Generac Welding System 005411 0 User Manual

Models:  
005411-0, 005413-0, 005415-0, 005751-0,  
005752-0, 005753-0, 005855-0, 005856-0,  
005857-0  
Owner's Manual  
Air-cooled Recreational  
Vehicle Generators  
RV 45, 55 and 65  
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Introduction  
The operator (driver) is responsible for proper and safe use of the  
vehicle and its equipment, and the safety of all vehicle occupants.  
We strongly recommend that the operator read this manual and  
thoroughly understand all instructions before using this equipment.  
We also strongly recommend instructing other occupants in the  
vehicle to properly start and operate the generator. This prepares  
them if they need to operate the equipment in an emergency.  
INTRODUCTION  
READ THIS MANUAL THOROUGHLY  
If any portion of this manual is not understood, contact the near-  
est Authorized Service Dealer for starting, operating and servicing  
procedures.  
Throughout this publication, and on tags and decals affixed to the  
generator, DANGER, WARNING, CAUTION and NOTE blocks are  
used to alert personnel to special instructions about a particular  
operation that may be hazardous if performed incorrectly or care-  
lessly. Observe them carefully. Their definitions are as follows:  
CONTENTS  
This manual contains pertinent owner’s information, including  
warranty, electrical diagrams, exploded views and lists of repair  
parts. In addition, the latter portion of this manual contains infor-  
mation necessary for the proper installation of these generators.  
After this heading, read instructions that, if not  
strictly complied with, will result in personal  
injury, including death, and property damage.  
OPERATION AND MAINTENANCE  
It is the operator's responsibility to perform all safety checks, to  
make sure that all maintenance for safe operation is performed  
promptly, and to have the equipment checked periodically by  
an Authorized Service Dealer. Normal maintenance service and  
replacement of parts are the responsibility of the owner/operator  
and, as such, are not considered defects in materials or workman-  
ship within the terms of the warranty. Individual operating habits  
and usage contribute to the need for maintenance service.  
After this heading, read instructions that, if not  
strictly complied with, may result in personal  
injury or property damage.  
After this heading, read instructions that, if not  
strictly complied with, could result in damage  
to equipment and/or property.  
Proper maintenance and care of the generator ensures a minimum  
number of problems and keep operating expenses at a minimum.  
See an Authorized Service Dealer for service aids and acces-  
sories.  
NOTE:  
After this heading, read explanatory statements that require  
special emphasis.  
HOW TO OBTAIN SERVICE  
When the generator requires servicing or repairs, simply contact  
an Authorized Service Dealer for assistance. Service technicians  
are factory-trained and are capable of handling all service needs.  
These safety warnings cannot eliminate the hazards that they  
indicate. Common sense and strict compliance with the special  
instructions while performing the service are essential to prevent-  
ing accidents.  
When contacting an Authorized Service Dealer about parts and  
service, always supply the complete model number and serial  
number of the unit as given on its data decal, which is located on  
the generator.  
Four commonly used safety symbols accompany the Danger,  
Warning and Caution blocks. The type of information each indi-  
cates follows:  
nThis symbol points out important safety  
information that, if not followed, could  
endanger personal safety and/or property of  
others.  
Model No. _________________ Serial No.______________  
This symbol points out potential explosion  
hazard.  
  
Authorized SERVICE  
DEALER LOCATION  
To locate the nearest AUTHORIZED SERVICE  
DEALER, please call this number:  
This symbol points out potential fire hazard.  
This symbol points out potential electrical  
shock hazard.  
1-800-333-1322  
ONLY DEALER LOCATION INFORMATION  
CAN BE OBTAINED AT THIS NUMBER.  
1
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Safety Rules  
nSAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be  
copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to  
all operators and potential operators of this equipment.  
Study these SAFETY RULES carefully before installing, operating  
or servicing this equipment. Become familiar with this manual and  
with the unit. The generator can operate safely, efficiently and reli-  
ably only if it is properly installed, operated and maintained. Many  
accidents are caused by failing to follow simple and fundamental  
rules or precautions.  
GENERAL HAZARDS  
• For safety reasons, the manufacturer recommends that the  
installation, initial start-up and maintenance of this equipment  
is carried out by an Authorized Service Dealer.  
• The generator engine releases DEADLY carbon monoxide gas  
through its exhaust system. This dangerous gas, if breathed  
in sufficient concentrations, can cause unconsciousness or  
even death. Never operate the generator set with the vehicle  
inside any garage or other enclosed area. Shut down the  
generator and do not operate it until it has been inspected  
and repaired.  
The manufacturer cannot anticipate every possible circumstance  
that might involve a hazard. The warnings in this manual, and on  
tags and decals affixed to the unit, are, therefore, not all-inclusive.  
If using a procedure, work method or operating technique the  
manufacturer does not specifically recommend, ensure that it is  
safe for others. Also make sure the procedure, work method or  
operating technique that chosen does not render the generator  
unsafe.  
• DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM  
IS LEAKING OR HAS BEEN DAMAGED.  
• SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a)  
inability to think coherently, (b) nausea, (c) vomiting,  
(d) twitching muscles, (e) throbbing temples, (f) dizzi-  
ness, (g) headaches, (h) weakness, and (i) sleepiness. IF  
EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO  
FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET  
MEDICAL HELP.  
• Never sleep in the vehicle while the genset is running unless  
the vehicle has a working carbon monoxide detector. The  
exhaust system must be installed in accordance with the  
genset installation manual. Make sure there is ample fresh  
air when operating the genset in a confined area.  
• Keep hands, feet, clothing, etc., away from drive belts, fans,  
and other moving or hot parts. Never remove any drive belt or  
fan guard while the unit is operating.  
• Adequate, unobstructed flow of cooling and ventilating air is  
critical to correct generator operation and is required to expel  
toxic fumes and fuel vapors from the generator compartment.  
Without sufficient cooling airflow, the engine/generator quickly  
overheats, which causes serious damage to the generator. Do  
not alter the installation or permit even partial blockage of ven-  
tilation provisions, as this can seriously affect safe operation of  
the generator.  
nDespite the safe design of this generator,  
operating this equipment imprudently,  
neglecting its maintenance or being careless  
can cause  
possible injury or death. Permit only respon-  
sible and capable persons to operate or  
maintain this equipment.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
nParts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
• When working on this equipment, remain alert at all times.  
Never work on the equipment when physically or mentally  
fatigued.  
• Inspect the generator regularly, and contact the nearest  
Authorized Service Dealer immediately for parts needing repair  
or replacement.  
CALIFORNIA PROPOSITION 65 WARNING  
Engine exhaust and some of its constituents are known  
to the State of California to cause cancer, birth defects  
and other reproductive harm.  
• Before performing any maintenance on the generator, discon-  
nect its battery cables to prevent accidental start up. Disconnect  
the cable from the battery post indicated by a NEGATIVE, NEG  
or (–) first. Reconnect that cable last.  
• Never use the generator or any of its parts as a step. Stepping  
on the unit can stress and break parts, and may result in dan-  
gerous operating conditions from leaking exhaust gases, fuel  
leakage, oil leakage, etc.  
CALIFORNIA PROPOSITION 65 WARNING  
This product contains or emits chemicals known to the  
State of California to cause cancer, birth defects and  
other reproductive harm.  
2
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Safety Rules  
ELECTRICAL HAZARDS  
FIRE HAZARDS  
• The generator covered by this manual produces dangerous  
electrical voltages and can cause fatal electrical shock. Avoid  
contact with bare wires, terminals, connections, etc., while the  
unit is running. Ensure all appropriate covers, guards and bar-  
riers are in place before operating the generator. If work must  
be done around an operating unit, stand on an insulated, dry  
surface to reduce shock hazard.  
• Do not handle any kind of electrical device while stand-  
ing in water, while barefoot, or while hands or feet are wet.  
DANGEROUS ELECTRICAL SHOCK MAY RESULT.  
• During installation onto the vehicle, have the generator prop-  
erly grounded (bonded) either by solid mounting to the vehicle  
frame or chassis, or by means of an approved bonding conduc-  
tor. DO NOT disconnect the bonding conductor, if so equipped.  
DO NOT reconnect the bonding conductor to any generator part  
that might be removed or disassembled during routine mainte-  
nance. If the grounding conductor must be replaced, use only a  
flexible conductor that is of No. 8 American Wire Gauge (AWG)  
copper wire minimum.  
• For fire safety, the generator must be installed and maintained  
properly. Installation always must comply with applicable  
codes, standards, laws and regulations. Adhere strictly to local,  
state and national electrical and building codes. Comply with  
regulations the Occupational Safety and Health Administration  
(OSHA) has established. Also, ensure that the generator is  
installed in accordance with the manufacturer’s instructions  
and recommendations. Following proper installation, do noth-  
ing that might alter a safe installation and render the unit in  
noncompliance with the aforementioned codes, standards,  
laws and regulations.  
• Keep a fire extinguisher in the vehicle at all times. Extinguishers  
rated ABC” by the National Fire Protection Association are  
appropriate for use on the recreational vehicle generator elec-  
trical system. Keep the extinguisher properly charged and be  
familiar with its use. If there are any questions pertaining to fire  
extinguishers, consult the local fire department.  
• In case of accident caused by electric shock, immediately  
shut down the source of electrical power. If this is not pos-  
sible, attempt to free the victim from the live conductor. AVOID  
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting  
implement, such as a rope or board, to free the victim from the  
live conductor. If the victim is unconscious, apply first aid and  
get immediate medical help.  
• Never wear jewelry when working on this equipment. Jewelry  
can conduct electricity resulting in electric shock, or may get  
caught in moving components causing injury.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any fuel or oil  
spills immediately. Ensure that no combustible materials are left  
in the generator compartment, or on or near the generator, as  
FIRE or EXPLOSION may result. Keep the area surrounding the  
generator clean and free from debris.  
• Gasoline is extremely FLAMMABLE and its vapors are  
EXPLOSIVE. Do not permit smoking, open flame, sparks or any  
source of heat in the vicinity while handling gasoline. Comply  
with all laws governing the storage and handling of gasoline.  
• This generator may use liquid propane (LP) gas as a fuel. LP  
gas is highly EXPLOSIVE. The gas is heavier than air and tends  
to settle in low areas where even the slightest spark can ignite  
the gas and cause an explosion.  
3
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General Information  
1.1 GENERATOR IDENTIFICATION  
Please record the following information from the generator DATA DECAL or information decal.  
1. Model Number ____________________  
3. kW Rating _________________________  
5. Phase _____________________________  
2. Serial Number _________________  
4. Rated Voltage _________________  
6. Hertz __________________________  
18  
8
2
15  
13  
10, 17 3 4 5  
1
12 11  
14  
16  
6
7
10  
9, 17  
REFERENCE NUMBER IDENTIFICATION  
1. Generator Air Intake  
2. Data Plate  
3. Engine Start/Stop Switch  
4. 7.5 amp Fuse  
10. Fuel Pump  
11. Oil Filter  
12. Oil Drain Plug  
13. Oil Dipstick and Filler Tube  
14. Air Filter (Behind access panel.)  
15. Spark Plugs  
16. Exhaust Outlet  
17. Fuel Filter  
18. Evaporative Port  
5. Circuit Breaker  
6. Optional Remote Panel Receptacle  
7. Generator AC Output Leads  
8. Starter Contactor  
9. Fuel Inlet  
4
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General Information  
1.2 GENERATOR APPLICABILITY  
These generators have been designed and manufactured for sup-  
plying electrical power for recreational vehicles. DO NOT modify  
the generator or use it for any application other than for what it  
was designed. If there are any questions pertaining to its applica-  
tion, write or call the factory. Do not use the unit until advised by  
competent authority.  
1.3 INSTALLATION  
This Owner’s Manual has been prepared under the assumption  
that a competent, qualified technician installed the generator into  
a recreational vehicle. We also assume the installer complied  
with all applicable codes, standards and regulations pertaining to  
installation.  
An INSTALLATION MANUAL was shipped with the generator. That  
Manual contains manufacturer’s instructions and recommenda-  
tions for installing the unit into an industrial vehicle. After installa-  
tion, installers should forward the Installation Manual to Owners/  
Operators for their information.  
For fire safety, the generator must have been  
properly installed in compliance with ANSI  
119.2-1975/NFPA 501C-1974, “Standard for  
Recreational Vehicles, Part III – Installation  
of Electrical Systems.” The generator also  
must have been installed in strict compliance  
with the manufacturer’s detailed installation  
instructions. After installation, do nothing  
that might render the unit in noncompliance  
with such codes, standards and instructions.  
Owners/Operators have the responsibility to make sure that noth-  
ing is done that might render the installation unsafe or in non-  
compliance with applicable codes, standards and instructions.  
1.4 SAFETY  
Before using the generator set, carefully read GENERAL SAFETY  
RULES inside the cover. Comply with these RULES to prevent  
accidents and damage to equipment and/or property. The manu-  
facturer suggests copying and posting the GENERAL SAFETY  
RULES to potential operators of this equipment.  
Use the generator set to supply electrical power for operating one  
of the following electrical loads:  
• RV 45 G: 120 and/or 240 volts, single phase, 60 Hz electrical  
loads. These loads can require up to 4500 watts (4.5 kW) of  
total power, but cannot exceed 37.5 AC amperes of current at  
120 volts (breaker is limited to 30 Amps).  
• RV 55 G: 120 and/or 240 volts, single phase, 60 Hz electrical  
loads. These loads can require up to 5500 watts (5.5 kW) of  
total power, but cannot exceed 45.8 AC amperes of current at  
120 volts or exceed 22.9 AC amperes at 240 volts.  
• RV 65 G: 120 and/or 240 volts, single phase, 60 Hz electrical  
loads. These loads can require up to 6500 watts (6.5 kW) of  
total power, but cannot exceed 54.1 AC amperes of current at  
120 volts or exceed 27 AC amperes at 240 volts.  
1.5 GENERATOR AC CONNECTION  
SYSTEM  
These air-cooled generator sets are equipped with dual stator  
AC power windings. These two stator windings supply electrical  
power to customer electrical loads by means of a dual 2-wire  
connection system.  
Generators may be installed to provide the following outputs:  
1. 120 VAC loads only — two loads, each with a maximum  
total wattage requirement equal to half of the generator’s  
rated power output (in watts), and 120V across the generator  
output terminals. Figure 1.1 shows the generator lead wire  
connections for 120VAC ONLY.  
Do not overload the generator. Some instal-  
lations may require that electrical loads be  
nꢀ  
Figure 1.1 – Connection for 120 Volts Only  
alternated to avoid overloading. Applying  
excessively high electrical loads may dam-  
age the generator and may shorten its  
life. Add up the rated watts of all electrical  
lighting, appliance, tool and motor loads  
the generator will power at one time. This  
total should not be greater than the watt-  
age capacity of the generator. If an electri-  
cal device nameplate gives only volts and  
amps, multiply volts times amps to obtain  
watts (volts x amps = watts). Some elec-  
tric motors require more watts of power (or  
amps of current) for starting than for con-  
tinuous operation.  
5
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General Information  
2. 120/240 VAC loads — one load with a maximum total watt-  
age requirement equal to the generator’s rated power output,  
and 240V across the generator output terminals; or two sepa-  
rate loads, each with a maximum total wattage requirement  
equal to half of the generator’s rated power output (in watts),  
and 120V across the generator output terminals. Figure 1.2,  
shows the generator lead wire connections for 120/240 VAC  
loads. Also refer to the "Line Breakers" section for circuit  
breaker ratings.  
