.3 FUEL SUPPLY
The engine must have an adequate supply of proper
fuel to operate. Before starting it, check that suffi-
cient fuel is available.
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.
NOTE:
Depending on the installation, the generator may
have either a separate fuel tank, or it may “share”
the vehicle engine’s fuel tank.
‹
2.4.4 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator 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.
To start the generator from either the generator con-
trol panel or from the optional remote panel, proceed
as follows:
1. Turn OFF electrical loads using the means pro-
vided in the vehicle (such as a main line circuit
breaker or transfer switch).
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Section 2 – Operation
Recreational Vehicle Generator
NOTE:
2.8 SUMMER/WINTER HEAT
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.
RISER SYSTEM
Under certain weather conditions, it is possible for
ice to form in the venturi area of the carburetor. This
condition can be very dangerous because it can pre-
vent the governor system from functioning properly,
which results in a “runaway” engine.
The most common weather conditions leading to this
problem are temperatures in the range of 25° F to
35° F (-4° C to 1.7° C), along with high humidity. This
ice formation also can be attributed to the load being
applied during these weather conditions. Generators
running with no-load or light loads applied usually
have the most problems.
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.
The Summer/Winter Lever (Figure 2.3) should be
in the WINTER position for ambient temperatures
below 40° F (4.4° C) and in the SUMMER position for
ambient temperatures above 40° F (4.4° C).
If the engine does not start after it has been
Figure 2.3 – Heat Riser System
cranking for 15 seconds, release the Start/Stop
switch and try again. Holding the switch for
longer than 15 seconds can damage the starter
motor.
4. Let the engine run at no-load for a few minutes to
stabilize and warm up.
5. Turn ON electrical loads using the means pro-
vided (such as a main circuit breaker or transfer
switch).
2.6 STOPPING THE GENERATOR
1. Turn OFF all electrical loads using the means
provided (such as a main circuit breaker or
transfer switch).
2. Let generator run at no-load for a few minutes, to
stabilize internal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position.
2.7 APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator,
observe these guidelines:
When the heat riser is in the SUMMER (down) posi-
tion (Figure 2.2), air is drawn into the air cleaner
from the upper intake tube.
• Before applying electrical loads, let the generator
stabilize and warm up for a minute or two.
• DO NOT overload the generator.
When the heat riser is in the WINTER (up) position,
air is drawn from the lower intake tube, which is
positioned to draw the heated air near the exhaust
manifold.
‹
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.
To prevent carburetor icing, the owner/operator
should physically position the heat riser to the prop-
er position dependent on the temperature.
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.
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Section 2 – Operation
Recreational Vehicle Generator
Figure 2.4 – Low Oil Pressure and
High Temperature Switches
‹
2.8.1 DO NOT OVERLOAD THE GENERATOR
Read the rated wattage/amperage capacity of the gen-
erator on the generator data decal (see "Generator
Identification").
Applying electrical loads in excess of the unit’s rated
capacity will cause the engine/generator to automati-
cally shut down.
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.
• 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 dur-
ing motor starting). Be sure to allow for this when
connecting electrical loads to the generator. First,
figure the watts needed to start electric motors in
the system. To that figure, add the running watt-
ages of other items that will be operated by the
generator.
‹
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 2.5). During engine
cranking only, a positive DC (battery) voltage is deliv-
ered through the diode, resistor, brushes and slip
rings, and the generator rotor. Application of this
voltage to the rotor “flashes the field” whenever it is
started. Flashing of the field each time the generator
starts makes sure that a sufficiently strong magnetic
field is available to produce “pickup” voltage in the
stator windings.
• Do not apply heavy electrical loads for the first two
or three hours of operation.
2.9 PROTECTION SYSTEMS
Figure 2.5 – Field Boost Circuit
‹
2.9.
LOW OIL PRESSURE SWITCH
This switch (Figure 2.4) 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.
‹
2.9.2 HIGH TEMPERATURE SWITCH
This switch (Figure 2.4), which has normally open
(N.O.) contacts, is mounted near the oil filter. The
contacts close if the temperature should exceed
approximately 293º F (145º C), initiating an engine
shutdown.
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Section 3 – Maintenance
Recreational Vehicle Generator
‹
2.9.4 OVERVOLTAGE PROTECTION
‹
2.10.3 EFFECTS OF MOISTURE AND DIRT
A solid-state voltage regulator (Figure 2.6) 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).
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.
Figure 2.6 – Solid State Voltage Regulator
3.1 CHECKING THE ENGINE OIL LEVEL
For oil capacities and requirements, see section
“Engine Oil Requirements”. Check the engine crank-
case oil level at least every eight hours of operation,
or before use. To check the engine oil level, proceed
as follows (see Figure 3.1):
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.
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
“FULL” MARK.
2.10 ADDITIONAL INFORMATION
‹
2.10.1 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.
Never operate the engine with the oil level
below the “Add” mark on the dipstick. Doing
this could damage the engine.
5. Install and tighten the oil fill cap and the dipstick
before operating the engine.
‹
2.10.2 OPERATION IN HIGH GRASS
OR BRUSH
Never operate the generator while the vehicle is
parked over high grass, weeds, brush, leaves or any
other combustible substance. Such materials can
ignite and burn from the heat of the exhaust system.
The generator exhaust system becomes extremely
hot during operation and remains hot for a long time
after it has shut down.
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Section 3 – Maintenance
Recreational Vehicle Generator
8. Remove the oil fill cap on the rocker cover
and slowly add the proper type and amount
of recommended oil (see section "Engine Oil
Requirements"). Periodically use the dipstick to
check the oil level and continue to fill the crank-
case until the oil reaches the dipstick “Full” mark.
DO NOT FILL ABOVE THE “FULL” MARK.
9. Install and tighten the oil fill cap and the dipstick
before operating the engine.
3.2 CHANGING THE ENGINE OIL
AND/OR OIL FILTER
• Change the engine oil after the first 25 hours of
operation. Thereafter, change the oil every 100
operating hours. Change the oil more frequently if
operating consistently under heavy load or at high
ambient temperatures.
• Change the engine oil filter after the first 25 hours
of operation, and every 100 operating hours there-
after.
10. Start the engine and check for leaks.
NOTE:
• To change the oil and/or oil filter, proceed as fol-
Check the oil level and fill to the “FULL” mark
after checking for leaks. The filter will retain some
oil.
lows (see Figure 3.1):
1. Run the engine until it is thoroughly warmed up
(at least five minutes) then shut OFF the engine.
2. Immediately after the engine shuts OFF, pull the
oil drain hose free of its retaining clip. Remove
the cap from the hose 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 cap onto the
end of the oil drain hose. Retain the hose in the
clip.
4. With the oil drained, remove the old oil filter by
turning it counterclockwise.
5. Apply a light coating of clean engine oil to the
gasket of the new filter.
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):
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.
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover, foam precleaner and paper filter.
3. Remove the foam precleaner from the cover.
4. Wash the foam precleaner in liquid detergent and
water.
Figure 3.1 – Oil Maintenance Features
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Section 3 – Maintenance
Recreational Vehicle Generator
5. Wrap the foam precleaner in a clean cloth and
gently squeeze it dry.
Figure 3.3 – Cleaning Air Intake
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 fil-
ter.
9. Tighten the two screws to retain the filter in
place.
Figure 3.2 – Engine Air Cleaner
3.5 CHECKING THE ENGINE
PAPER
SPARK PLUG
AIR FILTER
Clean the spark plug and reset the spark plug gap
every 100 hours of operation.
FOAM
PRECLEANER
1. Clean the area around the base of the spark plug
to keep dirt and debris out of the engine. Clean
by scraping or washing using a wire brush and
commercial solvent. Do not blast the spark plug
to clean.
AIR CLEANER
COVER
2. Remove the spark plug and check the condition.
Replace the spark plug if worn or if reuse is ques-
tionable.
SCREWS
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).
‹
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):
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.
1. Follow steps 1-3 in the "Cleaning the Foam
Precleaner" section; service the foam precleaner
if necessary.
Figure 3.4 – Setting the Spark Plug Gap
2. Remove the paper filter.
3. Clean the air filter by tapping it gently on a solid
surface. If the filter is too dirty, replace it with a
new one. Dispose of the old filter properly.
4. Clean the air cleaner cover then reassemble
following steps 7-9 in the "Cleaning the Foam
Precleaner" section.
3.4 CLEAN AIR INTAKE
Clean all foreign material from the air intake (Figure
3.3) at least once every 100 hours of operation. Clean
more often if necessary.
Inspect the area around the generator exhaust muf-
fler periodically and remove all grass, leaves, dirt,
etc., from this area.
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Section 3 – Maintenance
Recreational Vehicle Generator
3.6 FUEL FILTER (GASOLINE ONLY)
Remove and replace the fuel filter (Figure 3.5) once
each year or every 100 hours of operation, whichever
comes first.
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.
Figure 3.5 – Fuel Filter
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.
Fuel Filter
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
3.7 SPARK ARRESTOR MUFFLER
interior and cause problems, and may also con-
taminate the generator fuel system.
If the generator is not equipped with a spark arres-
tor exhaust muffler and is to be used on any forest
covered, brush covered or grass covered unimproved
land, a spark arrestor may need to be installed. The
spark arrestor must be maintained in effective work-
ing order by the vehicle owner/operator.
3.9 BATTERY MAINTENANCE
All lead-acid batteries will discharge when not in
use. The generator battery should be inspected as
follows:
For assistance in ordering, installing and maintaining
spark arrestor exhaust mufflers, contact the nearest
Authorized Service Dealer.
‹
3.9.1 WEEKLY
Exhaust mufflers supplied by the manufacturer are
spark arrestor types. The manufacturer's exhaust
mufflers for recreational vehicle generators do not
have a spark arrestor screen, but are of the more effi-
cient “toroid” or “swirl” type. To remove carbon and
combustion deposits from such mufflers, remove the
plug from the muffler and run the engine for approxi-
mately 15 minutes. Shut down the engine, let the
muffler cool and install the plug.
• 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.
‹
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.
NOTE:
Be sure to reinstall the muffler plug tightly.
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.
Engine vibration could cause a loose plug to
fall out. Without the plug in place, hot engine
exhaust is directed out the opening. This hot
exhaust, depending on the installation, could
be directed to areas not able to withstand the
extreme heat such as wooden floor boards or
other flammable material. This could result in a
fire.
Damage will result if the battery connections are
made in reverse.
14
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Section 3 – Maintenance
Recreational Vehicle Generator
3.10 MAJOR SERVICE MANUAL
To obtain a service manual for the generator, con-
tact the nearest Authorized Service Dealer or, go to
www.generac.com. Make sure to identify the MODEL
NUMBER and SERIES.
DANGER
Do not dispose of the battery in a fire. The bat-
tery is capable of exploding. Storage batteries
give off explosive hydrogen gas. This gas can
form an explosive mixture around the battery
for several hours after charging. The slightest
spark can ignite the gas and cause an explosion.
Such an explosion can shatter the battery and
cause blindness or other injury. Any area that
houses a storage battery must be properly venti-
lated. Do not allow smoking, open flame, sparks,
or any spark producing tools or equipment near
the battery. Discharge static electricity from body
before touching the battery by first touching a
grounded metal surface.
3.11 DRIVE BELT
The engine drives the generator rotor by means of a
pulley and drive belt arrangement. The drive belt and
pulleys are warranted for the life of the generator. Drive
belt tension was properly adjusted before the unit was
shipped from the factory. If suspecting that the drive
belt tension is incorrect, contact an Authorized Service
Dealer.
3.12 EXERCISING THE GENERATOR
The manufacturer recommends starting and operat-
ing the generator at least once every seven days. Let
the unit run for at least 30 minutes to “exercise” the
engine.
A battery presents a risk of electrical shock and
high short circuit current. The following precau-
tions are to be observed when working on bat-
teries:
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery;
• Disconnect any charging source prior to connecting
or disconnecting battery terminals; and
• Do not use any jumper cables or booster battery to
crank and start the generator engine. If any battery
has discharged, remove it for recharging.
3.13 OUT OF SERVICE PROCEDURE
‹
3.13.1 REMOVAL FROM SERVICE
If the generator cannot be exercised every seven days,
and it is to be out of service longer than 30 days, pre-
pare the generator for storage as follows:
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line
and allow the unit to shut down.
3. While the engine is still warm from running, drain
the oil completely. Refill the crankcase with SAE
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.
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following
procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or water. The 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.
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.
15
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Section 3 – Maintenance
Recreational Vehicle Generator
‹
3.13.2 RETURN TO SERVICE
To return the unit to service after storage, proceed
as follows:
1. Check the tag on the engine for oil viscosity and
classification. Verify that the correct recommend-
ed oil is used in the engine (see the "Engine Oil
Requirements" section). 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.
4. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected
incorrectly.
5. Turn OFF all electrical loads. Add fuel if neces-
sary and then start the engine.
6. Allow the unit to warm up thoroughly.
7. Apply electrical loads to at least 50 percent of the
unit’s rated wattage capacity.
8. When the engine is thoroughly warmed up, shut
it down.
9. The generator is now ready for service.
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
GENERAL HAZARDS
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 famil-
iar with the procedures for installing such products,
or similar products that are manufactured. The
manufacturer also assumes that personnel have been
trained in the recommended installation procedures
for these products and that such training includes (a)
use of common hand tools, (b) use of special tools,
and (c) use of any tools and/or equipment from other
suppliers.
• For safety reasons, the manufacturer recommends
that the installation, initial start-up and 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 conceivable
methods, procedures or techniques by which to per-
form an installation. Nor can the manufacturer antic-
ipate every possible hazard that might result from
each installation method, procedure or technique.
The manufacturer has not undertaken any such wide
evaluation. Therefore, people who use a method, pro-
cedure 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.
• 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.
Despite the safe design of this generator, operat-
ing this equipment imprudently, neglecting its
maintenance or being careless can cause pos-
sible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Potentially lethal voltages are generated by
• 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 could occur.
these machines. Ensure all steps are taken to ren-
der 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 regu-
lations.
• 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 that an approved, flexible, noncon-
ductive fuel line between the generator fuel connec-
tion point and rigid fuel lines be installed.
• If the generator is equipped with a liquid propane
(LP) gas fuel system, install the unit so it complies
with all codes, standards and regulations pertain-
ing to such systems. LP gas is highly explosive.
The gas tends to settle in low areas where even the
slightest spark can ignite it and cause an explo-
sion. Do not allow gas vapors to enter the vehicle.
• 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. These generators are designed
specifically for installing in recreational vehicles.
They operate 120-volt, single-phase, 60-Hertz, AC
electrical loads that require 40.0 amps (gasoline) or
37.5 amps (LP fuel) at 120 volts.
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 through a pulley
and drive belt arrangement. The generator supplies
120 volts AC at 60 Hertz when the rotor is operating
at 3,600 rpm.The drive belt arrangement allows the
engine to operate at a lower speed than the rotor.
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
Before handling, installing, operating or servicing this
equipment, carefully read the “Notice to Installer”
and “Safety Rules” on pages 18 and 19. Comply with
all safety rules to prevent death, personal injury or
damage to equipment and/or property. Stress safety
to all installers, operators and service technicians
who work on this equipment.
Figure 1.1 – 120-volt Single Voltage Connection
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 all air-cooled genera-
tors uses a GROUNDED neutral.