NOTE  
Some installations using a “shared” fuel tank may have a gen-  
erator fuel pickup tube that is shorter than the vehicle engine’s  
pickup tube. Such an arrangement causes the generator engine  
to “run out of gas” while adequate fuel for the vehicle remains  
in the tank.  
To reduce lead and carbon deposits use high quality UNLEADED  
gasoline with the generator. Leaded REGULAR grade gasoline is an  
acceptable substitute.  
This procedure should be done by an Authorized Service Dealer or  
other qualified installer.  
NOTE:  
Using unleaded gasoline contributes to longer engine valve life by  
reducing lead and carbon deposits.  
Figure 1.2 - Connection for 120/240 Volts  
T1  
RED  
CB1  
nThe manufacturer does not recommend  
using any gasoline containing alcohol (such  
as “gasohol”). If using any gasoline contain-  
ing alcohol, it must not contain more than  
10 percent ethanol (Do not use E85), and it  
must be removed from the generator during  
storage. Do NOT use any gasoline contain-  
ing methanol. If using gasoline with alcohol,  
inspect more frequently for fuel leaks and  
other abnormalities.  
T2  
WHITE  
1.6.2 ENGINE OIL REQUIREMENTS  
All oil should meet minimum American Petroleum Institute (API)  
Service Class SJ, SL or better. Use no special additives. Select the  
oil's viscosity grade according to the expected operating tempera-  
ture (also see chart).  
CB2  
T3  
BLACK  
GROUNDED NEUTRAL  
STATOR POWER  
WINDINGS  
• SAE 30 Î Above 32° F  
• 10W-30 Î Between 40° F and -10° F  
• Synthetic 5W-30 Î 10° F and below  
1.6 SPECIFICATIONS  
1.6.1 FUEL REQUIREMENTS (GASOLINE)  
SAE 30  
This generator is equipped with a gasoline fuel system as standard  
equipment. Specific installations may provide either a separate fuel  
tank for the generator, or the generator may “share” the vehicle  
engine’s fuel tank.  
10W-30  
Syntthetiic 5W-30  
1.6.1.1 Fuel Consumption (gph)  
Model  
RV45G  
RV55G  
RV65G  
10% Load  
50% Load  
100% Load  
.33  
.35  
.37  
.45  
.55  
.65  
.73  
.89  
.97  
Crankcase and oil filter capacity is approximately 1.4 L or 1.5 U.S.  
quarts. DO NOT use special additives. See sections "Checking the  
Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter" for  
oil level check and filling procedures.  
6
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General Information  
1.6.3 GENERATOR SPECIFICATIONS  
SERIES  
RV45G  
3600  
RV55G  
3600  
RV65G  
3600  
Rotor RPM  
Rotor Poles  
2
2
2
Engine RPM  
2571  
2571  
2571  
Rated Max. Continuous AC Output Watts*  
4500  
5500  
6500  
Voltage*  
120  
120  
120  
Rated Max. Continuous Current Amps (240V)  
37.5 (18.7)  
1
45.8 (22.9)  
1
54.1 (27)  
1
Phase  
Frequency  
Weight  
Length  
Width  
60 Hertz  
278 lbs.  
33.7 in.  
21.5 in.  
16.8 in.  
60 Hertz  
285 lbs.  
33.7 in.  
21.5 in.  
16.8 in.  
60 Hertz  
293 lbs.  
33.7 in.  
21.5 in.  
16.8 in.  
Height  
*
All units are re-connectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output  
** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambient temperature, altitude, engine condition, etc.. Maximum power  
decreases about 3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16° C (60° F) ambient temperature.  
• Fuel Metering System  
~ Carburetor assembly  
~ Fuel pump and lines  
• Air Induction System  
~ Intake pipe / manifold  
~ Air cleaner  
• Ignition System  
~ Spark plug  
~ Ignition module  
• Catalytic Converter (if equipped)  
1.6.4 ENGINE SPECIFICATIONS  
Type of Engine........................................................................GT-530  
Cooling Method................................................................ Air-cooled  
Rated Horsepower ...................................................18 at 3600 rpm  
Displacement........................................................................... 530cc  
Compression Ratio................................................................8.5 to 1  
Cylinder Block.................................. Aluminum w/Cast Iron Sleeve  
Type of Governor.......................................Electronic, Fixed Speed  
Engine Governor Speed................................................... 2571 rpm  
Air Cleaner................................................................. Paper Element  
Starter .................................................................. 12-volt DC Electric  
Ignition System ............................ Solid-state w/Flywheel Magneto  
Recommended Spark Plug  
The Emissions Compliance Period referred to on the Emissions  
Compliance Label indicates the number of operating hours for  
which the engine has been shown to meet Federal and California  
emission requirements. See the table below to determine the com-  
pliance period for this generator. The displacement of the engine is  
listed on the Emissions Compliance Label.  
NGK....................................................................................BPR6HS  
Spark Plug Gap ............................................. 0.030 inch (0.76 mm)  
Recommended Min. Battery.................. 400 Cold Cranking Amps  
Class II Emission Certified  
Displacement  
Category  
Compliance Period  
500 Hours  
1.7 EXHAUST EMISSIONS  
A
B
C
A
B
C
INFORMATION (GASOLINE)  
> 66 cc - < 225 cc  
250 Hours  
The Environmental Protection Agency (EPA) and the California Air  
Resource Board (CARB) require that this generator comply with  
exhaust emission standards. The generator is certified to meet all  
applicable exhaust emission levels. This generator is certified for  
use as a mobile engine. It is important that you follow the mainte-  
nance specifications listed in this manual to ensure that the engine  
complies with emission standards for the duration of its life. This  
engine is certified to operate on gasoline. The emission control  
system on the generator consists of the following:  
125 HOurs  
1000 Hours  
500 Hours  
225 cc  
250 Hours  
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Operation  
Figure 2.1 – Typical Control Panel  
1.8 EVAPORATIVE EMISSIONS  
INFORMATION  
This generator is subject to evaporative emission standards which  
have been implemented by the California Air Resource Board  
(CARB) and the Environmental Protection Agency (EPA). If this  
generator is offered for sale in the state of California, it must be  
covered by a CARB evaporative Executive Order. If this generator  
is offered for sale to the final consumer in any other state, certified  
low-permeation fuel line must be used to supply fuel to the genera-  
tor as required by EPA.  
Anyone who installs or configures a fuel system to supply this  
generator with gasoline is required to comply with all applicable  
evaporative emission regulations. If this generator is configured  
such that it shares the primary fuel system of a vehicle in which it  
is installed, reduced certification requirements may apply. See the  
ca.gov/msprog/macs/mac0505/mac0505.pdf for further details. If  
this generator is installed such that it uses a dedicated fuel system,  
detailed evaporative emission requirements apply; contact a repu-  
table fuel system manufacturer to purchase a complete fuel sys-  
tem certified for use with this generator, or consult the California  
Code of Regulations if you wish to obtain certification on your  
own. See the installation instructions in this manual for connecting  
fuel system vapor lines to the engine.  
The switch center position is the RUN position.  
To stop a running engine, press momentarily the bottom half of the  
switch to kill the ignition.  
2.1.2 7.5 AMP FUSE  
The fuse protects the engine’s DC control circuit against electrical  
overload. If the fuse element has melted open due to overloading,  
the engine cannot be cranked. If the fuse must be replaced, use  
only an identical 7.5 amp replacement fuse.  
This generator is not legal for sale in the state of California unless  
all CARB evaporative emission requirements are adhered to, and  
is not legal for sale in any other state unless certified low-per-  
meation fuel line is used to supply the generator with gasoline.  
Contact the California Air Resource Board or the Environmental  
protection agency for further information. CARB regulations can  
be found in 13 CCR §§2750 – 2773; EPA regulations can be  
found in 40 CFR Part 90.  
2.1.3 LINE BREAKERS  
Protects generator’s AC output circuit against overload, i.e., pre-  
vents unit from exceeding wattage/amperage capacity. The circuit  
breaker ratings are as follows:  
2.1 GENERATOR CONTROL PANEL  
The following features are mounted on the generator control panel  
(Figure 2.1):  
Model  
RV45  
RV55  
RV65  
Cir. Breaker 1  
Cir. Breaker 2  
240 Volt  
N/A  
30A  
20A  
30A  
N/A  
30A  
30A  
25A 2P  
30A 2P  
2.1.1 START/STOP SWITCH  
This generator is started with a "One Touch" starting sequence.  
Push up on the top half of the momentary switch. Hold for one  
(1) second and release. Note flashing indicator light on the switch.  
Fuel pump engages automatically for a three (3) to five (5) second  
delay before starter motor cranks the engine for 16 seconds or  
until the engine starts. If the engine does not start, the starter  
will cool for seven (7) seconds and crank the engine again for 16  
seconds. If the engine does not start, the starter will cool for seven  
(7) seconds before cranking for seven (7) seconds to a maximum  
cycle total of 90 seconds. Once started, the light on the switch  
stays on continuously. If the generator does not start at the end  
of the start sequence, a fault code will flash on the switch (see  
Diagnostics).  
NOTE:  
If this generator has been reconnected for dual voltage AC out-  
put (120/240 volts), install line breakers having an amperage  
rating equal to that stated in the preceding chart. The replace-  
ment line breakers consist of two separate breakers with a  
connecting piece between the breaker handles (so that both  
breakers will operate at the same time). If the unit is recon-  
nected for dual voltage, it is no longer RVIA listed.  
The switch center position is the RUN position.  
To stop a running engine, press momentarily the bottom half of the  
switch to kill the ignition.  
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Operation  
2.1.4 DIAGNOSTICS  
2.3.2 PRECHOKE  
If the generator shuts down due to a fault, the indicator will flash a  
code to identify the problem.  
The choke system also has a temperature-sensitive metal strip that  
adjusts choke valve angle according to ambient temperatures (i.e.,  
in cold ambient temperatures, choke valve closes more). Once the  
engine starts, an element heats the temperature-sensitive strip to  
a normal operating condition, opening the choke valve. This may  
take about three minutes in cooler weather (Gasoline only.).  
• 2 Flashes = Low Battery (Voltage falls below 11.0 VDC for one  
minute)  
NOTE:  
Alarm will clear automatically if voltage rises over 11.0 VDC.  
Battery voltage is not monitored during crank cycle.  
2.4 BEFORE STARTING THE  
• 3 Flashes = Overcrank (Unit does not start through entire start  
ENGINE  
cycle)  
NOTE:  
• 4 Flashes = Overspeed (Alternator spins at 4200 rpm/72 Hz  
or greater)  
Instructions and information in this manual assume the genera-  
tor has been properly installed, connected, serviced, tested and  
adjusted by a qualified installation technician or installation  
contractor.  
• 5 Flashes = Low Oil Pressure (Drops below the 5 psi threshold  
of the switch)  
NOTE:  
There is a five second delay of the alarm when the engine is  
first started up.  
2.4.1 INSTALLATION  
Generator installation must have been properly completed so it  
complies with all applicable codes, standards and regulations  
and with the manufacturer's recommendations. (See Part II -  
Installation Instructions.)  
• 6 Flashes = High Oil Temperature (Unit shuts down when tem-  
perature switch limit is reached)  
NOTE:  
2.4.2 ENGINE LUBRICATION  
As the unit cools down it will attempt to restart automatically  
when the temperature switch opens again.  
Have the engine crankcase properly serviced with the recommend-  
ed oil before starting. Refer to sections "Engine Specifications",  
"Checking the Engine Oil Level" and "Changing the Engine Oil and/  
or Oil Filter" for oil servicing procedures and recommendations.  
• 7 Flashes = Underspeed (Alternator spins less than 3240  
rpm/54 Hz for three (3) seconds)  
NOTE:  
After a fault is indicated, press stop momentarily to clear the  
alarm once the problem is fixed.  
nAny attempt to crank or start the engine  
before it has been properly serviced it with  
the recommended oil may result in an engine  
failure.  
2.2 OPTIONAL REMOTE  
START/STOP PANEL  
A remote mounted Start/Stop Panel is available that allows start-  
ing and stopping the generator engine conveniently from inside the  
vehicle. The remote panel includes a Start/Stop switch, hourmeter,  
generator run lamp, and a wire harness.  
2.4.3 FUEL SUPPLY  
The engine must have an adequate supply of proper fuel to oper-  
ate. Before starting it, check that sufficient fuel is available.  
NOTE:  
Depending on the installation, the generator may have either a  
separate fuel tank, or it may “share” the vehicle engine’s fuel  
tank.  
2.3 AUTOMATIC CHOKE  
This engine is equipped with an automatic choke that consists of  
two main components: a choke solenoid and prechoke (Gasoline  
only.).  
2.4.4 COOLING AND VENTILATING AIR  
2.3.1 CHOKE SOLENOID  
Air inlet and outlet openings in the generator compartment must  
be open and unobstructed for continued proper operation. Without  
sufficient cooling and ventilating airflow, the engine/generator  
quickly overheats, which causes it to shut down and may damage  
the generator.  
During engine cranking (Start/Stop switch at START), a solid-state  
choke module signals the choke solenoid to activate and cycle  
(choke on/choke off) until the engine starts. The choke solenoid  
thus opens and closes the carburetor choke valve only when  
the engine is cranking. When the engine starts, the choke stops  
cycling (Gasoline only.).  
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Operation  
NOTE:  
2.4.5 ENGINE EXHAUST GAS  
If starting from the generator control panel, turn OFF loads  
by setting the generator’s main circuit breaker to the OFF (or  
open) position. If starting from a remote panel, turn OFF loads  
using the means provided in the vehicle (such as a main circuit  
breaker). Electrical load circuits should be turned ON after the  
generator has started, stabilized and warmed up.  
Before starting the generator engine, be sure there is no way for  
exhaust gases to enter the vehicle interior and endanger people or  
animals. Close windows, doors and other openings in the vehicle  
that, if open, might permit exhaust gases to enter the vehicle.  
2. To crank and start the engine, push up on the Start/Stop  
switch momentarily and release. There is a delay as the fuel  
pump primes and the generator automatically begins the start  
sequence (Note the flashing light on the switch.).  
3. Let the engine run at no-load for a few minutes to stabilize and  
warm up.  
The generator engine releases DEADLY  
n
carbon monoxide gas through its exhaust  
system. This dangerous gas, if breathed in  
sufficient concentrations, can cause uncon-  
sciousness or even death. Never operate  
the generator set with the vehicle inside  
any garage or other enclosed area. DO NOT  
OPERATE THE GENERATOR IF THE EXHAUST  
SYSTEM IS LEAKING OR HAS BEEN  
4. Turn ON electrical loads using the means provided (such as a  
main circuit breaker or transfer switch).  
DAMAGED. Shut down the generator and  
do not operate it until it has been inspected  
and repaired. SYMPTOMS OF CARBON  
MONOXIDE POISONING ARE (a) inability to  
think coherently, (b) nausea, (c) vomiting, (d)  
twitching muscles, (e) throbbing temples, (f)  
dizziness, (g) headaches, (h) weakness, and  
(i) sleepiness. IF EXPERIENCING ANY OF  
THESE SYMPTOMS, MOVE INTO FRESH AIR  
IMMEDIATELY. IF SYMPTOMS PERSIST, GET  
MEDICAL HELP.  
2.6 STOPPING THE GENERATOR  
1. Turn OFF all electrical loads using the means provided (such  
as a main circuit breaker or transfer switch).  
2. Let generator run at no-load for a few minutes, to stabilize  
internal engine generator temperatures.  