• A separate green ground wire is connected to the
recreational vehicle’s junction box.
2. NFPA 70, “NFPA Handbook of the National
• For these units, loads connected across T1 (red)
to T2 (white), MUST NOT exceed 30 amperes
or 3,600 watts, and loads connected across T3
(black) and T2 (white) MUST NOT exceed 20
amperes or 2,400 watts each at 120 volts. The
combined loading of the two breakers should not
exceed 5,500 watts.
Electric Code,” available same as Item 1.
3. ANSI C1-1975 and ANSI 119.2-1975, available
from the American National Standards Institute,
1430 Broadway, New York, NY 10018.
4. ANSI A119.2/NFPA 501C, available from the
Recreational Vehicle Association, 1896 Preston
White Drive, Reston, VA 22090.
NOTE:
5. California Administrative Code, Title 25, available
from the State of California, Documents Section,
P.O. Box 1015, North Highlands, CA 95660.
Do NOT connect loads in excess of circuit breaker
ratings.
20
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Section 1 – General Information
Recreational Vehicle Generator
Figure 1.2 – Major Features and Dimensions (Drawing 0F1127)
21
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Section 2 – Installation
Recreational Vehicle 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.
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.
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.
Figure 2.1 – Typical Horizontal Support Frame
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 the "Generator Support" section.
• The location must provide an access opening
that is large enough to permit generator removal
(unless the generator is to be removed from under-
neath the supporting framework).
• The location must provide easy access to fre-
quently serviced components, such as filters, oil
drains, spark plugs and other common mainte-
nance parts.
• The location must provide sufficient room to allow
minimum clearances as outlined in the "Generator
Compartment" section. 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.
‹
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 gen-
erator is adequately protected, road test the installa-
tion 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
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:
• The installer must make certain that the selected
location will permit adequate cooling and ventilat-
ing airflow to be supplied.
• Vehicle construction MUST be capable of support-
ing the weight of the generator.
22
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Section 2 – Installation
Recreational Vehicle Generator
‹
2.1.4 GENERATOR RESTRAINT
‹
2.2.2 COMPARTMENT CONSTRUCTION
Use four 3/8"-16 hardened steel bolts (Grade 5) to
fasten the generator to the supporting frame or the
support tubing. These bolts must pass through (a)
the generator mounting base, (b) the compartment
floor (if a compartment is used) and (c) the supporting
framework (Figure 2.3). All bolts must be long enough
so that when tight, at least three threads are visible
past the retaining lock nuts. Refer to the "Generator
Compartment" section 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 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.
• All seams, splices and joints of the compart-
ment walls (unless vapor tight by design) should
be caulked to prevent poisonous, flammable or
explosive vapors from entering the vehicle interior.
NOTE:
NOTE:
Refer to “Figure 1.2 – Major Features and
Dimensions”.
Figure 2.4 – Clearances
Plywood
Compartment
1 1/2" Clearance on Top
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" Clearance
in Back
1" Each Side
• 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.
1/2"
Insulation
in Front
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Section 2 – Installation
Recreational Vehicle Generator
• 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:
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.
Figure 2.6 – Types of Lock Seams
‹
2.2.4 ACOUSTICS
For additional noise abatement, the installer may
wish to consider the following:
• Using special sound insulating materials.
• Construction of a special noise abatement 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 the "Sound Insulating
Materials" section.
• 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.
DANGER
• Line the compartment interior walls and floor, as
well as the underside of the floor, with 26-gauge
galvanized steel.
Do not install any flammable material directly
above or around the compartment. Heat, trans-
• Vapor seal all compartment seams and joints.
• Over the galvanized steel lining, install a combina-
tion of acoustical materials as mentioned in the
"Sound Insulating Materials" section.
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 materials
in high temperature areas.
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.
• 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).
Sound insulating materials should be of a nonflam-
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.
24
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Section 2 – Installation
Recreational Vehicle Generator
Figure 2.7 – Typical Noise Abatement
‹
2.2.5 COMPARTMENT FLOOR CUTOUTS
Provide openings in the generator compartment for
the following items (Figure 2.8):
• Engine exhaust and cooling air outlets
• Generator cooling air inlet
• Four holes for passage of generator mounting bolts.
See the "Generator Restraint" section.
DANGER
Fuel lines and exhaust piping must not penetrate
into the vehicle living area.
Figure 2.8 – Compartment Floor Cutout
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Section 2 – Installation
Recreational Vehicle Generator
NOTE:
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.
Screening, louvers or expanded metal that cover
air openings restrict airflow. Compensate for this
by making the actual air opening proportionately
larger. See the "Compensating for Restrictions" sec-
tion.
Figure 2.10 – Air Inlet in Compartment Door
DANGER
Never use discharged cooling air for heating or
permit such air to enter the vehicle interior. This
air contains deadly carbon monoxide gas and
other poisonous, flammable or explosive gases.
‹
2.3.1 GENERATOR AIRFLOW
Engine operation drives cooling fans for the two-stage
cooling air system. A pressure fan draws cooling air
into the top of the generator (Figure 2.9). This airflow
cools the engine/generator and electronic components.
The second part of the cooling system, a suction fan,
draws air that is heated from a hot engine into a col-
lector pan at the base of the unit. This heated air
(although cooler than exhaust muffler) is then deflected
out the bottom toward the ground.
NOTE:
Be sure to meet the minimum clearances illus-
trated in Figure 2.4.
When the unit is installed on a suspended mounting
system, one of several different methods of supplying
airflow may be used as follows:
Figure 2.9 – Airflow Through Engine/Generator
• Provide a door in the vehicle skirt having an air
inlet opening (Figure 2.11).
Figure 2.11 – Suspended Mount: Inlet Door
• Using ductwork (Figure 2.12). The installer must
be sure air is available to the top of the generator
since air inlets are located at the top.
• By providing an opening in the vehicle skirt and
space behind the generator for cooling airflow
(Figure 2.13). Recommended clearance behind
the back of the generator is at least 1/2 inch (13
mm).
‹
2.3.2 COOLING AIR INLET OPENINGS
The minimum size of the air inlet opening, whether
the generator is housed in a conventional compart-
ment or not, is at least 100 square inches (see
Figure 2.10). This rule applies whether inlet air is
brought in through an opening in the compartment
door, an opening in the vehicle skirt, through duct-
work, or by any other means.
26
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Section 2 – Installation
Recreational Vehicle Generator
Figure 2.12 – Air Inlet Using Ductwork
‹
2.3.4 TESTING THE INSTALLATION
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:
The installation must be tested, especially if air is
brought in from below the generator set.
2.4 GASOLINE FUEL SYSTEM
The installation of a gasoline fuel system (Figure
2.14) 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.
Figure 2.13 – Air Inlet in Vehicle Skirt
VEHICLE FLOOR
VEHICLE
SKIRT
Figure 2.14 – Generator Fuel System
AIR
INLET
PRIMEPACT
Every
8
hours Every 25 hours Every 100 hours
Maintenance Schedule
o
r
b
e
f
o
r
e
u
s
e
o
r
3
m
o
n
t
h
s
o
r
o
n
c
e
a
y
e
a
r
Check engine oil level
Change oil
•
•
•
Change oil filter
Clean
Clean air intake
Clean reset spark plugs
&
re-oil foam pre cleaner
•
•
•
•
&
Replace fuel filter
Inspect battery posts & cables
•
•
“Exercise” generator
•
MINIMUM
CLEARANCE
1-1/2"
FUEL LINE
‹
2.3.3 COMPENSATING FOR RESTRICTIONS
FUEL PUMP
FUEL FILTER
Such materials as screening, louvers or expanded
metal can restrict the free flow of air. Compensate
for this restriction by making the actual air opening
proportionately larger.
DANGER
Some materials may offer only a 60 percent “free air
inlet area.” Other more efficient materials may pro-
vide up to a 90 percent free air inlet area. The per-
centage of free air inlet opening is usually available
from the material supplier or manufacturer.
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.
To determine the actual air inlet opening size
required, divide 100 square inches by the per-
centage of free air inlet area for the material being
used.
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.
For example: If planning to use screening with an 80
percent free air inlet area, divide 100 by 0.8, which
results in 125 square inches. Minimum actual size of
air inlet opening in this case is 125 square inches.
27
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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 a separate fuel tank must be installed
for the generator set. All fuel tanks installed on the
vehicle must be constructed, installed and restrained
so they comply with applicable codes, standards and
regulations.
• The flexible hose must comply with SAE J1737
(30R7), “Standard for Fuel and Oil Hose.” It must
be approved for use with gasoline and low perme-
ability.
• 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 two to three inches (51
to 76 mm) shorter than the vehicle engine's pickup
tube. This prevents the generator from depleting the
entire fuel supply during prolonged generator operat-
ing periods.
2.5 LP GAS FUEL SYSTEM
DANGER
Do NOT tee the generator fuel supply line
LP gas is highly EXPLOSIVE. The gas is heavier
into the vehicle engine fuel supply line. If this
than air and tends to settle in low areas. Even
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.
the slightest spark can ignite it and cause and
explosion. Only competent, qualified people
should be allowed to install, test, adjust or ser-
vice an LP gas fuel system. Install the optional
fuel system in compliance with applicable codes,
standards and regulations. After the installation,
do not do anything that might render the sys-
tem in noncompliance with applicable codes and
standards.
‹
2.4.2 GENERATOR FUEL SUPPLY LINE
2.4.2.1 Rigid Fuel Lines
The LP powered range of generators are fitted with a
nonadjustable, factory set system. These systems are
tamper-proof to meet 1997 California Air Resources
Board requirements for engine emission.
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:
‹
2.5.1 PARTS NOT INCLUDED IN FUEL
SYSTEM
• 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.
The propane fuel system does NOT include such
items as (a) gas tank, (b) gas piping, (c) fittings, (d)
valves, and (e) primary regulator, used to store the
gaseous fuel and deliver it to the gaseous fuel sole-
noid (Figure 2.15).
• 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.
DANGER
Use only approved components in the fuel sup-
ply system. All components must be properly
installed in accordance with applicable codes.
Improper installation or use of unauthorized
components may result in fire or an explosion.
Follow approved methods to test the system for
leaks. No leakage is permitted. Do not allow fuel
vapors to enter the vehicle interior.
28
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Section 2 – Installation
Recreational Vehicle Generator
Figure 2.15 – Typical Propane Gas Fuel System
‹
2.5.4 PRIMARY REGULATOR
Gas pressure delivered to the solenoid valve must be
properly regulated by means of a primary gas regu-
lator. Mount the primary regulator at the gas tank
outlet or in the supply line from the gas tank. The
following rules apply:
• For best results, the primary regulator supplies
gaseous fuel to the secondary regulator at 11
inches water column. Do NOT exceed 14 inches
water column.
• The installer must be sure the primary regulator is
rated at sufficient gas flow to operate the generator
plus all other gas appliances in the circuit.
NOTE:
Recommended MINIMUM gas flow rate for all air-
cooled generators is 67 cubic feet per hour.
If an existing primary gas regulator does not have
a sufficient flow capacity for the generator and
other gas appliances in the circuit, (a) install a
primary regulator with adequate flow rate, or (b)
install a separate regulator only and rated at least
67 cubic feet per hour. The inlet side of any pri-
mary regulator that supplies the generator must
connect directly to a gas pressure tank. Do NOT
tee the generator line into a gas circuit feeding
other areas.
‹
2.5.2 SOME IMPORTANT CONSIDERATIONS
When installing an LP gas system, consider seriously
the following items:
‹
2.5.5 GASEOUS CARBURETION
• All fittings, lines, hoses and clamps must be
tight and free of leaks. Apply a pipe sealant to
threads when assembling threaded connections.
This reduces the possibility of leakage.
LP gas vapors should be supplied to the secondary
regulator inlet at about 11 inches water column (posi-
tive pressure). The engine pistons draw air in dur-
ing the intake stroke (Figure 2.16). This air passes
through a carburetor venturi, which creates a low
pressure that is proportional to the quantity of air
being pumped. The low pressure from the carburetor
venturi acts on the regulator diaphragm to pull the
diaphragm toward the source of low pressure. A lever
attached to the diaphragm opens a valve to permit
gas glow through the carburetor.
• Test the entire fuel system for leaks using approved
test methods.
• Optimum gas pressure at the inlet to the gaseous
fuel solenoid valve and secondary regulator is 11
inches water column.
• The installer’s fuel supply connection point is at
the gaseous fuel solenoid valve. This is a 3/4-inch
(female) connection. Provide a suitable 3/4-inch
NPT (male) connector to attach to the fuel supply
line.
• Use a length of approved flexible fuel hose between
the gaseous fuel solenoid valve and rigid gas pip-
ing. The flexible line should be at least six (6)
inches longer than necessary.
Figure 2.16 – LP Gas Carburetion Diagram
‹
2.5.3 VAPOR WITHDRAWAL
LP gas is stored in pressure tanks as a liquid. The
gas systems used with these generators were designed
only for vapor withdrawal type systems. Vapor with-
drawal systems use the gas vapors that form above
the liquid fuel in the tank. Do NOT attempt to use the
generator with any liquid withdrawal type system.
29
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Section 2 – Installation
Recreational Vehicle Generator
The greater the airflow through the carburetor ven-
turi, the lower the pressure at the venturi throat. The
lower the pressure at the venturi throat, the greater
the diaphragm movement, and the greater the move-
ment of the regulator valve. The more the regulator
valve opens, the greater the gas flow that is propor-
tional to airflow through the generator.
The leak test must comply fully with NFPA, Paragraph
318. All connections, hoses, valve regulators, fittings,
and other fuel system parts must be tested under
gas or air pressure of not less than 90 psi (620 kPa),
while using soap and water or an equivalent solution
to check for leaks. Other approved methods of testing
for leaks may be used, if appropriate. DO NOT USE
ANY FLAME TO TEST FOR LEAKS.
The following facts about the secondary regulator
must be emphasized:
DANGER
• The regulator must be sensitive to venturi throat
pressure changes throughout the operating range.
• The regulator must be properly adjusted so it will
stop the flow of gas when the engine is not running
(no air flow through the carburetor).
• The slightest airflow (and vacuum in the venturi
throat) should move the regulator valve off its seat
and permit gas to flow.
Gaseous fuel lines between the tank and the sec-
ondary regulator are under a positive pressure
(about 11 inches water column). Gas pressure at
the outlet side of the secondary regulator, how-
ever, is a negative pressure and can draw flame
inside a line or fitting and cause an explosion.
2.6 EXHAUST SYSTEM
‹
2.5.6 FUEL SUPPLY LINES
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.
• LP gas lines must be accessible, but protected
against possible damage.
• Do NOT connect electrical wiring to any LP gas fuel
line or run wiring alongside the lines.
• Route gas lines away from hot engine exhausts.
• Retain gas lines with metal clamps that do not have
sharp edges.
• Install an approved length of flexible hose between
the gaseous fuel solenoid valve and rigid fuel
supply lines. The flexible line must be nonmetal-
lic, nonorganic and nonconductive. It must be
approved for use with LP gas.
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.
‹
2.5.7 EXCESS FLOW VALVE
LP gas tanks should have an excess flow valve,
according to NFPA 501C, Paragraph 3-4.4. This
valve and the gas lines must be carefully sized so the
valve will close when a fuel line is severed or broken.
Consult the Natural-LP Gas Association for informa-
tion and limitations of excess flow valves.