3. Place the Start/Stop switch in its STOP position. The engine  
will come to a complete stop.  
2.7 APPLYING LOADS TO  
GENERATOR  
When applying electrical loads to the generator, observe these  
guidelines:  
nNever sleep in the vehicle while the genset  
is running unless the vehicle has a working  
• Before applying electrical loads, let the generator stabilize and  
warm up for a minute or two.  
• DO NOT overload the generator.  
carbon monoxide detector. The exhaust sys-  
tem must be installed in accordance with the  
genset installation manual. Make sure there  
is ample fresh air when operating the genset  
in a confined area.  
2.7.1 LETTING THE ENGINE STABILIZE  
The generator supplies correct rated voltage only at the proper  
governed speed. Some electrical appliances may be extremely  
sensitive to voltage. Incorrect voltages can damage such appli-  
ances.  
2.5 STARTING THE GENERATOR  
NOTE:  
If electrical loads are applied at reduced operating speeds, such  
loads imposed on the engine when sufficient power is not available  
may shorten engine life. Never turn ON electrical loads until after  
the generator engine has started and stabilized at no-load.  
Read the vehicle manufacturer’s instructions. The owner/  
operator should become familiar with the vehicle in which this  
generator is installed. Differences exist between vehicles. For  
example, some vehicles may use a transfer switch to isolate  
dockside power from the generator, while other vehicles may  
use an isolating receptacle. Some vehicles may be equipped  
with a DC converter which allows the generator to power certain  
DC lighting and other DC loads.  
2.7.2 DO NOT OVERLOAD THE GENERATOR  
Read the rated wattage/amperage capacity of the generator on the  
generator data label (See the "Generator Identification" section.).  
To crank and start the generator engine, proceed as follows:  
Applying electrical loads in excess of the unit’s rated capacity will  
cause the engine/generator to automatically shut down.  
1. Turn OFF electrical loads using the means provided in the  
vehicle (such as a main line circuit breaker or transfer  
switch).  
To avoid overloading, add up the wattage of all connected electrical  
lighting, appliance, tool and motor loads. This total should not be  
greater than the generator’s rated wattage capacity.  
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Operation  
• Most lighting, appliance, tool and motor loads indicate their  
required watts on their nameplate or data plate. For light bulbs,  
simply note the wattage rating of the bulb.  
2.8.3 FIELD BOOST  
The Controller Circuit Board houses a field boost diode and resistor  
that are not part of the automatic choke circuit. These two compo-  
nents are part of a “field boost” circuit (Figure 2.3). During engine  
cranking only, a positive DC (battery) voltage is delivered through  
a diode, resistor, brushes, slip rings, and the generator rotor.  
Application of this voltage to the rotor “flashes the field” whenever  
it is started. Flashing of the field each time the generator starts  
makes sure that a sufficiently strong magnetic field is available to  
produce “pickup” voltage in the stator windings.  
• If a load does not show its rated wattage, multiply that load’s  
rated VOLTS times AMPS to obtain WATTS.  
• Induction type motors (such as those that run the vehicle’s  
furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2  
times more watts of power for starting than for running (for a  
few seconds during motor starting). Be sure to allow for this  
when connecting electrical loads to the generator. First, figure  
the watts needed to start electric motors in the system. To that  
figure, add the running wattages of other items that will be oper-  
ated by the generator.  
Figure 2.3 – Field Boost Circuit  
• Do not apply heavy electrical loads for the first two or three  
hours of operation.  
2.8 PROTECTION SYSTEMS  
2.8.1 LOW OIL PRESSURE SWITCH  
This switch (Figure 2.2) has normally closed (N.C.) contacts that  
are held open by engine oil pressure during cranking and operat-  
ing. Should oil pressure drop below a preset level, switch contacts  
close, and the engine automatically shuts down. The unit should  
not be restarted until oil is added.  
2.8.2 HIGH TEMPERATURE SWITCH  
This switch (Figure 2.2), which has normally open (N.O.) contacts,  
is mounted near the oil filter. The contacts close if the temperature  
should exceed approximately 270º F (132º C) for gasoline mod-  
els.  
2.8.4 OVERVOLTAGE PROTECTION  
A solid-state voltage regulator (Figure 2.4) controls the generator’s  
AC output voltage. This regulator supplies an excitation current to  
the rotor. By regulating the rotor’s excitation current, the strength  
of its magnetic field is regulated and, in turn, the voltage delivered  
to connected electrical loads is controlled. When the AC frequency  
is 60 Hertz, voltage is regulated at 125 to 120 volts.  
Figure 2.2 – Low Oil Pressure and  
High Temperature Switches  
Figure 2.4 – Solid State Voltage Regulator  
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Maintenance  
2.8.5 OPERATION IN HIGH GRASS OR BRUSH  
3.2 CHANGING THE ENGINE OIL  
AND/OR OIL FILTER  
Never operate the generator while the vehicle  
is parked over high grass, weeds, brush,  
nHot oil may cause burns. Allow engine to  
cool before draining oil. Avoid prolonged  
leaves or any other combustible substance.  
Such materials can ignite and burn from the  
heat of the exhaust system. The generator  
exhaust system becomes extremely hot dur-  
ing operation and remains hot for a long time  
after it has shut down.  
or repeated skin exposure with used oil.  
Thoroughly wash exposed areas with soap.  
Oil Change Intervals – see Section “RV Generator Service  
Interval”.  
To change the oil and oil filter, proceed as follows:  
3.1 CHECKING THE ENGINE OIL  
1. Run the engine until it is thoroughly warmed up (at least five  
minutes) then shut off the engine.  
2. With the engine still warm from running, remove the round  
access grommet from underneath the front of the generator.  
Place a suitable container underneath to catch all the drain  
oil.  
LEVEL  
For oil capacities and requirements, see the “Engine Oil  
Requirements” section. Check the engine crankcase oil level at  
least every eight hours of operation, or before it is used. To check  
the engine oil level, proceed as follows (see Figure 3.1):  
1. Be sure the generator is as level as possible.  
2. Remove the dipstick and wipe it dry with a clean, lint-free  
cloth.  
3. Install and tighten the dipstick cap; then, remove it again. The  
oil level should be at the dipstick “Full” mark.  
4. If necessary, remove the oil fill cap on the rocker cover and  
slowly add oil until it reaches the dipstick “Full” mark. DO NOT  
FILL ABOVE THE “FULLMARK.  
3. Use the 0G4818 tool (supplied with the generator) to turn the  
old filter counter-clockwise and remove. Let oil drain into the  
container located directly below.  
4. Locate the oil drain hose inside and pull the yellow drain plug  
out of the access hole (Figure 3.1).  
5. Turn the yellow cap counter-clockwise to remove and finish  
draining the old oil.  
6. After the oil has been drained, replace the oil drain plug by  
tightening it clockwise and return.  
7. Clean off the oil filter bracket and any old oil that may have  
spilled while draining.  
nNever operate the engine with the oil level  
below the Add” mark on the dipstick. Doing  
8. Apply a light coating of clean engine oil the gasket of the new  
oil filter (Figure 3.2).  
this could damage the engine.  
9. Screw the new oil filter on by hand until its gasket lightly con-  
tacts the oil filter adapter. Then, tighten the filter an additional  
¾ to one turn. Replace and secure the round access grom-  
met.  
5. Install and tighten the oil fill cap and the dipstick before oper-  
ating the engine.  
Figure 3.1 — Oil Dipstick/Fill Tube and  
Location of Oil Drain Plug  
Figure 3.2 — Engine Oil Filter  
Engine  
Oil Filter  
Oil Fill  
Oil Drain Hose  
Oil Dipstick  
Twist Counter-clockwise to Loosen  
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Maintenance  
10. Remove the dipstick, valve cover plug and add new oil (see  
3.4 CHECKING THE ENGINE  
“Engine Oil Requirements”) to engine. DO NOT FILL ABOVE  
SPARK PLUG  
THE “FULLMARK.  
Reset the spark plug gap or replace the spark plugs as necessary.  
See the Service Schedule section for maintenance requirements.  
11. Install and tighten plug and dipstick before starting the  
engine.  
12. Start engine and check for leaks.  
1. Clean the area around the base of the spark plugs to keep dirt  
and debris out of the engine.  
NOTE:  
2. Remove the spark plugs and check the condition. Replace the  
spark plugs if worn or if reuse is questionable. See the Service  
Schedule section for recommended interval. Clean by scrap-  
ing or washing using a wire brush and commercial solvent.  
Do not blast the spark plugs to clean.  
3. Check the spark plug gap using a wire feeler gauge. Adjust the  
gap to 0.76mm (0.030 inch) by carefully bending the ground  
electrode if necessary (Figure 3.4).  
Check the oil level and fill to the “FULLmark after checking for  
leaks. The filter will retain some oil.  
3.3 MAINTAINING THE ENGINE  
AIR CLEANER  
Replace the paper air filter element after every 200 hours of opera-  
tion. (Perform more often when operating in dusty conditions)  
1. At the Air Cleaner Cover, turn the yellow plastic knob ¼ turn  
counter-clockwise.  
Figure 3.4 – Setting the Spark Plug Gap  
2. Pull the top of the Cover out as it hinges on the bottom of the  
Air Cleaner Base.  
3. Separate the Cover by lifting up and out from the Base.  
4. Pull the old filter out and discard safely.  
5. Install the new filter in place on the Air Cleaner Base (Figure  
3.3).  
6. Interlock the Air Cleaner Cover to hinge with the Air Cleaner  
Base.  
7. Align the Cover and gently push the top closed.  
8. Engage the yellow plastic knob and turn ¼ turn clockwise to  
secure.  
nSparking can occur if the wire terminal does  
not fit firmly on the spark plug terminal end.  
If necessary, re-form the wire terminal to  
obtain a tight fit.  
Figure 3.3 – Engine Air Cleaner  
Air Cleaner Base  
3.5 FUEL FILTER (GASOLINE ONLY)  
Remove and replace the fuel filter (Figure 3.5) every 400 hours of  
operation.  
Air Cleaner  
Figure 3.5 – Fuel Filter  
Knob  
FUEL FILTER  
TO FUEL PUMP  
Air Cleaner Cover  
CUSTOMER FUEL CONNECTION  
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Maintenance  
3.6 CLEAN SPARK ARRESTOR  
The engine exhaust muffler has a spark arrestor screen. Inspect and  
clean the screen every 200 hours of operation or once each year,  
whichever comes first.  
nDo NOT use a forceful spray of water to  
clean the generator. Water will enter the gen-  
erator interior and cause problems, and may  
also contaminate the generator fuel system.  
NOTE:  
If using the generator on any forest-covered, brush-covered or  
grass-covered unimproved land, it must equipped with a spark  
arrestor. The spark arrestor must be maintained in good condi-  
tion by the owner/operator.  
3.8 BATTERY MAINTENANCE  
NOTE:  
This generator is not equipped with an internal battery charger.  
It is intended for use in systems where an external battery char-  
ger is installed by the RV O.E.M. or an aftermarket installer.  
Clean and inspect the spark arrestor as follows:  
• Remove the screen by removing the screw.  
• Slide the spark arrestor screen out from the tail pipe.  
• Inspect screen and replace if torn, perforated or otherwise  
damaged. DO NOT USE a defective screen. If screen is not  
damaged, clean it with commercial solvent.  
All lead-acid batteries will discharge when not in use. The generator  
battery should be inspected as follows:  
3.8.1 WEEKLY  
• Replace the screen and the screw.  
• Inspect the battery posts and cables for tightness and corro-  
sion. Tighten and clean as necessary.  
Figure 3.6 - Spark Arrestor  
• Check the battery fluid level of unsealed batteries and, if nec-  
essary, fill with Distilled Water Only. Do not use tap water in  
batteries.  
3.8.2 EVERY SIX MONTHS  
• Have the state of charge and condition checked. This should be  
done with an automotive-type battery hydrometer.  
TAILPIPE  
P/N 0G5857  
NOTE:  
Servicing of the battery is to be performed or supervised by  
personnel knowledgeable of batteries and the required precau-  
tions. Keep unauthorized personnel away from batteries.  
SPARK ARRRESTOR  
SCREEN P/N 089680  
Damage will result if the battery connections are made in  
reverse.  
RETAINING  
SCREW P/N 056892  
Do not dispose of the battery in a fire. The  
battery is capable of exploding. Storage bat-  
3.7 CLEANING THE GENERATOR  
Keep the generator set as clean and dry as possible. Protect the  
unit against excessive dust, dirt, corrosive vapors, road splash,  
etc. Permitting dirt and moisture to accumulate on generator  
windings will have an adverse effect on the insulation resistance  
of those windings.  
teries give off explosive hydrogen gas. This  
gas can form an explosive mixture around  
the battery for several hours after charging.  
The slightest spark can ignite the gas and  
cause an explosion. Such an explosion can  
shatter the battery and cause blindness or  
other injury. Any area that houses a storage  
battery must be properly ventilated. Do not  
allow smoking, open flame, sparks, or any  
spark producing tools or equipment near the  
battery. Discharge static electricity from body  
before touching the battery by first touching  
a grounded metal surface.  
When moisture is allowed to remain in contact with windings,  
some of the moisture will be retained in voids and cracks in the  
insulation. This causes a reduced insulation resistance and will  
eventually cause problems. Dirt will make the problem worse,  
since dirt tends to hold moisture in contact with windings. Salt (as  
from sea air) also will worsen the problem since it tends to absorb  
moisture from the air. Salt and moisture, when combined, form a  
good electrical conductor which is detrimental to the generator.  
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Maintenance  
A battery presents a risk of electrical shock  
and high short circuit current. The following  
precautions are to be observed when work-  
ing on batteries:  
• Make sure the piston is at Top Dead Center (TDC) of its com-  
pression stroke (both valves closed). To get the piston at TDC,  
remove the intake screen at the front of the engine to gain  
access to the flywheel nut. Use a large socket and socket  
wrench to rotate the nut and hence the engine in a clockwise  
direction. While watching the piston through the spark plug  
hole. The piston should move up and down. The piston is at  
TDC when it is at its highest point of travel.  
• Remove watches, rings or other metal objects;  
• Use tools with insulated handles;  
• Wear rubber gloves and boots;  
• Do not lay tools or metal parts on top of the  
battery;  
To adjust valve clearance (if necessary):  
• Disconnect any charging source prior to connect-  
ing or disconnecting battery terminals; and  
• Do not use any jumper cables or booster battery  
to crank and start the generator engine. If any  
battery has discharged, remove it for recharging.  
• Make sure the engine is at 60° to 80° F.  
• Make sure that the spark plug wire is removed from the spark  
plug and out of the way.  
• Remove the four screws attaching the valve cover with a #2 or  
#3 Phillips screwdriver.  
• Loosen the rocker jam nut. Use an 10mm allen wrench to turn  
the pivot ball stud while checking clearance between the rocker  
arm and the valve stem with a feeler gauge. Correct clearance  
is 0.002-0.004 inch (0.05-0.1 mm). (Figure 3.7).  
Do not open or mutilate the battery.  
Released electrolyte has been known to  
nꢀ  
be harmful to the skin and eyes, and to be  
toxic.  