Manual shutoff valves on the supply tank and else-
where in the system must be fully open when oper-
ating the generator. The excess flow valve functions
properly only if all valves are fully open.
‹
2.5.8 LEAKAGE TESTS
Never tee the generator engine exhaust pipe
into the vehicle engine exhaust piping. This
Do not place the generator into service until the gas
system has been properly tested for leaks. To test the
system, a separate source of 12 volts DC is needed to
open the gaseous fuel solenoid valve.
causes excessive back pressure on the generator
engine. Also, water from one engine can damage
the other engine.
30
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Section 2 – Installation
Recreational Vehicle Generator
• If there is any possibility of the tailpipe or muffler
being damaged, protect these damage-prone areas
by means of a protective device (such as a skid
bar).
‹
2.6.1 MUFFLERS AND SPARK ARRESTORS
This muffler meets code and standard requirements
of the U.S. Forest Service. Use only mufflers and
parts approved by the manufacturer. Any person(s)
installing an unapproved muffler, or an unapproved
exhaust system part, or modifying an exhaust system
in any way that might cause a hazard, is liable for
any damage, injury or warranty expense that might
be caused by such unapproved installation or modi-
fication.
• 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.
Failure to provide and maintain a spark arrestor may
be in violation of the law. If this generator is used on
any forest covered, brush covered or grass covered
unimproved land, a spark arrestor must be installed.
The vehicle owner or operator must maintain this
device in good condition. In the state of California,
the preceding is required by law (Section 4442 of
the California Public Resources Code). Other states
may have similar laws. Federal laws apply on federal
lands.
‹
2.6.2 TYPE OF EXHAUST SYSTEM
• Plan exhaust system installation carefully. Comply
with all applicable codes, standards and regula-
tions.
Two types of exhaust systems for these generators
are available from the manufacturer. They include
the following:
2.7 ELECTRICAL CONNECTIONS
Be sure to read the "Generator AC Connection
System" section.
• “Out-the-bottom” exhaust system dimensions are
15/16” O.D., model 9742.
• “Out-the-side” exhaust system dimensions are 1-
1/4” O.D., 18 gauge, model 4172.
NOTE:
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.
• 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.
No matter what type of exhaust kit best fits the
recreational vehicle, the mounting base has open-
ings for either “bottom-out” or “side-out” exhaust
systems. Use the cover plate provided with the
generator to cover the opening NOT used.
‹
2.6.3 EXHAUST SYSTEM SAFETY
• 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 cannot be maintained, locate, insulate or
shield the exhaust part(s) so that the temperature
of any combustible material is not raised more
than 117° F (65° C) above the ambient air tem-
perature.
• 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.
‹
2.7.1 ELECTRICAL JUNCTION BOX
Install an approved, square electrical junction box
with a blank cover on the interior or exterior wall
of the area planned for installation of the generator
(NOT on the generator). Route the generator's AC
output leads into this junction box through approved
flexible conduit. This is the point of first termination
for generator AC output leads.
31
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Section 2 – Installation
Recreational Vehicle Generator
Line T1 (red) to T2 (white) is protected against
overload by a 30-amp circuit breaker (CB1). Use
this line-to-neutral connection separately to operate
120-volt, single-phase, 60 Hertz, AC loads requiring
up to 3,600 watts (3.6 kW) of power. Line T3 (black)
to T2 (white) also is protected against overload by a
20-amp circuit breaker (CB2). Use this line-to-neu-
tral connection separately to operate similar loads.
However, be sure the total unit load does not exceed
the maximum rating of the generator. The neutral line
(T2, white) on all units is a grounded neutral.
‹
2.7.2 WIRING
• Wiring should be of stranded copper to reduce the
chance that vibration may cause breakage.
• Wire gauge size should be large enough to handle at
least 115 percent of the installed generator's rated
maximum current.
• If neutral conductors are used, they must be the
same size as other leg wires.
• Route power supply conductors from generator AC
output leads T1 (red), T2 (white), T3 (black) and
the green ground wire through approved flexible
conduit to the electrical junction box on the com-
partment wall.
• If flexible metal conduit is used between the genera-
tor and the compartment junction box, the conduit
end that terminates the compartment junction box
must be vapor-sealed. Flexible metal conduit is NOT
vapor tight along its entire length.
• From the junction box, route power supply wires
through approved conduit to either (a) double-pole,
double-throw transfer switch, or (b) approved isola-
tion receptacle. Connecting to a transfer switch or
isolation receptacle must prevent vehicle electrical
circuits from being connected to two different power
supplies at the same time (such as generator and
dockside power).
Do NOT connect electrical loads in excess of any
circuit breaker rating or problems with circuit
breaker tripping will develop, which causes a loss
of AC output. Also, do NOT exceed the generator's
rated wattage capacity. Add the watts or amperes
of all lighting, appliance, tool and motor loads
the generator will operate at one time. This total
should be less than the unit's rated wattage/
amperage capacity.
‹
2.7.4 CONDUIT
Route the connections between the generator and the
junction box through approved, flexible conduit. The
following general rules apply:
• Conductors must be rated 221° F (105° C) or must
be of a larger conductor size.
• 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.
‹
2.7.3 GENERATOR AC CONNECTIONS
Generator AC output leads T1 (red), T2 (white) and
T3 (black) come out of the generator as shown in
Figure 2.17. Leads T1 (red) and T3 (black) are “hot,”
while T2 (white) is the grounded neutral lead. There
is also a green lead that connects to ground in the
junction box of the recreational vehicle.
Figure 2.17 – Generator AC Output Leads
‹
2.7.5 ISOLATING DIFFERENT POWER
SOURCES
Connections from the junction box must terminate in
a double-pole, double-throw transfer switch (Figure
2.18). An alternate method for isolating different
power sources is by using an isolating receptacle
(Figure 2.19). Whichever method is use, be certain
that both power sources are NOT connected at the
same time.
T3
T2
T1
Green
(Ground)
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Section 2 – Installation
Recreational Vehicle Generator
‹
2.7.6 POWER SUPPLY CORD
‹
2.7.7 GROUND FAULT CIRCUIT INTERRUPTERS
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.
The National Electrical Code (NFPA 70, 551-7)
requires that ground fault circuit interrupters (GFCIs)
on all external and some internal electrical recepta-
cles be installed. Contact the manufacturer or dealer
for recommendations.
Figure 2.18 – Transfer Switch Isolation Method
PRIMEPACT
Every
8
hours Every 25 hours Every 100 hours
Maintenance Schedule
o
r
b
e
f
o
r
e
u
s
e
o
r
3
m
o
n
t
h
s
o
r
o
n
c
e
a
y
e
a
r
Check engine oil level
Change oil
•
•
•
Change oil filter
Clean
Clean air intake
Clean reset spark plugs
&
re-oil foam pre cleaner
•
•
•
•
&
Replace fuel filter
Inspect battery posts & cables
•
•
“Exercise” generator
Figure 2.19 – Installation With Isolation Receptacle
PRIMEPACT
Every
8
hours Every 25 hours Every 100 hours
Maintenance Schedule
o
r
b
e
f
o
r
e
u
s
e
o
r
3
m
o
n
t
h
s
o
r
o
n
c
e
a
y
e
a
r
Check engine oil level
Change oil
•
•
•
Change oil filter
Clean
Clean air intake
Clean reset spark plugs
&
re-oil foam pre cleaner
•
•
•
•
&
Replace fuel filter
Inspect battery posts & cables
•
•
“Exercise” generator
33
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Section 2 – Installation
Recreational Vehicle Generator
Figure 2.20 – Connecting Battery Cables
2.8 BATTERY INSTALLATION
‹
2.8.1 RECOMMENDED BATTERY
Install a battery that meets the following require-
ments:
• 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:
‹
2.8.4 BATTERY COMPARTMENT
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.
Install the generator battery in its own, vented com-
partment. Place the battery compartment away from
any source of heat, sparks or flame.
‹
2.8.2 BATTERY CABLES
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.
Using battery cables that are too long or too small in
diameter may cause a drop in voltage, which causes
starting problems. For the best cold weather starting,
the voltage drop between battery terminals and the
generator connection point should not exceed 0.12
volts per 100 amperes of cranking current.
These generators are rated at about 100 DC amperes
of cranking current.
2.9 OPTIONAL ACCESSORIES
A plug-in receptacle (Figure 2.21) is provided on the
generator set, above the muffler enclosure. Use this
receptacle to connect an optional remote-mounted
start/stop panel to the generator. Installation of such
a panel will permit starting and stoping the gen-
erator engine from any convenient location inside the
vehicle.
Select battery cables based on (a) cable length and (b)
prevailing ambient temperatures. Generally, the longer
the cable and the colder the weather, the larger the
cable size must be, as shown in the chart.
CABLE LENGTH
in Feet (meters)
0 to 10 (0 to 3)
11 to 15 (3.4 to 4.5)
16 to 20 (4.5 to 6)
CABLE SIZE
Figure 2.21 – Remote Panel Plug-in Receptacle
2*
0
000
*For warm weather, use No. 2 cable up to 20 feet.
‹
2.8.3 BATTERY CABLE CONNECTIONS
1. Connect the battery cable from the battery post or
terminal indicated by a POSITIVE, POS or (+) to
the lug on the starter contactor (Figure 2.20).
NOTE:
Check to be sure the battery cable boot for the
starter cable has been installed.
2. Connect the battery cable from the battery post
indicated by a NEGATIVE, NEG or (-) to the
frame ground connection (Figure 2.20).
3. Connect cables so the connectors are clean and
tight.
34
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Section 3 – Post-installation Start-up Adjustments
Recreational Vehicle Generator
‹
2.9.1 REMOTE PANEL MODELS
3.3 INITIAL START
When absolutely certain that the unit has been prop-
erly installed and prepared for use, start the engine
as follows:
The remote panels mount a rocker type start/stop
switch, a “Generator Run” advisory lamp and an
hourmeter. The hourmeter should be used in con-
junction 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 “Starting the Generator”,
for cranking and starting instructions. The engine
may require more cranking for initial starting
since the fuel lines have to be primed (use of the
primer switch will shorten this time).
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 the "Testing
Under Load" section. Run the unit at least 30
minutes with loads applied.
• Model 004057 includes the remote panel and a 10
foot long, 4 wire harness.
• Model 004184 includes the remote panel and a 30
foot long, 4 wire harness.
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.
Do not make any unnecessary adjustments.
Factory settings are correct for most applications.
When making adjustments, however, be careful
to avoid overspeeding the engine.
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.
3.2 BEFORE INITIAL START-UP
Before starting, complete the following:
1. Check the engine crankcase oil level and, if nec-
essary, fill to the dipstick “FULL” mark (cross-
hatched area) with the recommended oil. Do not
fill above the FULL mark.
2. Check the fuel supply. Gas fuel lines must have
been properly purged and leak tested in accor-
dance with applicable fuel codes. All fuel shutoff
valves in the fuel supply lines must be open.
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.
DANGER
If a liquid propane (LP) gas fuel system has been
installed, it must be properly tested for leaks
before operating the system in compliance with
ANSI A119.2/NFPA 501C. No leakage is permitted.
Be sure no gasoline fuel vapors enter the vehicle
interior.
3.4 TESTING UNDER LOAD
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:
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.
THE MANUFACTURER RECOMMENDS TESTING
THE GENERATOR FOR ADEQUATE COOLING.
35
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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 for
❑ Check that remote start/stop panels (if used) are
leaks.
installed properly.
❑ Check that hourmeter kit (if used) is installed
‹
OPTIONAL LP GAS FUEL SYSTEM
properly.
❑ Fuel system is properly installed and checked for
❑ Check that any other options and accessories (if
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_________________________________________________
36
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Section 4 – 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
two (2) seconds).
enough to flash the field
5. Generator internal failure
5. Contact an Authorized Service
Dealer.
37
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Section 5 — Electrical Data
Recreational Vehicle Generator
Electrical Schematic and Wiring Diagram – Drawing No. 0D1754-A
38
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Section 5 — Electrical Data
Recreational Vehicle Generator
Electrical Schematic and Wiring Diagram – Drawing No. 0D1754-A
39
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Regulator (Model 02010-2) – Drawing No. 0F1125-C
2
5
11
28
6
7
8
12
30
10
29
9
13
16
14
17
18
21
19
15
22
20
23
24
26
25
27
40
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Regulator (Model 02010-2) – Drawing No. 0F1125-C
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0D5694
0F4795
0F5022
0C6070
0C4680
0C4647
0C4643
0D3973
0E6183
072683A
0D3308
070728
0C5764A
0C4643A
0C6066
0C5968
0C5759
0C5761
0C6069
0C6731
0C6067
0C4706
0C6068
0C5762
045764
0C6606
0E4170
0C5760
1
4
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
8
1
1
1
CASTING, TWIN REGULATOR HOUSING
SCREW PPHM SEMS M4-0.7 X 10
SOLENOID COIL, 12VDC
5
6
SPRING-SOLENOID PLUNGER
PLUNGER LP REG. ASSY
GASKET, SOLENOID
7
8
9
INLET, TWIN REGULATOR NO HOLE
PLUG, EXPANSION 16MM TWINREG
ELBOW 90D STREET 1/2" BRASS
PLUG 1/8" NPTF PIPE
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
WASHER FLAT 3.2MM ID X 10MM OD
SCREW PFILHM M3-0.5 X 5
SPRING, REGULATOR 45N/M 29MM
INLET, TWIN REG 11.11 DIA.
SEAL, INLET REGULATOR
SUPPORT, INLET SEAL
PIN, PIVOT ARM
LEVER, REGULATOR
GASKET, DIAPHRAGM
RIVET .118 X .125 ALUMINUM
SUPPORT, DIAPHRAGM
DIAPHRAGM, TWIN REGULATOR
CAP, DIAPHRAGM SUPPORT
COVER,TWIN REGULATOR
SCREW HHTT M4-0.7 X 8 BP
BARBED STR 1/2" X 1/2" NPT
CONNECTION 3/4"NPT - 3/8" 45D
JET LP GN220 ENGINE
41
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Base and Pulleys (Model 04164-3) – Drawing No. 0F1124-B
42
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Base and Pulleys (Model 04164-3) – Drawing No. 0F1124-B
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
1
ASSEMBLY REGULATOR (SEE E.V.