Figure 3.7 - Valve Clearance Adjustment  
The electrolyte is a dilute sulfuric acid that  
is harmful to the skin and eyes. It is electri-  
nꢀ  
Rocker  
Arm  
cally conductive and corrosive. The follow-  
ing procedures are to be observed:  
Pivot Ball  
Stud  
Jam Nut  
• Wear full eye protection and protective clothing;  
• Where electrolyte contacts the skin, wash it off  
immediately with water;  
Valve  
Stem  
• Where electrolyte contacts the eyes, flush  
thoroughly and immediately with water and  
seek medical attention; and  
• Spilled electrolyte is to be washed down with  
an acid neutralizing agent. A common practice  
is to use a solution of 1 pound (500 grams)  
bicarbonate of soda to 1 gallon (4 liters) or  
water. The bicarbonate of soda solution is to  
be added until the evidence of reaction (foam-  
ing) has ceased. The resulting liquid is to be  
flushed with water and the area dried.  
NOTE:  
3.9 ADJUSTING VALVE CLEARANCE  
Hold the rocker arm jam nut in place as the pivot ball stud is  
turned.  
After the first 50 hours of operation, check the valve clearance  
in the engine, adjust if necessary.  
When valve clearance is correct, hold the pivot ball stud in place  
with the allen wrench and tighten the rocker arm jam nut. Tighten  
the jam nut to 174 in/lbs. torque. After tightening the jam nut,  
recheck valve clearance to make sure it did not change.  
Important: If feeling uncomfortable about doing this procedure or  
the proper tools are not available, please contact the Authorized  
Dealer for service assistance. This is a very important step to  
insure longest life for the engine.  
• Install new valve cover gasket.  
• Re-attach the valve cover.  
NOTE:  
To check valve clearance:  
• The engine should be cool before checking. If valve clearance is  
0.002" - 0.004" (0.05 - 0.1mm), adjustment is not needed.  
• Remove spark plug wires and position wires away from plugs.  
• Remove spark plugs.  
Start all four screws before tightening or it will not be possible  
to get all the screws in place. Make sure the valve cover gasket  
is in place.  
• Install spark plugs.  
• Re-attach the spark plug wire to the spark plug.  
• On the GT-530, repeat the process for the other cylinder.  
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Maintenance  
3.13.2 RETURN TO SERVICE  
To return the unit to service after storage, proceed as follows:  
3.10 MAJOR SERVICE MANUAL  
To obtain a service manual for the generator, contact the near-  
est Authorized Service Dealer. Make sure to identify the MODEL  
NUMBER and SERIES.  
1. Check the tag on the engine for oil viscosity and classification.  
Verify that the correct recommended oil is used in the engine  
(see "Engine Oil Requirements"). If necessary, drain and refill  
with the proper oil.  
2. Check the state of the battery. Fill all cells of unsealed batter-  
ies to the proper level with distilled water. DO NOT USE TAP  
WATER IN THE BATTERY. Recharge the battery to 100 percent  
state of charge, or, if defective, replace the battery.  
3. Clean and wipe the entire generator.  
3.11 DRIVE BELT  
The engine drives the generator rotor by means of a pulley and  
drive belt arrangement. Drive belt tension was properly adjusted  
before the unit was shipped from the factory. If suspect that drive  
belt tension is incorrect, contact an Authorized Service Dealer.  
4. Reconnect the battery. Observe battery polarity. Damage may  
3.12 EXERCISING THE GENERATOR  
The manufacturer recommends starting and operating the genera-  
tor at least once every seven days. Let the unit run for at least 30  
minutes to “exercise” the engine.  
occur if the battery is connected incorrectly.  
5. Turn OFF all electrical loads. Add fuel if necessary and then  
start the engine.  
6. Allow the unit to warm up thoroughly.  
7. Apply electrical loads to at least 50 percent of the unit’s rated  
3.13 OUT OF SERVICE PROCEDURE  
wattage capacity.  
8. When the engine is thoroughly warmed up, shut it down.  
9. The generator is now ready for service.  
3.13.1 REMOVAL FROM SERVICE  
If the generator cannot be exercised every seven days, and it is to  
be out of service longer than 30 days, prepare the generator for  
storage as follows:  
3.14 RV GENERATOR SERVICE  
INTERVAL  
1. Start the engine and let it warm up.  
1st 8 Hours,  
2. Close the fuel shutoff valve in the fuel supply line and allow  
then every 200 Hours......................... Change Engine Oil/Filter  
1st 50 Hours,  
the unit to shut down.  
3. While the engine is still warm from running, drain the oil  
completely. Refill the crankcase with SAE 5W-30 oil having  
API classification “For Service SJ/SL.”  
then every 500 Hours.................................. Adjust Valve Lash  
200 Hours ..................................................Clean Spark Arrestor  
200 Hours .................................Replace Paper Air Filter Element  
400 Hours ......................................................Replace Fuel Filter  
500 Hours ..................................................Replace Spark Plugs  
4. Attach a tag to the engine indicating the viscosity and clas-  
sification of the oil in the crankcase.  
5. Remove the spark plug and pour two or three tablespoons of  
clean, fresh engine oil into the spark plug threaded openings.  
Reinstall and tighten the spark plug.  
6. Remove the battery and store it in a cool, dry room on a  
wooden board. Never store the battery on any concrete or  
earthen floor.  
7. Clean and wipe the entire generator.  
16  
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Part II - Installation Instructions  
Part II –  
Installation  
Instructions  
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS  
SHOULD ATTEMPT INSTALLATION!  
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Safety Rules  
nDANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly with  
article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational  
Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the man-  
ufacturer’s instructions and recommendations.  
NOTICE TO INSTALLER  
GENERAL HAZARDS  
These Installation Instructions have been published by the manu-  
facturer to aid in the installation of the products described in this  
manual. The manufacturer assumes that installation personnel  
are familiar with the procedures for installing such products, or  
similar products manufactured. The manufacturer also assumes  
that personnel have been trained in the recommended installation  
procedures for these products and that such training includes (a)  
use of common hand tools, (b) use of special tools, and (c) use of  
any tools and/or equipment from other suppliers.  
• For safety reasons, the manufacturer recommends that the  
installation, initial start-up and maintenance of this equipment  
is carried out by an Authorized Service Dealer.  
• The generator engine releases DEADLY carbon monoxide gas  
through its exhaust system. This dangerous gas, if breathed  
in sufficient concentrations, can cause unconsciousness or  
even death. Never operate the generator set with the vehicle  
inside any garage or other enclosed area. Shut down the  
generator and do not operate it until it has been inspected  
and repaired.  
The manufacturer cannot possibly know of and advise the rec-  
reational vehicle trade of all conceivable methods, procedures or  
techniques by which to perform an installation. Nor can the manu-  
facturer anticipate every possible hazard that might result from  
each installation method, procedure or technique. The manufactur-  
er has not undertaken any such wide evaluation. Therefore, people  
who use a method, procedure or technique that the manufacturer  
does not specifically recommend must first completely satisfy  
themselves that their safety, the safety of the vehicle's occupants  
and the product's safety is not endangered by the method, proce-  
dure or technique selected.  
• DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM  
IS LEAKING OR HAS BEEN DAMAGED.  
• SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a)  
inability to think coherently, (b) nausea, (c) vomiting,  
(d) twitching muscles, (e) throbbing temples, (f) dizzi-  
ness, (g) headaches, (h) weakness, and (i) sleepiness. IF  
EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO  
FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET  
MEDICAL HELP.  
• Never sleep in the vehicle while the genset is running unless  
the vehicle has a working carbon monoxide detector. The  
exhaust system must be installed in accordance with the  
genset installation manual. Make sure there is ample fresh  
air when operating the genset in a confined area.  
• Keep hands, feet, clothing, etc., away from drive belts, fans,  
and other moving or hot parts. Never remove any drive belt or  
fan guard while the unit is operating.  
Information, illustrations, specifications, etc., contained in these  
Installation Instructions are based on the latest information avail-  
able at the time of publication. Every effort has been expended  
to be sure that such data is both accurate and current. However,  
the manufacturer reserves the right to change, alter or otherwise  
improve this product at any time without prior notice.  
• Adequate, unobstructed flow of cooling and ventilating air is  
critical to correct generator operation and is required to expel  
toxic fumes and fuel vapors from the generator compartment.  
Without sufficient cooling airflow, the engine/generator quickly  
overheats, which causes serious damage to the generator. Do  
not alter the installation or permit even partial blockage of ven-  
tilation provisions, as this can seriously affect safe operation of  
the generator.  
• When working on this equipment, remain alert at all times.  
Never work on the equipment when physically or mentally  
fatigued.  
• Before performing any maintenance on the generator, discon-  
nect its battery cables to prevent accidental start up. Disconnect  
the cable from the battery post indicated by a NEGATIVE, NEG  
or (–) first. Reconnect that cable last.  
nDespite the safe design of this generator,  
operating this equipment imprudently, neglect-  
ing its maintenance or being careless can  
cause possible injury or death. Permit only  
responsible and capable persons to operate  
or maintain this equipment.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
nParts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
• Never use the generator or any of its parts as a step. Stepping  
on the unit can stress and break parts, and may result in dan-  
gerous operating conditions from leaking exhaust gases, fuel  
leakage, oil leakage, etc.  
• Never insert any tool or other object through openings in the  
generator interior, even if the unit is not running. Serious injury  
or damage to the equipment could be done.  
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Safety Rules  
ELECTRICAL HAZARDS  
FIRE HAZARDS  
• The generator covered by this manual produces dangerous  
electrical voltages and can cause fatal electrical shock. Avoid  
contact with bare wires, terminals, connections, etc., while the  
unit is running. Ensure all appropriate covers, guards and bar-  
riers are in place before operating the generator. If work must  
be done around an operating unit, stand on an insulated, dry  
surface to reduce shock hazard.  
• Do not handle any kind of electrical device while stand-  
ing in water, while barefoot, or while hands or feet are wet.  
DANGEROUS ELECTRICAL SHOCK MAY RESULT.  
• During installation onto the vehicle, properly ground (bond) the  
generator either by solid mounting to the vehicle frame or chas-  
sis, or by means of an approved bonding conductor. DO NOT  
connect the bonding conductor to any generator part that might  
be removed or disassembled during routine maintenance. If  
the grounding conductor must be replaced, use only a flexible  
conductor that is of No. 8 American Wire Gauge (AWG) copper  
wire minimum.  
• For fire safety, the generator must be installed and maintained  
properly. Installation always must comply with applicable  
codes, standards, laws and regulations. Adhere strictly to local,  
state and national electrical and building codes. Comply with  
regulations the Occupational Safety and Health Administration  
(OSHA) has established. Also, ensure that the generator is  
installed in accordance with the manufacturer’s instructions  
and recommendations. Following proper installation, do noth-  
ing that might alter a safe installation and render the unit in  
noncompliance with the aforementioned codes, standards,  
laws and regulations.  
• Keep a fire extinguisher in the vehicle at all times. Extinguishers  
rated ABC” by the National Fire Protection Association are  
appropriate for use on the recreational vehicle generator electrical  
system. Keep the extinguisher properly charged and be familiar  
with its use. If there are any questions pertaining to fire extin-  
guishers, consult the local fire department.  
• If the vehicle electrical circuits can be powered by any other  
source of electricity (such as a “dockside” power receptacle),  
there must be no possibility of connecting the different power  
sources to the vehicle circuits at the same time. The dockside  
(utility) power source must be positively isolated from the  
vehicle circuits whenever the generator is operating. Failure to  
isolate the vehicle circuits from the dockside power supply when  
the generator is running may result in damage to the generator  
or serious injury or death to dockside (utility) power workers due  
to backfeed of electrical energy.  
• In case of accident caused by electric shock, immediately shut  
down the source of electrical power. If this is not possible,  
attempt to free the victim from the live conductor. AVOID DIRECT  
CONTACT WITH THE VICTIM. Use a nonconducting implement,  
such as a rope or board, to free the victim from the live conduc-  
tor. If the victim is unconscious, apply first aid and get immediate  
medical help.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any fuel or oil spills  
immediately. Ensure that no combustible materials are left in the  
generator compartment, or on or near the generator, as FIRE or  
EXPLOSION may result. Keep the area surrounding the generator  
clean and free from debris.  
• GasolineisextremelyFLAMMABLEanditsvaporsareEXPLOSIVE.  
Do not permit smoking, open flame, sparks or any source of  
heat in the vicinity while handling gasoline. Comply with all laws  
governing the storage and handling of gasoline.  
• Fuel lines must be properly installed and fastened, and free of  
leaks. There must be no possibility of gasoline vapors entering  
the vehicle interior.  
• It is required that an approved, flexible, nonconductive fuel line  
between the generator fuel connection point and rigid fuel lines  
be installed.  
• Never wear jewelry when working on this equipment. Jewelry  
can conduct electricity resulting in electric shock, or may get  
caught in moving components causing injury.  
• If the generator is equipped with a liquid propane (LP) gas fuel  
system, install the unit so it complies with all codes, standards  
and regulations pertaining to such systems. LP gas is highly  
explosive. The gas tends to settle in low areas where even the  
slightest spark can ignite it and cause an explosion. Do not  
allow gas vapors to enter the vehicle.  
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General Information  
1.1 PURPOSE AND SCOPE OF THE  
1.4 EQUIPMENT DESCRIPTION  
Instructions and information in this section pertain to air-cooled  
generators. These generators are designed specifically for install-  
ing in recreational vehicles. They operate 120-volt, single-phase,  
60-Hertz, AC electrical loads.  
INSTALLATION INSTRUCTIONS  
These Installation Instructions have been prepared especially for  
the purpose of familiarizing installers and owners of the applicable  
equipment with the product's installation requirements. Give seri-  
ous consideration to all information and instructions in the manual,  
both for safety and for continued reliable operation of the equip-  
ment.  
1.5 GENERATOR ENGINE  
OPERATING SPEED  
The generator’s revolving field (rotor) is driven by a two-cylinder,  
four-cycle engine through a pulley and drive belt arrangement. The  
generator supplies 120 volts AC at 60 Hertz when the rotor is oper-  
ating at 3,600 rpm. The drive belt arrangement allows the engine to  
operate at a lower speed than the rotor.  
Because of the different recreational vehicle models and the  
variations between the models, it would be extremely difficult, if  
not impractical, to provide detailed instructions for every possible  
installation. For that reason, instructions and illustrations in this  
manual are general in nature. Illustrations are not intended to serve  
as detailed installation blueprints.  
1.6 GENERATOR AC  
The installation should comply strictly with all applicable codes,  
standards and regulations pertaining to the installation and use of  
this product. If any portion of this manual appears to be in conflict  
with such codes, standards or regulations, the applicable codes,  
standards or regulations must take precedence over the manual.  
CONNECTION SYSTEM  
These air-cooled generator sets are equipped with dual stator AC  
power windings. These two stator windings supply electrical power  
to customer electrical loads by means of a dual 2-wire connection  
system.  
Generators may be installed to provide the following outputs:  
1.2 SAFETY  
Before handling, installing, operating or servicing this equipment,  
carefully read the “Notice to Installer” and “Safety Rules”. Comply  
with all safety rules to prevent death, personal injury or damage to  
equipment and/or property. Stress safety to all installers, operators  
and service technicians who work on this equipment.  
1. 120 VAC loads only — two loads each, with a maximum total  
wattage requirement equal to half of the generator’s rated  
power output (in watts), and 120V across the generator out-  
put terminals (see Fig. 1.1).  
2. 120/240 VAC loads — one load with a maximum total wattage  
requirement equal to the generator’s rated power output, and  
240V across the generator output terminals; or two separate  
loads, each with a maximum total wattage requirement equal  
to half of the generator’s rated power output (in watts), and  
120V across the generator output terminals (see Fig. 1.3).  
1.3 STANDARDS BOOKLETS  
Installation, use and servicing of this equipment should comply  
strictly with published standards, as well as the manufacturer's  
recommendations. The following standards booklets (latest revi-  
sion) are available from the sources indicated:  
Figure 1.1 – Connection for 120 Volts Only  
1. NFPA Standard 501C, “Standard for Recreational Vehicles,”  
available from the National Fire Protection Association,  
Batterymarch Park, Quincy, MA 02269.  
2. NFPA 70, “NFPA Handbook of the National Electric Code,”  
available same as Item 1.  
3. ANSI C1-1975 and ANSI 119.2-1975, available from the  
American National Standards Institute, 1430 Broadway, New  
York, NY 10018.  
4. ANSI A119.2/RVIA EGS-1, available from the Recreational  
Vehicle Association, 1896 Preston White Drive, Reston, VA  
22090.  
5. California Administrative Code, Title 25, available from the  
State of California, Documents Section, P.O. Box 1015, North  
Highlands, CA 95660.  
6. CSA Electrical Bulletin 946, available from the Canadian  
Standards Association, Housing and Constructions Materials  
Section, 178 Rexdale Boulevard, Rexdale, Ontario, Canada,  
M9W 1R3.  
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Installation  
Figure 1.2 - Major Features and Dimensions (Drawing No. 0G5519-D)  
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Installation  
• The location must provide sufficient room to allow minimum  
clearances as outlined in "Generator Compartments". If sound  
insulation is to be used on the compartment walls and ceiling,  
the minimum recommended applies to the space between the  
generator and such insulation.  
Figure 1.3 - Connection for 120/240 Volts  
T1  
RED  
CB1  
• The location must provide adequate cooling and ventilating  
airflow for the generator without a great deal of work and  
expense.  
• If mounting the generator in an enclosed compartment, the base  
of the generator must rest flat on the floor without any gaps.  
• When using a suspended mounting system, ensure the base of  
the generator is flush with the surrounding bodywork. If the unit  
is mounted higher in the structure, heated air may recirculate  
into the generator causing it to overheat.  
T2  
WHITE  
2.1.2 GENERATOR SUPPORT  
CB2  
T3  
BLACK  
The generator must be securely attached to a metal framework that  
has been made part of the vehicle frame structure by bolting or  
welding. The metal framework on which the generator will rest and  
which will restrain the generator set should consist of at least two  
horizontal beams. These beams should consist of (a) 1-1/2-inch  
square, 11-gauge steel tubing OR (b) 1-1/2-inch, 11-gauge angle  
iron. A typical supporting frame with horizontal support tubing, is  
shown in Figure 2.1.  
GROUNDED NEUTRAL  
STATOR POWER  
WINDINGS  
• The AC connection system on air-cooled generators uses a  
GROUNDED neutral.  
• A separate green ground wire is connected to the recreational  
vehicle’s junction box.  
• Total load connected across T1 (Red) to T2 (White), and T3  
(Black) to T2 (White), must not exceed rating for the specific  
generator (see "Generator Specifications").  
NOTE:  
Figure 2.1 – Typical Horizontal Support Frame  
Do NOT connect loads in excess of circuit breaker ratings.  
2.1 LOCATION AND SUPPORT  
2.1.1 GENERATOR LOCATION  
NOTE  
Be sure the installation complies with all standards and codes  
listed in the "Standards Booklets" section of this manual.  
The most desirable location for the generator set is between the  
vehicle's main frame members. However, this is seldom possible.  
Most units must be installed on the side of the vehicle and are  
difficult to reinforce.  
The generator can be installed so that it sits on top of the horizontal  
support tubing if the vehicle design permits. Another method is  
to suspend the generator below the horizontal support tubing by  
means of suitable, structurally sound metal framework. The fol-  
lowing general rules apply:  
Many recreational vehicles have been factory equipped with an  
area for the generator set. Some vehicles may even have a genera-  
tor compartment provided by the vehicle manufacturer.  
• Vehicle construction MUST be capable of supporting the weight  
of the generator.  
• Whether the generator is mounted above the horizontal support  
tubing or suspended below the tubing, the supporting frame  
used must be structurally sound.  
• If the generator cannot be bolted directly to the supporting  
frame or support tubing, consider using additional tubing,  
angle brackets or other supports to give the supporting frame  
sufficient strength.  
Plan the generator location based on the following:  
• The generator set must be installed on a framework that is  
part of the recreational vehicle, as outlined in the "Generator  
Support" section.  
• The location must provide an access opening that is large  
enough to permit generator removal (unless the generator is to  
be removed from underneath the supporting framework).  
• The location must provide easy access to frequently serviced  
components, such as filters, oil drains, spark plugs and other  
common maintenance parts.  
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Installation  
2.1.3 SUSPENDED MOUNTING  
2.2 GENERATOR COMPARTMENTS  
Whether the generator set is being installed inside a compartment  
specifically manufactured to house a generator or inside a compart-  
ment that the installer constructs, the compartment MUST meet  
certain specifications as outlined in the following sections:  
If planning to suspend the generator below the horizontal sup-  
port tubing, the suspension method to use with the vehicle frame  
members must (a) be able to support the weight of the generator  
AND (b) provide sufficient restraint for the generator. One typical  
suspended mounting system is shown in Figure 2.2. The location  
of a suspended mounting system must be carefully planned, keep-  
ing the following general rules in mind:  
2.2.1  
COMPARTMENT SIZE  
Plan the compartment size carefully. Provide a minimum clearance  
of 1/2 inch (13 mm) on the front top, sides, and from the back for  
air circulation AFTER the compartment has been lined with metal  
and sound insulation (Figure 2.4).  
• Protect the generator against road splash and debris. Baffles or  
splash guards may be required to protect certain areas of the  
generator. To make sure the generator is adequately protected,  
road test the installation through mud, water and slush.  
NOTE:  
Refer to “Figure 1.2 – Major Features and Dimensions”.  
Figure 2.2 – Typical Suspended Mounting System  
Figure 2.4 – Clearances  
Plywood  
Compartment  
1/2" Clearance on Top  
1/2" Clearance  
in Back  
1/2" Each Side  
• The installer must make certain that the selected location will  
permit adequate cooling and ventilating airflow to be supplied.  
1/2"  
Insulation  
in Front  
2.1.4 GENERATOR RESTRAINT  
Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the  
generator to the supporting frame or the support tubing. These  
bolts must pass through (a) the generator mounting base, (b) the  
compartment floor (if a compartment is used) and (c) the support-  
ing framework (Figure 2.3). All bolts must be long enough so that  
when tight, at least three threads are visible past the retaining lock  
nuts. Refer to "Generator Compartments" for the location of the  
generator mounting holes. Torque Bolts to 31 ft./lbs..  
2.2.2 COMPARTMENT CONSTRUCTION  
• The generator compartment should be either constructed of, or  
lined with, 26-gauge galvanized steel.  
NOTE:  
Figure 2.3 – Typical Generator Restraint  
Aluminum is NOT an acceptable alternative to galvanized steel  
due to aluminum’s low melting point.  
• If the compartment is lined with galvanized steel, it may be  
constructed of any material. The manufacturer recommends  
that the compartment be constructed of 1/2-inch thick plywood  
(not strandboard), with the floor made of a double thickness of  
1/2-inch plywood with the grain of the wood at cross section  
for added strength (Figure 2.5).  
• If constructing a compartment, line the exterior (underside) of  
the compartment floor with 26-gauge galvanized steel.  
• All seams, splices and joints of the compartment walls (unless  
vapor tight by design) should be caulked to prevent poison-  
ous, flammable or explosive vapors from entering the vehicle  
interior.  
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Installation  
Figure 2.5 – Typical Compartment Construction  
Figure 2.6 – Types of Lock Seams  
Do not install any flammable material directly  
above or around the compartment. Heat,  
transferred through the compartment struc-  
ture, may be sufficient to ignite, char or dis-  
color seat cushions, fiberboard and other  
flammable materials. Use approved nonflam-  
mable insulating materials in high tempera-  
ture areas.  
2.2.3 SOUND INSULATING MATERIALS  
NOTE:  
Once installers have determined that a compartment is properly  
constructed and metal lined, they can add acoustical material.  
This may include additional sealant or insulating material, to reflect  
noise away from the vehicle interior.  
Caulking must be done so that the caulking material will stay in  
place permanently. Pressing such materials as putty tape onto  
joints and seams is not acceptable. A high quality silicone rub-  
ber base sealant is recommended.  
Sound insulating materials should be of a nonflammable type. One  
excellent insulating material is a 1-inch (25 mm) thick fiberglass  
having a 2-pound density. When fiberglass is used, its coated side  
should face toward the compartment interior.  
• Holes and openings made in the compartment walls to allow for  
the passage of electrical conduit, conductors, hoses, cables,  
etc., into the vehicle living area must be sealed vapor tight with  
silicone rubber base sealant.  
• If flexible metal conduit is used, it must be sealed internally at  
the end where it terminates inside the compartment’s electrical  
junction box.  
Do not install sound insulation or any absor-  
bent material on the compartment floor inte-  
NOTE:  
rior. Such materials will become soaked with  
combustible or explosive vapors and liquids  
and will become a fire hazard.  
Flexible metal conduit, due to its unique construction, is NOT  
vapor tight along its entire length.  
• Seams and joints of the galvanized steel (whether used as a liner  
or for the compartment itself) must be lapped and mechanically  
secured. Such seams may be manufactured, welded, bolted,  
riveted or screwed. Manufactured lock seams are shown in  
Figure 2.6. Installer constructed compartments typically utilize  
a standard lap joint.  
Using a combination of sound insulating materials can often  
reduce noise more effectively than a single material. For example,  
a sheet of lead or visco-elastic material, along with a layer of other  
acoustical material, is more effective than when a single material  
is used.  
• After the compartment has been metal lined and vapor  
sealed, line the compartment interior walls and ceiling with an  
approved, nonflammable sound insulating material. See "Sound  
Insulating Materials".  
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Installation  
2.2.4 ACOUSTICS  
2.2.5 COMPARTMENT FLOOR CUTOUTS  
For additional noise abatement, the installer may wish to consider  
the following:  
Provide openings in the generator compartment for the following  
items (Figure 2.9):  
• Using special sound insulating materials.  
• Construction of a special noise abatement compartment.  
NOTE:  
• Engine exhaust and cooling air outlets  
• Generator cooling air inlet  
• Four holes for passage of generator mounting bolts. See  
"Generator Restraint".  
Any method used to reduce noise must not adversely affect the  
flow of cooling and ventilating air into or out of the compart-  
ment.  
nFuel lines and exhaust piping must not pen-  
etrate into the vehicle living area.  
In addition to the effective use of sound insulating materials,  
construction of a special noise abatement compartment might be  
considered to reduce noise levels. Such a compartment might be  
constructed as follows (Figure 2.7):  
2.3 COOLING AND VENTILATING  
• Use 5/8-inch thick or 3/4-inch thick plywood in the compart-  
ment.  
AIR  
It is absolutely essential that an adequate flow of air for cooling,  
ventilating and engine combustion be supplied to the generator set.  
Without sufficient airflow, the engine/generator quickly overheats.  
Such overheating can cause serious operating difficulties and also  
may cause fire and personal injury. The installer must make sure  
that sufficient air is available to the generator for cooling, ventilat-  
ing and combustion. The installer also must provide for a path for  
exhausting the cooling air to the exterior of a compartment, if so  
equipped.  
• Construct the compartment floor of a double thickness of 5/8-  
inch or 3/4-inch plywood.  
• Line the compartment interior walls and floor, as well as the  
underside of the floor, with 26-gauge galvanized steel.  
• Vapor seal all compartment seams and joints.  
• Over the galvanized steel lining, install a combination of acousti-  
cal materials as mentioned in "Sound Insulating Materials".  
To prevent fire or explosion, do not install  
any insulation or other absorbent materials  
Never use discharged cooling air for heating  
or permit such air to enter the vehicle inte-  
rior. This air contains deadly carbon monox-  
ment floor.  
ide gas and other poisonous, flammable or  
explosive gases.  
• Seal all compartment door edges to prevent noise leakage  
around the door perimeter.  
2.3.1 GENERATOR AIRFLOW  
Figure 2.7 – Typical Noise Abatement  
Engine operation drives cooling fans for the two-stage cooling  
air system. A pressure fan draws cooling air into the top of the  
generator (Figure 2.8). This airflow cools the engine/generator and  
electronic components. The second part of the cooling system, a  
suction fan, draws air that is heated from a hot engine into a col-  
lector pan at the base of the unit. This heated air (although cooler  
than exhaust muffler) is then deflected out the bottom toward the  
ground.  
Figure 2.8 – Airflow Through Engine/Generator  
COOLING AIR IN  
ENGINE AIR IN  
COOLING  
AIR OUT  
• Line the compartment door interior (except for air openings)  
with suitable, fireproof sound insulation (such as 1-inch (25  
mm) thick fiberglass with a 2-pound density).  
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Installation  
Figure 2.9 — Compartment Floor Cutout (Drawing 0G4432-A)  
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Installation  
If the generator is to share the vehicle engine's tank, separate  
fuel pickup tubes are required for the engine and the generator.  
The manufacturer recommends that the fuel pickup tube be two  
to three inches (51 to 76 mm) shorter than the vehicle engine's  
pickup tube. This prevents the generator from depleting the entire  
fuel supply during prolonged generator operating periods.  
6.3.2 TESTING THE INSTALLATION  
The manufacturer recommends testing the installation to be sure  
adequate cooling airflow is available to the unit before placing the  
unit into service. If the unit shows signs of overheating, enlarge the  
air openings. Never place a unit into service until absolutely certain  
that cooling and ventilation is adequate.  
Gasoline generators are equipped with an Evaporative Emissions  
Port that may be used in conjunction with a certified fuel system  
where required by law.  
NOTE:  
The installation must be tested, especially if bringing in air from  
below the generator set.  
nDo NOT tee the generator fuel supply line  
into the vehicle engine fuel supply line. If  
2.4 GASOLINE FUEL SYSTEM  
this is done, the generator will be starved of  
fuel when both engines are operating at the  
same time. Also, while the vehicle engine is  
not running, generator operation may drain  
the vehicle engine supply line, making it dif-  
ficult to start the vehicle engine.  
Gasoline is highly flammable, and its vapors  
are explosive. Comply with all codes, stan-  
dards and regulations pertaining to gasoline  
fuel systems used in recreational vehicle  
generators. Properly install and maintain  
the fuel system and keep it entirely free of  
leaks. Gasoline vapors must not enter the  
vehicle interior.  
2.4.2 GENERATOR FUEL SUPPLY LINE  
2.4.2.1 Rigid Fuel Lines  
Those lines used to supply fuel from a tank to the generator must  
comply with applicable codes, standards and regulations. The fol-  
lowing general rules apply to rigid fuel lines:  
The installation of a gasoline fuel system (Figure 2.10) for a  
recreational vehicle generator set must comply with applicable  
codes, standards and regulations. The entire fuel system must be  
completely free of leaks. There must be no possibility of gasoline  
vapors entering the vehicle interior.  
• Rigid lines should be of annealed, seamless, drawn aluminum  
or steel.  
Figure 2.10 – Generator Fuel System  
• Lines and fittings must comply with SAE J512F, Standard  
Automotive Fittings,” or with ANSI B126.26 (latest edition).  
• Route the fuel line so that at least 2 inches (51 mm) of clear-  
ance is maintained between the line and any exhaust system  
parts.  
• Do not attach electrical wiring to fuel lines. Route the wiring so  
it cannot come into contact with any fuel line.  