0F1125)
#8 HOSE CLAMP
33
079246
2
SCREW HHC M6-1.0 X 16MM W/ LOCK
WASHER
2
3
057822
074994
022145
022129
045771
066849
022473
062684
0A8475
077603
2
16"
8
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
056893
0A8407
0A8531
039253
0C1320
0A8010
0A8010A
0A8726
0A8250
022131
075224B
23897
12
1
1
3
1
1
1
1
1
1
1
3
1
1
1
1
1
1
3
1
1
2
2
2
1
2
1
2
1
2
1
2
SCREW CRIMPTITE #10-24 X 1/2"
GASKET, BLOWER SIDE
PLATE, BLOWER SIDE
SCREW HHC M8-1.25 X 20MM
HOUSING, BLOWER
HOSE, 1/2" I.D. PETROLEOM
WASHER FLAT 5/16"- M8
WASHER LOCK M8 - 5/16"
NUT HEX M8-1.25
4
5
12
3
6
7
2
SCREW, TAPTITE M5-0.8 X 16MM LONG
WASHER FLAT 1/4" - M6
GROUNDING LUG
GASKET, BLOWER HOUSING
GASKET, BLOWER HOUSING
GASKET, BLOWER / PAN
CAPSCR., HEX HD. 3/8"-24 X 2"
WASHER FLAT 3/8"- M10
PULLEY, ENGINE
8
1
9
1
10
11
2
LOCK WASHER SPECIAL #10
SAFETY BOLT SCREW HHC 5/16"-18 X
3.5"
2
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
0C2368
051730
029459
075215
052858
073146
075209
075242
075237
0A6479
046911
025017
022237
022259
081105
0A8614
090239
040976
0A8341
077643
090859
1
2
2
2
6
4
2
4
4
1
4
6
6
2
2
1
1
2
1
1
1
BASE, MOUNTING
WASHER FLAT #10
SCREW HHC M8-1.25 X 60MM
SPRING, BELT TENSION
WASHER, SPRING CENTER
NUT TOP LOCK FL M8-1.25
SLIDE (NYLON)
0A6858
042633
075216
049451
073106B
0A8694
063036
0A8594
0D1227
022152
022158
0D1741
0742600131
024114
075763A
023152
053407
0A4456
0E9193
0A2110
GASKET, COLLECTOR PAN
SCREW HHC 3/8"-24 X 1"
BELT (POLY V 4L)-40"
WASHER, PULLEY RETAINER
PULLEY, ALT.
SCREEN, SLIDE PAN
SUPPORT, NYLON SLIDE
SPRING, GENERATOR MOUNT
WASHER, SPRING RETAINER
SKID, RUBBER MOUNT
MOUNT, (RUBBER)
SCREW CRIMPTITE #8-18 X 1/4"
PAN, SLIDE
STARTER CONTACTOR
WASHER LOCK #10
NUT HEX #10-32
SCREW HHC 3/8"-16 X 1/2"
WASHER LOCK 3/8"
NUT HEX 5/16"-18
BOOT, STARTER CONTACTOR
STARTER CABLE
NUT HEX 5/16"-24
NUT FLANGE 5/16"-18
SKID, RUBBER MOUNT
GASKET, EXHAUST MANIFOLD
SCREW SHC M8-1.25 X 20MM
MANIFOLD, EXHAUST
BOOT, BATTERY CABLE
SCREW HHC 3/8"-16 X 3/4"
GROUND CABLE
WASHER LOCK SPECIAL 3/8"
BRACKET, LP REGULATOR
SCREW, SWAGE 1/4-28 X 1/2"
EXHAUST PIPE GASKET
EXHAUST COVER PLATE
43
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Alternator and Panel (Model 04164-3) – Drawing No. 0D1776-D
44
31
58
51
57
20
8
12
45
44
38
35
63
11
23
22
11
17
40
6
18
13
61
14
14
10
9
36
15
15
16
37
43
34
18
62
24
3
63
35
17
19
4
21
49
44
48
55
64
2
29
45
46
5
1
47
28
50
7
53
25
42
59
27
26
26
56
39
33
65
31
3
30
31
44
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Alternator and Panel (Model 04164-3) – Drawing No. 0D1776-D
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
0C9675
0A5649H
0A5646H
073159
031971
0C9674
0A6529
052858
066386
066849
0A8475
0C3818
075234
022473
022097
055816
090141
0A1658
074906
094039
0E9881
022129
027756
086316
053650
0C4258
075244
094071
094070
075476
022264
065795
090987
1
1
1
1
1
1
4
4
1
3
3
1
1
2
5
1
2
2
4
1
1
4
4
1
1
1
1
1
1
3
4
1
2
LOWER BEARING CARRIER
ROTOR ASSEM.
STATOR ASSEM.
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
086317A
075235
082737
049813
055440
043182
045771
053623
023484S
083049
022152
051716
090144
090145
025105
086315
090734
1
3
4
4
2
2
4
1
1
1
5
3
1
1
4
1
4
PANEL SUPPORT BRACKET
M5-0.8 X 30 LG. CAPSCREW
VIBRATION MOUNT
3
4
BALL BEARING
BALL BEARING
M6-1.0 HEX NUT
5
M5-08 X 25 LG. HEX HD. CAPSCR.
M3-LOCK WASHER
HEX NUT, M8
6
UPPER BEARING CARRIER
STUD-STATOR
7
8
M8-1.25 FLANGE LOCK NUT
BRUSH HOLDER
C/BREAKER 2.5A.-ON
BUSHING
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
M5-0.8 X 16 LG. TAPTITE
SPECIAL LOCK WASHER, M5
GENERATOR TOP HOUSING
RESISTOR1R 5% 25 WLVG
¼"/ M6-FLAT WASHER
¼"/ M6-LOCK WASHER
M6-1.0 X 70 LG. CAPSCREW
GROUND CABLE
REGULATOR VOLTAGE
LOCKWASHER, #10
M5-0.8 HEX NUT
C/BREAKER 20A.
C/BREAKER 30A. ALL UNITS
#6-32 SCREW W/LOCK WASHER
PANEL COVER
M4-0.7 X 12 LG. CAPSCR.W/LOCK-
WASHER & FLAT WASHER
#6-FLAT WASHER
SPECIAL LOCK WASHER, M6
M6-1.0 X 20 LG. TAPTITE
CONTROLLER P.C.B.
DECAL, UNIT
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
022985
032300
022676
087798
092113
075210A
0A8475A
051715
090157
090156
074908
031791
023897
0D2724
031879
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
FUSE HOLDER
FUSE AGC-15A.
5/16" -M8 LOCK WASHER
NYLON WASHER
SWITCH S.P.D.T. (START-STOP)
SWITCH S.P.D.T.-(FUEL PUMP)
TERMINAL BLOCK
PANEL SHEET METAL
4-PIN CONNECTOR
SPECIAL LOCK WASHER, M4
M4-0.7 HEX NUT
CONDUIT ASSEMBLY
ASSEMBLY, REMOTE CABLE
M5-.08 X 110 LG. PPHMS
SPACER-PLASTIC
DECAL, CB RATING 30A.
DECAL, CB RATING 20A.
M5-0.8 X 10 LONG TAPTITE
CLAMP, HOSE
M4-0.7 X 16 LG. CAPSCREW
#8/ M4-LOCK WASHER
BATTERY CHARGE RECTIFIER
M3-0.5 X 12 LG. PPHMS
#10/ M5-FLAT WASHER
BOOT, ROCKER SWITCH
WASHER FLAT #4
45
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Engine Sheet Metal (Model 02010-2 and 04164-3) – Drawing No. 0D1760-E
46
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Engine Sheet Metal (Model 02010-2 and 04164-3) – Drawing No. 0D1760-E
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0A4323
045756
029289
SRV 091222D
067198N
067890
0A4456
056893
0A6358
091646
092572
092079
022717A
073132
061669
089685
022129
049813
057821
059637
0D9004A
059985
025034
0A8875
0A7299
0A9539
0A7838
038593
022473
0A6357
0A6360
0A6489
0A6359
131-074260
090892
091159
091160
091161
049821
086999
0A8584
075281
0C1085
043182
070185B
0E9649
082774
0C2308
0A1658
090388
075474A
0D1624
0C4373
1
8
SCROLL, FLYWHEEL
SCREW, TAPTITE M6-1.0 X 10MM
FOAM TAPE
FLYWHEEL
3
2.5 FT.
1
4
5
1
WASHER, BELLVILLE M20 X 2.2
NUT, M20 X 1.5, FLYWHEEL
3/8" SPECIAL LOCK WASHER
SCREW, CRIMPTITE #10-24 X 0.5"
COVER,TOP FLYWHEEL
6
1
7
1
8
21
1
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
53
1
DEFLECTOR, EXHAUST PORT
ASSEMBLY, IGNITION COIL
SCREW, TAPTITE M6-1.0 X 25MM
GROMMET, RUBBER
1
2
1
1
BOOT, SPARK PLUG
PLUG, BUTTON ¾"
1
2
GROMMET, RUBBER
LOCK WASHER-M8
NUT, HEX M6-1.0
6
1
2
CAPSCR, HEX HD M8-1.25 X 40MM
SCREW, TAPTITE 3/8"-16 X 0.75"
ASSY, STATER MOTOR
2
1
2
SOCKET HD. CAPSCR., M8-1.25 X 45MM
PLUG, BUTTON 1-1/16"
1
1
ASSEMBLY, DIPSTICK & CAP
OIL DRAIN/DIPSTICK TUBE
OIL DRAIN HOSE ASSEMBLY
PIPE NIPPLE, 3/8" X 8" LG.