• Route fuel lines so if they leak, fuel does not drip onto any  
electrical or exhaust system parts.  
• Use nonferrous metal straps without sharp edges to secure  
fuel lines.  
2.4.2.2 Flexible Fuel Line  
a, b  
e
d
Use an approved flexible length of fuel hose between the generator  
fuel inlet connection and rigid fuel lines. This prevents breaking of  
the line caused by vibration, shifting, settling or movement. The  
following rules apply:  
Factory installed generator fuel system components include (a)  
fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and  
(d) interconnecting lines and fittings, (e) evaporative port. Connect  
a fuel supply line to the fuel filter inlet. Use a flexible length of  
approved fuel hose between the fuel filter inlet connection and  
rigid fuel lines.  
• The flexible hose must comply with SAE J30R7, “Standard for  
Fuel and Oil Hose.” It must be approved for use with gasoline  
and low permeability.  
• The hose should be at least 6 inches (152 mm) longer than  
is needed to prevent the hose from rupturing if the generator  
shifts or settles.  
2.4.1 FUEL TANK  
Either the generator must share the vehicle engine's fuel tank, or a  
separate fuel tank for the generator set must be installed. All fuel  
tanks installed on the vehicle must be constructed, installed and  
restrained so they comply with applicable codes, standards and  
regulations. The generator has an evaporative emissions port to  
evacuate accumulated gasoline vapors when necessary.  
27  
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Installation  
Figure 2.11 - Spark Arrestor  
2.5 EXHAUST SYSTEM  
The generator exhaust system must be safely and properly  
installed. Only approved mufflers and other exhaust system parts  
must be used. A properly installed exhaust system must be vapor  
tight, quiet and completely safe.  
TAILPIPE  
P/N 0E0683  
nThe generator engine gives off DEADLY  
carbon monoxide gas through its exhaust  
system. This dangerous gas, if breathed in  
sufficient concentrations, can cause uncon-  
sciousness or even death. Never operate  
the generator set with the vehicle inside  
any garage or other enclosed area. DO  
NOT OPERATE THE GENERATOR IF THE  
EXHAUST SYSTEM IS LEAKING OR HAS  
BEEN DAMAGED. SYMPTOMS OF CARBON  
MONOXIDE POISONING ARE (a) inability to  
think coherently; (b) vomiting; (c) twitch-  
ing muscles; (d) throbbing temples; (e)  
dizziness; (f) headaches; (g) weakness;  
and (h) sleepiness. IF FEELING ANY OF  
THESE SYMPTOMS, MOVE INTO FRESH AIR  
IMMEDIATELY. IF SYMPTOMS PERSIST, GET  
MEDICAL HELP. Do not operate the generator  
until its exhaust system has been inspected  
and properly repaired.  
SPARK ARRRESTOR  
SCREEN P/N 089680  
RETAINING  
SCREW P/N 056892  
Figure 2.12 — Spark Arrestor Installation  
nNever tee the generator engine exhaust pipe  
into the vehicle engine exhaust piping. This  
causes excessive back pressure on the gen-  
erator engine. Also, water from one engine  
can damage the other engine.  
2.5.2 EXHAUST SYSTEM SAFETY  
• Maintain a clearance of at least 3 inches (76 mm) between  
exhaust system parts and any combustible material (such as  
wood, felt, cotton, organic fibers or other like material). If the  
3-inch (76 mm) clearance cannot be maintained, locate, insu-  
late or shield the exhaust part(s) so that the temperature of any  
combustible material is not raised more than 117° F (65° C)  
above the ambient air temperature.  
• Extend the exhaust system at least 1 inch (25 mm) past the  
outer edge of the vehicle. Do not terminate the exhaust system  
under the vehicle.  
2.5.1 MUFFLERS AND SPARK ARRESTORS  
This muffler meets code and standard requirements of the U.S.  
Forest Service. Use only mufflers and parts approved by the  
manufacturer. Any person(s) installing an unapproved muffler,  
or an unapproved exhaust system part, or modifying an exhaust  
system in any way that might cause a hazard, is liable for any  
damage, injury or warranty expense that might be caused by such  
unapproved installation or modification.  
• Terminate the exhaust tailpipe such that exhaust gases will not  
be drawn back into the generator compartment and recircu-  
lated.  
• If there is any possibility of the tailpipe or muffler being dam-  
aged, protect these damage-prone areas by means of a protec-  
tive device (such as a skid bar).  
Failure to provide and maintain a spark arrestor may be in violation  
of the law. If this generator is used on any forest covered, brush  
covered or grass covered unimproved land, a spark arrestor must  
be provided. The vehicle owner or operator must maintain this  
device in good condition. In the state of California, the preceding  
is required by law (Section 4442 of the California Public Resources  
Code). Other states may have similar laws. Federal laws apply on  
federal lands.  
• Install the generator exhaust system according to safe automo-  
tive practices.  
• Use enough exhaust system hangers to prevent any part of the  
system from being dislocated.  
• Use exhaust system parts recommended by the manufacturer.  
Using unapproved exhaust mufflers and exhaust system parts  
is the responsibility of the person(s) installing such unauthor-  
ized parts.  
When installing/replacing the tailpipe or spark arrestor compo-  
nents, verify that the tailpipe has a hole to securely fasten the  
spark arrestor components (see Figures 2.11 and 2.12). Use only  
manufacturer supplied hardware. Substitution of parts may cause  
damage to the screen or a loose fit to the tailpipe.  
28  
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Installation  
• Do not terminate the exhaust system under any opening, win-  
dow or vent that can be opened or is not permanently sealed  
from the vehicle interior.  
• From the junction box, route power supply wires through  
approved conduit to either (a) double-pole, double-throw trans-  
fer switch, or (b) approved isolation receptacle. Connecting to  
a transfer switch or isolation receptacle must prevent vehicle  
electrical circuits from being connected to two different power  
supplies at the same time (such as generator and dockside  
power).  
• Exhaust piping must be large enough to prevent excessive back  
pressure on the generator engine.  
• Never tee the generator engine exhaust pipe into the vehicle  
engine exhaust piping. This causes excessive back pressure on  
the generator engine. Also, water from one engine can damage  
the other engine.  
• Conductors must be rated 221° F (105° C) or must be of a  
larger conductor size.  
• Plan exhaust system installation carefully. Comply with all appli-  
2.6.3 GENERATOR AC CONNECTIONS  
cable codes, standards and regulations.  
Generator AC output leads T1 (red), T2 (white) and T3 (black)  
come out of the generator as shown in Figure 2.13. Leads T1 (red)  
and T3 (black) are “hot,” while T2 (white) is the grounded neutral  
lead. There is also a green lead that connects to ground in the  
junction box of the recreational vehicle.  
2.6 ELECTRICAL CONNECTIONS  
The following general rules apply to electrical connections in a  
recreational vehicle:  
• Qualified electricians who are familiar with applicable codes,  
standards and regulations should install electrical wiring.  
• The wiring should comply with codes, standards and regula-  
tions. The National Electrical Code (NFPA 70), and state and  
local codes apply.  
Figure 2.13 – Generator AC Output Leads  
• Switches and circuit breakers should be of a type approved for  
use in recreational vehicles and must be mounted and installed  
to prevent damage from road shock.  
• Wiring must be of adequate size, have approved insulative  
qualities and be properly supported.  
• Conduit and wire openings into the generator compartment  
(if used) must be vapor-sealed to prevent entry of flammable,  
explosive or poisonous gases into the vehicle.  
2.6.1 ELECTRICAL JUNCTION BOX  
Install an approved, square electrical junction box with a blank  
cover on the interior or exterior wall of the area planned for installa-  
tion of the generator (NOT on the generator). Route the generator's  
AC output leads into this junction box through approved flexible  
conduit. This is the point of first termination for generator AC  
output leads.  
T3  
T2  
T1  
AC Output Leads  
Green  
2.6.2 WIRING  
(Ground)  
• Wiring should be of stranded copper to reduce the chance that  
vibration may cause breakage.  
• Wire gauge size should be large enough to handle at least 115  
percent of the installed generator's rated maximum current.  
• If neutral conductors are used, they must be the same size as  
other leg wires.  
• Route power supply conductors from generator AC output leads  
T1 (red), T2 (white), T3 (black) and the green ground wire  
through approved flexible conduit to the electrical junction box  
on the compartment wall.  
• If flexible metal conduit is used between the generator and the  
compartment junction box, the conduit end that terminates the  
compartment junction box must be vapor-sealed. Flexible metal  
conduit is NOT vapor tight along its entire length.  
4500 Watts  
Line T1 (black) to T2 (white) is protected by circuit breaker a  
(CB1). Use this line to neutral connection to operate 120 volt,  
single-phase, 60 Hz, AC loads.  
5500 and 6500 Watts  
Line T1 (red) to T2 (white) is protected against overload by a cir-  
cuit breaker (CB1). Use this line-to-neutral connection separately  
to operate 120-volt, single-phase, 60 Hertz, AC loads. Line T3  
(black) to T2 (white) also is protected against overload by a circuit  
breaker (CB2). Use this line-to-neutral connection separately to  
operate similar loads. However, be sure the total unit load does not  
exceed the maximum rating of the generator. The neutral line (T2,  
white) on all units is a grounded neutral.  
29  
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Installation  
2.7.1 RECOMMENDED BATTERY  
Install a battery that meets the following requirements:  
Do NOT connect electrical loads in excess  
of any circuit breaker rating or problems will  
• The battery must be a 12-volt, automotive type storage bat-  
tery.  
• For prevailing ambient temperatures above 32° F (0° C), use  
a battery rated 70 amp-hours and capable of delivering 400  
cold-cranking amperes.  
• For prevailing ambient temperatures below 32° F (0° C), use  
a battery rated 95 amp-hours and capable of delivering 400  
cold-cranking amperes.  
develop with circuit breaker tripping, which  
causes a loss of AC output. Also, do NOT  
exceed the generator's rated wattage capac-  
ity. Add the watts or amperes of all lighting,  
appliance, tool and motor loads the generator  
will operate at one time. This total should be  
less than the unit's rated wattage/amperage  
capacity.  
NOTE:  
If the battery is to be used to power other vehicle accessories,  
as well as start the generator, a battery with a larger capacity  
may be needed.  
2.6.4 CONDUIT  
Route the connections between the generator and the junction box  
through approved, flexible conduit. The following general rules  
apply:  
2.7.2 BATTERY CABLES  
• Cut wiring to the required length and allow extra wire for junc-  
tion box connections.  
Using battery cables that are too long or too small in diameter  
may cause a drop in voltage, which causes starting problems. For  
the best cold weather starting, the voltage drop between battery  
terminals and the generator connection point should not exceed  
0.12 volts per 100 amperes of cranking current.  
• Carefully prepare conduit ends to prevent sharp edges from  
cutting through wiring insulation.  
• Route conduit so it does not interfere with generator move-  
ment.  
• If using metallic conduit, vapor seal the end of the conduit  
where it enters the junction box. Do this because flexible metal-  
lic conduit is not vapor proof along its entire length.  
These generators are rated at about 100 DC amperes of cranking  
current.  
Select battery cables based on (a) cable length and (b) prevail-  
ing ambient temperatures. Generally, the longer the cable and the  
colder the weather, the larger the cable size must be, as shown in  
the chart.  
2.6.5 ISOLATING DIFFERENT POWER SOURCES  
Connections from the junction box must terminate in a double-  
pole, double-throw transfer switch (Figure 2.14). An alternate  
method for isolating different power sources is by using an isolat-  
ing receptacle (Figure 2.15). Whichever method is used, be certain  
that both power sources are NOT connected at the same time.  
CABLE LENGTH in Feet (meters)  
0 to 10 (0 to 3)  
CABLE SIZE  
2*  
0
11 to 15 (3.4 to 4.5)  
16 to 20 (4.5 to 6)  
000  
2.6.6 POWER SUPPLY CORD  
The power supply cord must comply with all applicable codes,  
standards and regulations. It must be large enough to handle the  
full amperage to which it will be subjected.  
*For warm weather, use No. 2 cable up to 20 feet.  
NOTE:  
Where a minimum of 1025 CCA (cold cranking amps) battery  
current is available, up to 30 feet of AWG #2 battery cable is  
permitted.  
2.6.7 GROUND FAULT CIRCUIT  
INTERRUPTERS  
The National Electrical Code (NFPA 70, article 551) requires that  
ground fault circuit interrupters (GFCIs) on all external and some  
internal electrical receptacles be installed. Contact the manufac-  
turer or dealer for recommendations.  
2.7.3 BATTERY CABLE CONNECTIONS  
1. Connect the battery cable from the battery post or terminal  
indicated by a POSITIVE, POS or (+) to the lug on the starter  
contactor (Figure 2.16).  
NOTE:  
2.7 BATTERY INSTALLATION  
Check to be sure the battery cable boot for the starter cable has  
been installed.  
NOTE:  
2. Connect the battery cable from the battery post indicated by a  
NEGATIVE, NEG or (-) to the frame ground connection (Figure  
2.16).  
This generator is not equipped with an internal battery charger.  
It is intended for use in systems where an external battery char-  
ger is installed by the RV O.E.M. or an aftermarket installer.  
3. Connect cables so the connectors are clean and tight.  
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Installation  
Figure 2.14 — Typical Transfer Switch Isolation Method  
Figure 2.15 — Typical Installation With Isolation Receptacle  
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Installation  
Figure 2.16 – Connecting Battery Cables  
Figure 2.17 – Remote Panel Plug-in Receptacle  
Positive Cable  
+
Battery  
Chasis Ground  
Negative Cable  
2.7.4 BATTERY COMPARTMENT  
Install the generator battery in its own, vented compartment. Place  
the battery compartment away from any source of heat, sparks  
or flame.  
Provide ventilation openings in the battery compartment. The  
minimum size of openings should be two (2) square inches at  
the top of the compartment. Mount the battery on a strong, rigid  
supporting structure, where leaks and spills of battery fluid will not  
cause damage.  
2.8 OPTIONAL ACCESSORIES  
A plug-in receptacle (Figure 2.17) is provided on the generator set.  
Use this receptacle to connect an optional remote-mounted start/  
stop panel to the generator. Installation of such a panel will permit  
starting and stopping the generator engine from any convenient  
location inside the vehicle.  
2.8.1 REMOTE PANEL MODELS  
The remote panels mount a rocker type start/stop switch, a  
“Generator Run” advisory lamp and an hourmeter. The hourmeter  
should be used in conjunction with the maintenance operations  
found in Part I of this manual.  
WIRE NO.  
WIRE COLOR  
Black  
FUNCTION  
Ground  
0
14  
Blue  
Engine Run Signal  
12 VDC  
712  
17  
Blue  
Brown/White  
Brown/Black  
Start  
18  
Stop  
32  
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Post Installation  
5. When all tests and adjustments at no-load are completed,  
apply electrical loads and check for proper operation under  
load (see "Testing Under Load"). Run the unit at least 30 min-  
utes with loads applied.  
6. Turn off all electrical loads by setting the generator’s main  
circuit breakers to their “OFF” (or open) position.  
7. Let the unit run at no-load for a few minutes to stabilize  
internal engine/generator temperatures. Then, shut down the  
engine.  
3.1 POST INSTALLATION TESTS  
The air-cooled generator set was factory tested and adjusted. It  
should not be necessary to adjust the unit any further except under  
special circumstances.  
nDo not make any unnecessary adjustments.  
Factory settings are correct for most applica-  
tions. When making adjustments, however,  
be careful to avoid overspeeding the engine.  