BRASS STREET ELBOW, 3/8"
FLAT WASHER, 1/4"-M6
1
1
1
1
1
1
WRAPPER, ENGINE SPARK PLUG
WRAPPER, STARTER SIDE
WRAPPER, REAR GEAR CASE
WRAPPER, CARB. SIDE
1
1
1
1
ASSEMBLY, WIRE-STARTER (#16)
SUPPORT, OIL FILTER
BUSHING, RUBBER
1
1
1
WASHER, RUBBER
1
BOLT, SHOULDER-M6-1.0 X 15MM
BOLT, SOCKET HD. CAPSCR.-M8-1.25 X 30MM
GASKET, OIL FILTER SUPPORT
SWITCH, OIL PRESSURE-10 PSI
SWITCH, OIL TEMPERATURE
SCREW, PHILIPS PAN HD. MACH.-M3-0.5 X 8MM
LOCK WASHER-M3
2
1
1
1
2
2
1
FILTER, OIL
1
ENGINE, LONG BLOCK-GN410VSRV
KEY, WOODRUFF 4 X 19 DIA.
COVER, CARB.
1
1
1
SPECIAL LOCK WASHER, M6
TAPTITE, M6-1.00 X 12MM
BOOT, TEMPERATURE SWITCH
BOOT, OIL PRESSURE SWITCH
SPACER, ENDFRAME
1
1
1
1
47
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
GN-410 Engine (Model 02010-2 and 04164-3) – Drawing No. 0E9615
48
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
GN-410 Engine (Model 02010-2 and 04164-3) – Drawing No. 0E9615
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
021533
0E3221
0E1466
071983
021713B
0A1442
021742
0E2985
076701
045756
080308
080309
080338
0D4788
083897
072694
0D3998
078672
078694
083907
021714
0D2274
086515
086516
086517
089673
0C4391
0A9877
0E3812
076361
0A5776
0A7811
078645
078691
074908
0A7975
0A5771
0B2104
0E9667
078658
078659
0A7628
089288C
0E3341
086025
0D9853B
0E9666
090747
0C3150
092362
068527
083921
077158
076329
0E0057
093064
1
1
1
2
1
8
4
1
1
2
2
1
1
1
2
2
2
1
1
2
1
2
4
1
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
4
1
1
1
1
1
PISTON RING SET
CONNECTING ROD
PISTON PIN
3
4
PISTON PIN RETAINER
CYLINDER HEAD GASKET
FLANGED HEX HD. CAPSCREW M8-1.25 X 42
M10 1.5 X 105MM HHFL
PISTON
5
6
7
8
9
CRANKCASE GASKET
M6-1.0 X 10 TAPTITE (THD. FORMING)
BREATHER GASKET
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
53
54
55
56
BREATHER COVER
OIL BREATHER SEPARATOR
PIPE PLUG-3/8"
TAPPET, SOLID
PIVOT BALL STUD
NUT HEX M8-1.0 G8
SEAL, VALVE STEM
PUSH ROD GUIDE PLATE
ROCKER ARM
CYLINDER HEAD W/VALVE SEATS AND GUIDES
VALVE SPRING RETAINER
VALVE SPRING KEEPER
EXHAUST VALVE
INTAKE VALVE
WASHER, VALVE SPRING
VALVE SPRING
CAMSHAFT ASSEMBLY
CRANKSHAFT SEAL
THRUST WASHER
PRESSURE RELIEF BALL
GOVERNOR SPOOL
GOVERNOR RETAINER (C-RING)
COVER, OIL PRESSURE RELIEF
M5-0.8 X 10MM TAPTITE
GOVERNOR GEAR ASSEMBLY
OIL PRESSURE SPRING
SPRING WASHER
OIL SUMP ASSEMBLY
GOVERNOR ARM "R" PIN
THRUST WASHER
GOVERNOR ARM RC45
CRANKCASE SUB ASSEMBLY
BALANCER
SET GEROTOR
PUSH ROD
CRANKSHAFT ASSEMBLY
BREATHER VALVE ASSEMBLY
ROCKER COVER GASKET
ROCKER COVER W/FILL
M6-1.0 X 20MM HEX HEAD. SCREW. AND LOCKWASHER
BEARING TUBE SHAFT
OIL SCREEN PICKUP ASSEMBLY
OIL FILL PLUG
"O" RING
OIL FILL CAP ASSEMBLY
49
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Engine Accessories (Model 04164-3) – Drawing No. 0F1135
50
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Engine Accessories (Model 04164-3) – Drawing No. 0F1135
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
0A6532
091039
051753
0E7585
089228
0A7336B
090970
0A6564
056893
0A6566
0A6780
096290
073111
081646
0A6563
0C3633
0A6581A
0C2332
092164
082025
0A7029
0A6913
091161
049813
092586
083512
0A6778
0A6785
0A6753
0A8222
086681
020753
022473
022097
0A6582
0A6503
0A6569
0A7660
0A6568
0A6567
091916
083532
1
1
1
1
1
1
1
1
3
1
1
2
1
1
1
2
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
MANIFOLD, INTAKE
GASKET, MANIFOLD/HEAD
HHCS-M6-1.0 X 40MM
SPARK PLUG, CHAMP
3
4
5
GASKET, CARB/MANIFOLD
CARBURETOR, GN 410 L/P
GASKET, CARB/AIR FILTER
BASE, AIR FILTER
6
7
8
9
CRIMPTITE #10-24 X 1/2"
DETENT
10
11
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SPRING, A/L BELLCRANK-CARB.
STUD, CARB. MOUNT 90 LG.
FILTER, AIR
PRE-CLEANER, AIR FILTER
COVER, AIR FILTER
KNOB, AIR CLEANER
BREATHER, TUBE
DECAL, AIRBOX QP55
ASSEMBLY, GOV. SPRING ADI BRACKET
NUT HEX LOCK M5-0.8 NYLON
NYLON WASHER, .31" X .26" X .13"
ROD, LINKAGE GOV. LEVER-BELLCRANK
BOLT, SHOULDER, M6-1.0 X 15MM
NUT, M6-1.0
WASHER, FELT
TAPTITE-M8-1.25 X 16MM
SPRING, A/L GOV. LEVER-BELLCRANK
ROD, LINKAGE BELLCRANK-CARB.
BELLCRANK, GOV. RODS
SPRING, GOVERNOR
NUT, GOVERNOR LEVER
HHCS-M6-1.0 X 60MM
M6 FLAT WASHER
M6 LOCK WASHER
TUBE, WINTER INLET
GROMMET 1/16"-1-1/2"
GROMMET, AIR IN/OUT
VALVE, WINTER/SUMMER
GROMMET, WINTER/SUMMER VALVE
SPRING, DETENT
LEVER, GOVERNOR ARM
BOLT, HEX HD. WASHER/LOCK WASHER-M6-1.0 X 30MM
51
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Section 7 – 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
52
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Section 7 – 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
53
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Section 7 – Warranty
Recreational Vehicle Generator
GENERAC POWER SYSTEMS’THREE-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. 0F1118
Revision D (06/15/06)
Printed in U.S.A.
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