NOTE:  
The generator set was thoroughly tested and adjusted at the fac-  
tory before shipping. No additional adjustment should be neces-  
sary. Only qualified service technicians who have been trained  
should perform adjustments outlined in this manual.  
3.2 BEFORE INITIAL START-UP  
Before starting, complete the following:  
1. Check the engine crankcase oil level and, if necessary, fill to  
the dipstick “FULLmark (cross-hatched area) with the rec-  
ommended oil. Do not fill above the FULL mark.  
2. Check the fuel supply. Gas fuel lines must have been properly  
purged and leak tested in accordance with applicable fuel  
codes. All fuel shutoff valves in the fuel supply lines must be  
open.  
3.4 TESTING UNDER LOAD  
Apply electrical loads equal to about 75 to 100 percent of the unit's  
rated wattage/amperage capacity.  
Let the unit run at least 30 minutes with load applied. During this  
part of the test, check that the unit is not running excessively hot  
and that adequate cooling airflow is available. Do not allow the unit  
to overheat during prolonged operation.  
3.3 INITIAL START  
NOTE:  
When certain that the unit has been properly installed and prepared  
for use, start the engine as follows:  
The generator engine is equipped with a high temperature  
switch. The switch has normally open (N.O.) contacts. When the  
engine temperature is too high, switch contacts close, and the  
engine shuts down automatically.  
1. Turn off all electrical loads. Do this by setting the generator’s  
main circuit breakers to their “OFF” (or open) position.  
2. Refer to Part I, “Starting the Generator”, for cranking and  
starting instructions. The engine may require more cranking  
for initial starting since the fuel lines have to be primed (use  
of the primer switch will shorten this time).  
THE MANUFACTURER RECOMMENDS THAT THE GENERATOR BE  
TESTED FOR ADEQUATE COOLING.  
3. Let the engine warm up for about five minutes to allow internal  
temperatures to stabilize.  
4. Carefully inspect the engine/generator for fuel, oil and exhaust  
system leaks. Before proceeding to the next step, correct any  
leakage immediately.  
33  
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Post Installation  
ELECTRICAL CONNECTIONS  
3.5 INSTALLATION CHECKLIST  
LOCATION AND SUPPORT  
Connections comply with local code requirements  
and all National Electrical Codes.  
Generator is properly located.  
Generator is properly supported.  
Generator is properly restrained.  
Junction box is properly installed.  
Wiring meets all standards.  
All connections are correct.  
Conduit is properly installed and sealed.  
Generator is properly bonded to the vehicle.  
GENERATOR COMPARTMENT  
Compartment construction is proper.  
Holes/Openings are vapor-sealed.  
Compartment size is correct.  
Compartment is vapor-sealed.  
Sound insulation is correct.  
Generator is always isolated from other power  
sources.  
BATTERY INSTALLATION  
Recommended battery is installed.  
Recommended cables are installed.  
Cables are clean and tight.  
Cables are connected properly.  
Proper ventilation is provided.  
Floor cutouts are properly completed.  
COOLING AND VENTILATING AIR  
Airflow is adequate.  
Air inlet opening is correct.  
Compensate for restrictions.  
Check that installation has been tested.  
Terminals are coated with anti-corrosion grease, and  
terminal covers are positioned.  
OPTIONAL ACCESSORIES  
Check that remote start/stop panels (if used) are  
GASOLINE FUEL SYSTEM  
Fuel tank complies with all applicable codes.  
installed properly.  
Check that hourmeter kit (if used) is installed  
Fuel system is properly installed and checked for  
properly.  
leaks.  
Check that any other options and accessories (if  
used) are installed properly.  
EXHAUST SYSTEM  
Exhaust system complies with all applicable codes.  
POST INSTALLATION TESTS  
Check that all tests are completed properly.  
Exhaust system is properly and safely installed.  
DATE OF INSTALLATION_________________________________________________  
NAME OF INSTALLER ____________________________________________________  
SIGNATURE OF INSTALLER _____________________________________________  
34  
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Troubleshooting  
4.1 TROUBLESHOOTING GUIDE  
Problem  
Cause  
Correction  
Engine won’t crank.  
1. 7.5 amp fuse blown.  
1. Replace blown fuse.  
2. Loose, or corroded or defective  
battery cable(s).  
2. Tighten, clean or replace,  
as necessary.  
3. Battery is discharged or defective.  
4. Defective Start/Stop switch.  
5. Defective starter contactor.  
6. Defective starter motor.  
7. Defective Engine Control Board  
3. Recharge or replace battery.  
4. Replace switch.  
5. Replace starter contactor.  
6. Replace starter motor.  
7. Contact an authorized service dealer.  
Engine cranks, won't start.  
1. Out of fuel.  
1. Refill fuel tank.  
2. Fuel pump not operating.  
3. Automatic choke not operating properly.  
4. Engine is flooded.  
5. Fuel filter is clogged.  
6. Engine spark plugs defective.  
7. Bad ignition magneto on engine.  
8. Bad carburetor.  
2. Repair or replace pump.  
3. Repair, replace or adjust.  
4. Wait 5-10 minutes; try again.  
5. Replace filter if clogged.  
6. Clean, regap or replace as needed.  
7. Replace if defective.  
8. Adjust, repair or replace.  
9. Clean or replace as needed.  
9. Dirty air cleaner.  
Engine starts hard, runs rough.  
Engine starts, then shuts down.  
1. Dirty engine air cleaner.  
2. Automatic choke is sticking.  
3. Defective spark plugs.  
1. Clean or replace as needed.  
2. Free choke linkage as needed.  
3. Clean, regap or replace.  
4. Replace it if defective.  
4. Defective ignition magneto.  
1. Engine oil level is low.  
2. Bad low oil pressure switch.  
3. Defective high temp switch.  
4. Water in fuel.  
1. Add oil as needed.  
2. Replace, if bad.  
3. Replace, if bad.  
4. Drain fuel tank and refill.  
5. Defective remote harness.  
5. Disconnect remote harness. Contact  
authorised service facility.  
No AC output voltage.  
1. Main breaker(s) open.  
2. Transfer switch (if so equipped) is  
set to wrong position.  
1. Close main breaker(s).  
2. Reset transfer switch.  
3. Failure in vehicle electrical system.  
4. Generator component failure.  
3. See vehicle manual.  
4. Contact an authorized service facility.  
35  
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Electrical Data  
Wiring Diagram Drawing No. 0G4221-C  
36  
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Wiring Diagram Drawing No. 0G4221-C  
Electrical Data  
37  
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Electrical Data  
Wiring Diagram Drawing No. 0H3633-A  
38  
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Wiring Diagram Drawing No. 0H3633-A  
Electrical Data  
39  
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Exploded Views & Parts Lists  
Enclosure Drawing No. 0G3881-F  
40  
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Enclosure Drawing No. 0G3881-F  
Exploded Views & Parts Lists  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
0G3396  
0C5644  
0G5236  
0D3700  
0G3401  
0G4077  
0G4433  
0G3377  
0G3431  
0F9199  
0G3430  
0G3402  
090388  
0G3422  
0G5237  
0G3399  
0D3472  
0G4933  
0G5238  
0G3397  
0G4391  
0G5239  
0G3392  
0G3754  
0G3398  
0G3912  
0G3400  
0G5240  
0G5242  
0G5241  
045756  
0G5755  
0G5761  
022473  
022097  
022287  
0G3429  
1
2
1
23  
1
1
1
1
1
1
1
1
13  
1
1
1
1
18  
1
1
1
1
1
1
1
1
1
1
1
2
9
1
1
1
1
1
1
ENCLOSURE DOOR  
SLIDE LATCH, FLUSH  
FOAM ENCLOSURE DOOR  
NUT FLANGE M6-1.0 NYLOK  
DUCT, AIR IN DOOR  
GROMMET, OIL FILTER  
U CHANNEL 1/8”  
TRAY, 530 RV  
GASKET AIR IN BOTTOM DUCT  
PLUG PLASTIC 1.093-1.125  
GASKET AIR IN TOP DUCT  
DUCT AIR IN ROOF  
SCREW HHTT M6-1.0X12 ZINC  
TOP DIVIDER PANEL  
FOAM, SIDE ENCLOSURE  
ENCLOSURE SIDE / BACK  
GROMMET OVAL 31.75X50.8  
SCREW SWT 1/4-20X5/8 W/W  
FOAM BACK ENCLOSURE ALT SIDE  
ENCLOSURE ROOF  
ENCLOSURE, BACK PANEL 530 RV  
FOAM BACK PANEL ENCLOSURE  
UPPER BLOWER HOUSING  
UPPER BLOWER HOUSING GASKET  
EXHAUST DIVIDER PANEL  
MUFFLER HOLD DOWN BRACKET  
ENCLOSURE EXHAUST SIDE PANEL  
FBR GLASS, ENCLOSURE MFLR BACK  
FOAM EXHAUST END ENCL FRONT  
FBR GLASS, ENCLOSURE MFLR SIDE  
SCREW HHTT M6-1.0X10 ZYC  
BUMPER  
10  
11  
12  
13  
14  
15  
16  
17  
18  
23  
24  
25  
26  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
STAND OFF  
WASHER, FLAT 1/4”  
WASHER, LOCK 1/4”  
SCREW HHC 1/4-20 X 3/4” G5  
GASKET, SCROLL DUCT  
SHEET METAL PAINT/MATERIAL CODE LEGEND  
The following exploded views contain part numbers of various sheet metal components. Only the base part number is listed. When ordering sheet metal, the  
correct color and material information must be included as a suffix at the end of the part number as shown below.  
Material  
S = Steel  
Color  
G = Gray  
B = Black  
Example:  
Desc.  
Roof  
Upper Blower Hsg.  
Part No.  
0G3397  
0G3392  
Material  
S = Steel  
S = Steel  
Color  
G = Gray  
B = Black  
Order As"  
0G33970ST08  
0G33920ST03  
41  
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Exploded Views & Parts Lists  
Control Panel Drawing No. 0H3635-C  
42  
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Control Panel Drawing No. 0H3635-C  
Exploded Views & Parts Lists  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
045757  
0F5458  
023484S  
0G9081*  
049813  
022473  
0A1658  
0G3380  
0F9176  
0G3662A  
028414  
0D3700  
0G5225  
028916  
087769  
025965  
022097  
0G5318  
0H3634  
0G4602  
0C7968  
022237  
0A4456  
0C7423  
022259  
022129  
022145  
0E0593  
0D8502  
0G5233  
0G3825  
0G3689  
092036  
0A9611  
032300  
0G4215  
1
2
1
1
1
2
1
1
SCREW HHC M6-1.0 X 25 G8.8  
SCREW PLASTITE HI-LOW #10X3/8  
BUSHING SNAP SB-1093-937  
WIRE HARNESS C/PNL FRAME  
NUT HEX M6 X 1.0 G8 YEL CHR  
WASHER FLAT 1/4-M6 ZINC  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
082025  
0F9719  
0G3977  
0G3530  
075476  
090987  
0C2174  
031879  
0D9784  
075235  
074908  
075210A  
0E6480  
090144 (5500W)  
090145 (6500W)  
090145  
4
1
1
1
2
2
1
2
2
4
4
1
2
1
1
1
NUT HEX LOCK M5-0.8 NYINS ZINC  
ASSY PCB VREG AIR COOLED 2006  
ASSY PCB RV CONTROLLER  
C/PNL FRAME RV  
SCREW PPHM M4-0.7 X 16  
SCREW PPHM M3-0.5 X 12  
RELAY 12V 25A SPST  
WASHER LOCK SPECIAL 1/4"  
FUEL PUMP MOUNTING BRACKET  
WASHER FLAT #4 ZINC  
28.75” HOSE,1/4" SAE30R7  
NUT HEX LOCK M3-0.5 NY INS  
SCREW HHC M5-0.8 X 30 G8.8  
SCREW HHTT M5-0.8 X 10 BP  
BLOCK 1 POSITION, 4 TAB  
NUT HEX LOCK M4-0.7 NY INS  
CIRCT BRK 20X1 MAG 10-32 CARL  
CIRCT BRK 30X1 MAG 10-32 CARL  
CIRCT BRK 30X1 MAG 10-32 CARL  
(4500W, 5500W, 6500W)  
EARTH STRAP  
NYLON SPACER .26 X 1.00 X 1.73  
PLUG, PLASTIC .75 (5410-1/5412-  
1/5414-1 ONLY)  
BARBED EL 90 ¼ NPT X 5/16  
(5751/5752/5753 ONLY)  
BULKHEAD ADAPTER  
(5751/5752/5753 ONLY)  
BUSHING REDUCER HEX ¼ TO 1/8 NPT  
(5751/5752/5753 ONLY)  
NIPPLE PIPE 1/8 NPT X 1 ½  
(5751/5752/5753 ONLY)  
SOLENOID 12 VDC (5751/5752/5753  
ONLY)  
BARBED EL 90 1/8 NPT X ¼  
(5751/5752/5753 ONLY)  
1
1
5
1
1
1
1
2
1
1
1
3
2
1
1
2
2
1
1
1
2
1
1
4
1
1
1
CLAMP HOSE BAND .50  
BARBED STR 1/8NPT X 1/4  
NUT FLANGE M6-1.0 NYLOK  
FUEL PUMP  
ELBOW 90D STREET 1/8 BRASS  
FILTER FUEL 1/8P-1/4H  
SCREW HHC 1/4-20 X 2-1/4” G5  
WASHER LOCK M6-1/4  
50  
AC HARNESS 530RV (5500 + 6500W)  
AC HARNESS 530RV EVAP (4500W)  
GROMMET, DOUBLE SLIT  
NUT HEX JAM 3/8-16 BRASS  
WASHER LOCK 3/8  
WASHER LOCK SPECIAL 3/8  
STUD 3/8-16 X 2-1/4 BRASS  
NUT HEX 5/16-18 STEEL  
WASHER LOCK M8-5/16  
WASHER FLAT 5/16-M8 ZINC  
STUD, 1/4-20 TO 5/16-18  
NEUTRAL CONNECTOR UL  
SCREW PPHTF #8-18 X 1/2 AB  
CONTROL PANEL COVER  
C/PNL FACE  
51  
52  
53  
0C2417A  
0G5986  
061669  
1
1
1
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
54  
55  
56  
57  
58  
59  
059502  
069598  
035579  
035483  
0G0247  
028740  
1
1
1
1
1
1
SCREW PPHM #6-32 X 1/4 SEMS  
FUSE 7.5AXBK/AGC7.5NX  
HOLDER FUSE  
*HARNESS NOT SHOWN  
SWITCH RKRSPDT(ON)OFF(ON)ILLUM  
43  
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Exploded Views & Parts Lists  
Base & Pulley Drawing No. 0G7720-B  
44  
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Base & Pulley Drawing No. 0G7720-B  
Exploded Views & Parts Lists  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
0G3377  
081105  
022259  
022129  
022145  
0G5217  
0G3748  
046526  
022131  
0G3384  
0C7758A  
0C1751  
0C2824  
022473  
022097  
043116  
0G3383  
0G4350  
0G3379  
0C3062  
0G4429  
0G3391  
0G3742  
0G7670  
0E0588  
0G4702  
029451  
0G3426  
0G5676  
0G5676A  
0G4692  
022473  
0A2110  
0G3410  
0G3393  
0G7887  
025145  
0C8565  
056892  
089680  
094670  
0G3394  
0G3395  
056893  
023897  
0G4260  
0E9369  
1
2
8
12  
13  
2
1
2
2
1
4
1
11  
7
7
7
1
1
2
2
1
1
1
1
1
2
1.5ft  
1
1
1
1
3
3
5
1
1
TRAY, 530 RV  
NUT FLANGE 5/16-18 LOCK  
NUT HEX 5/16-18 STEEL  
WASHER LOCK M8-5/16  
WASHER FLAT 5/16-M8 ZINC  
SCREW HHC 3/8-24 X 1-1/2 G8  
BELT V-RIBBED 4L X 43.75" LG  
WASHER LOCK M10  
WASHER FLAT 3/8-M10 ZINC  
ALTERNATOR PULLEY  
VIB MNT 1.5X1.38X5/16-18 DR 45  
FAN 7" DIA (NYLON)  
SCREW HHTR #10-32 X 9/16  
WASHER FLAT 1/4-M6 ZINC  
WASHER LOCK M6-1/4  
SCREW HHC M6-1.0 X 12 G8.8  
ENGINE PULLEY  
FAN ENGINE PULLEY RV  
BRACKET MUFFLER SUPPORT  
BOLT CARR 5/16-18 X 1  
EDGE TRIM W/ 3/4" HOLLOW CYL.  
BLOWER HOUSING WALL  
GASKET, LOWER BLOWER HOUSING  
FRAME GT530 RV MOUNTING  
SPACER, SAFETY BOLT .375 I.D.  
SCREW HHC 5/16-18 X 3 SPC  
TAPE ELEC UL FOAM 1/8 X 1/2  
DUCT AIR OUT  
GASKET,AIR OUT DUCT  
GASKET, AIR OUT DUCT OPPOSITE SIDE  
SCREEN, BOTTOM AIR OUT  
WASHER FLAT 1/4-M6 ZINC  
SCREW SWAGE 1/4-20 X 1/2 ZYC  
ISOLATION SPRING  
30  
31  
32  
33  
34  
MUFFLER, 530 RV  
MUFFLER. 530 RV (MODELS: 5410-1 / 5412-1 / 5414-1 ONLY)  
BOLT U 5/16-18 X 1.25 W/SADDLE  
SCREW SHC M8-1.25 X 18 G8.8  
SCREW CRIMPTITE 10-24 X 3/8  
SCREEN SPARK ARRESTOR  
CLAMP EXHAUST  
EXHAUST FLEX  
EXHAUST MANIFOLD  
SCREW CRIMPTITE 10-24 X 1/2  
WASHER FLAT #10 ZINC  
GASKET, EXH BASE, 530 RV  
GASKET, EXHAUST GT530  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
1
4
1
1
2
1
1
6
6
2
2
45  
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Exploded Views & Parts Lists  
Engine Accessories Drawing No. 0G7718-K  
46  
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Engine Accessories Drawing No. 0G7718-K  
Exploded Views & Parts Lists  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
3
4
5
6
7
8
9
0G7670  
0G3404  
0E9507  
023484S  
056893  
0G4129  
0C8563  
0G3405  
0G4985A  
0E9525A  
0E4997  
067198N  
067890  
0G3911  
0G4130  
082774  
0G3454  
022131  
0G5221A  
0G5221B  
0G6432  
0E9319  
0E9333  
040976  
0E9471  
0E9383D  
0G9640  
0G3890  
0G4378  
040173  
0G3406  
0G3455  
0G3413  
078601  
0G5057  
0E9511B  
0G3414  
0G3408  
045756  
1
1
8
1
14  
1
12  
1
1
1
1
1
1
1
1
1
1
3
1
1
4
2
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
FRAME  
50  
51  
52  
53  
54  
55  
56  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
80  
81  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
95  
96  
97  
98  
0G3386  
0A2311  
070185B  
0D9235  
0G4793  
043182  
0C1085  
0G4576  
0A2110  
0G3407  
0G3915  
0G3840  
0G3839  
0E9368  
0G7671  
0G3389  
0A7094  
0D8590  
0D8591  
0G3984  
043146  
022097  
0D6342  
0D9784  
0G4016  
043116  
0F1177  
077091  
075763A  
0742600173  
022473  
061906  
049813  
056892  
0E9323  
022129  
0A4456  
022746  
055934M  
0G6725  
0G6729  
078643C  
096290A  
046526  
0G9148  
0G7757A  
1
2
1
1
1
2
2
1
1
1
1
1
1
2
1
1
2
1
1
1
2
6
1
1
1
2
1
1
1
1
2
2
2
2
1
2
1
4
1
1
1
2
2
3
1
1
OIL FILTER SUPPORT  
SCREW SWAGE 1/4-20 X 1  
OIL FILTER  
OIL PRESSURE SWITCH 5 PSI  
SWITCH, THERMAL 270F  
WASHER, LOCK M3  
SCREW PPHM M3-0.5 X 8  
BRACKET, OIL CHECK TUBE  
SCREW SWAGE 1/4-20 X 1/2  
WRAPPER ENGINE VALLEY  
WRAPPER UPPER VALLEY  
WRAPPER INNER CYLINDER #2  
WRAPPER INNER CYLINDER #1  
SPARKPLUG  
ENGINE WRAPPER, STARTER SIDE  
SCREW HHFC M8-1.25 X 14  
SNAP BUSHING  
SCREW CRIMPTITE 10-24 X 1/2  
SHIELD WRAPPER, CYLINDER #1  
SCREW HHFC M6-1.0 X 12 G8.8  
ENGINE WRAPPER, BACK  
BACKPLATE  
ASSY, FLYWHEEL & RING GEAR 29D  
ASSY, GROUND WIRE CONNECTOR  
WASHER,BELV-20 X 2.2  
NUT HEX M20-1.5 G8  
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  
40  
41  
BLOWER HOUSING  
SHIELD WRAPPER, CYLINDER #2  
KEY, WOODRUFF 4 X 19D  
BREATHER HOSE  
WASHER FLAT 3/8 – M10 ZINC  
IGNITION COIL CYLINDER #1  
IGNITION COIL CYLINDER #2  
SCREW HHFC M6-1.0 X 25 SEMS  
GASKET, INTAKE  
OIL LINE OUT  
OIL LINE IN  
SCREW PPHM #4-40 X 1/4  
ASSEMBLY, BI-METAL/HEATER  
CHOKE SOLENOID  
CONTROLLER ASSEMBLY  
SCREW HHC M6-1.0 X 10 G8.8  
WASHER LOCK M6-1/4  
BALL STUD, 10 MM  
NUT HEX LOCK M3-0.5  
BRACKET, CONTROLLER SUPPORT  
SCREW HHC M6-1.0 X 12 G8.8  
ASSY, GROUNDING WIRE W/O DIODES  
COTTER PIN  
INTAKE MANIFOLD  
SCREW SHC M8-1.25 X 20 G12.9  
GASKET, MANIFOLD TO CARB/MIXER  
CARBURETOR  
ROD, CHOKE CONTROL  
ASSY GOVERNOR ROD  
GASKET, AIRBOX/CARB  
CLAMP, HOSE WORM GEAR  
WRAPPER, ENGINE OIL ADAPTOR  
SNORKEL, AIR BOX  
AIRBOX BASE  
AIR FILTER  
AIRBOX SEAL  
AIRBOX QUARTER KNOB  
AIRBOX COVER  
OIL DRAIN LINE  
SCREW HHTT M6-1.0 X 10 YELLOW  
CHROME  
CLAMP, VINYL 9.5 O.D.  
3/4 NPT TO 3/8 O.D. FLARE  
ASSY, CAP AND DIPSTICK  
OIL DRAIN/DIPSTICK TUBE  
90 DEGREE ELBOW 3/8 NPT X 3/8  
BARBED  
BOOT, BATT. CABLE  
WIRE ASSY. BATT. POS.  
WASHER, FLAT 1/4-M6  
SCREW HHC M8-1.25 X 85  
NUT M6-1.0  
SCREW CRIMPTITE 10-24 X 3/8  
START MOTOR  
WASHER, LOCK M8-5/16  
WASHER, LOCK SPECIAL 3/8  
SCREW HHC 3/8-16 X 1-3/4 G5  
CLAMP VINYL .75 X .343  
INSULATOR  
GASKET, MANIFOLD TO CARB/MIXER  
BOLT,CARB MOUNT M6-1.0 X 95  
STUD M6-1.0 X 100  
42  
43  
44  
45  
46  
0E0998  
0G3432  
0E0393A  
0E0361B  
043790  
1
2
1
1
1
WASHER LOCK M10  
PLUG, RUBBER (4703, 5, 6 & 7)  
HOSE MOLDED EVAP. PORT (05751,  
05752 & 05753)  
SCREW, BHSC M6-1 X 8  
SCREW BHSC M6-1 X 8MM BLACK  
47  
48  
49  
0G3662B  
0F0452B  
0G4426  
2
8”  
1
HOSE OETIKER CLAMP  
HOSE, 3/8” I.D.  
ASSY, OIL DRAIN FITTING  
99  
100  
0H4269  
0G9062  
1
1
47  
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Exploded Views & Parts Lists  
530 RV Engine Drawing No. 0G7719-B  
48  
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530 RV Engine Drawing No. 0G7719-B  
Exploded Views & Parts Lists  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
8
9
0E3812  
0D4788  
073144  
0G7260A  
078699B  
0A5776  
0E9482  
0C5315A  
0C5314A  
0E9379  
0E9382  
0G0919  
0E3372A  
0E9345  
076390  
0G4379  
0G4331  
076389  
0G1054  
0G1063G  
093064  
0E9334F  
080318  
0E9352  
0E9368  
077168  
084186  
088156  
0C4390  
0C3733  
0C3592  
077161  
077160  
076307  
0E9353A  
0E9304  
0C3591  
0C3590  
0E9351  
0G5728  
0E9455E  
083235  
0G7679  
0E9350  
0E9334G  
0E9305  
0E9429C  
0E9366  
0G5670  
0C8566  
0C5943  
0G0273  
0G5896  
0G0275  
0G0276  
2
1
9
1
6
1
1
1
1
1
1
3
1
1
4
2
2
2
2
1
1
1
8
2
2
12  
4
2
4
4
8
4
4
4
2
1
2
2
2
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
SEAL D 35 X 48.2  
3/8” SQUARE HEAD PLUG  
SCREW HHFC M8 – 1.25 X 45  
GEAR COVER  
SLEEVE DOWEL PIN  
11/32 DIAMETER PRESSURE RELIEF BALL  
OIL PRESSURE SPRING  
GEAROTOR, OUTER  
GEAROTOR, INNER  
SCREEN, OIL PICK-UP  
COVER, GEROTOR  
SCREW, HHFCS M6-1.0 x 12  
BREATHER SEPARATOR  
GEAR, GEAROTOR  
RETAINER RING  
PISTON RING SET  
PISTON  
PISTON PIN  
CONNECTING ROD ASSEMBLY  
CRANKSHAFT  
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  
OIL FILL CAP  
COVER ROCKER W/FILL  
SCREW HHFC M6-1.0 X 25  
GASKET, VALVE COVER  
SPARK PLUG  
SCREW HHC M8-1.25 X 56  
WASHER, VALVE SPRING  
SEAL, VALVE STEM  
VALVE SPRING  
VALVE RETAINER  
KEEPER, VALVE SPRING  
STUD, ROCKER ARM  
ROCKER ARM  
JAM NUT, ROCKER ARM  
PUSH ROD GUIDE PLATE  
CYLINDER HEAD CYL. 1  
INTAKE VALVE  
EXHAUST VALVE  
GASKET CYLINDER HEAD  
SCREEN  
PUSHROD  
TAPPET  
CAM SHAFT & GEAR  
GASKET, CRANKCASE  
COVER ROCKER  
CYLINDER HEAD CYL 2  
CRANKCASE  
GASKET, BREATHER ASSEMBLY  
BREATHER ASSY  
SCREW HHFC M6-1.0 X 20  
SEAL, OIL PASSAGE  
GASKET KIT  
BREATHER KIT  
KIT HEAD ASSY CYLINDER #1  
KIT HEAD ASSY CYLINDER #2  
49  
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Exploded Views & Parts Lists  
Rotor & Stator Drawing No. 0G3953-B  
50  
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Rotor & Stator Drawing No. 0G3953-B  
Exploded Views & Parts Lists  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
3
4
5
6
7
9
10  
11  
12  
13  
052858  
075237  
075242  
0C1878  
073146  
052203  
022145  
0G3913  
029459  
075215  
0G3382  
0G3877H  
0G3878H  
0G3879H  
0G3893H  
0G3894H  
0G3895H  
0G3381  
022129  
045771  
066386  
066849  
0G3542  
022131  
042633  
022237  
6
4
4
2
4
2
6
4
2
2
1
1
1
1
1
1
1
1
4
4
1
2
1
1
1
1
NUT TOP LOCK FL M8-1.25  
WASHER, SPRNG CENTER  
SPRING, GEN. MOUNT  
SUPPORT, SLIDE  
SLIDE, NYLON  
SCREW HHC M8-1.25 X 70 G8.8  
WASHER FLAT 5/16-M8 ZINC  
STUD, 530 RV STATOR  
TENSION SPRING  
WASHER, SPRING CENTR  
LOWER BEARING CARRIER  
RTR 200 4.5AD1 RV  
RTR 200 5.5AD1 RV  
RTR 200 6.5AD1 RV  
STR 200-4.5AD1 RV  
STR 200-5.5AD1 RV  
STR 200-6.5AD1 RV  
UPPER BEARING CARRIER  
WASHER LOCK M8-5/16  
NUT HEX M8-1.25 G8 CLEAR ZINC  
ASSEMBLY, BRUSH HOLDER  
SCREW HHTT M5-0.8 X 16  
FAN UPPER ALTERNATOR  
WASHER FLAT 3/8-M10 ZINC  
SCREW HHC 3/8-24 X 1 G5  
WASHER LOCK 3/8  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
51  
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Warranty  
CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT  
YOUR WARRANTY RIGHTS AND OBLIGATIONS  
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power  
Systems, Inc. (Generac), are pleased to explain the Emission Control System warranty on your new 2008 and later generator. New equip-  
ment that use small spark-ignited engines must be designed, built, and equipped to meet stringent anti-smog standards for the state of  
California and the federal government. Generac will warrant the emission control system on your generator for the period of time listed below  
provided there has been no abuse, neglect, unapproved modification or improper maintenance of your equipment.  
Your emission control system may include parts such as the: carburetor, ignition system, fuel system catalytic converter, and other associ-  
ated emission-related components (if equipped).  
MANUFACTURER’S WARRANTY COVERAGE:  
This emission control system is warranted for two years. If, during such warranty period, any emission-related part on your equipment is  
found to be defective in materials or workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service  
Dealer.  
OWNER'S WARRANTY RESPONSIBILITIES:  
As the generator owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner's  
Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on your generator, but Generac  
cannot deny warranty solely due to the lack of receipts.  
As the generator owner, you should be aware that Generac may deny any and/or all warranty coverage or responsibility if your generator,  
or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or the use of counterfeit  
and/or "grey market" parts not made, supplied or approved by Generac.  
You are responsible for contacting a Generac Authorized Warranty Dealer as soon as a problem occurs. The warranty repairs should be  
completed in a reasonable amount of time, not to exceed 30 days.  
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Dealer. To locate the  
Generac Authorized Warranty Service Dealer nearest you, call our toll free number:  
1-800-333-1322  
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS  
Warranty), which is provided to you by Generac pursuant to California and federal law. See also the "Generac Limited Warranties for Generac  
Power Systems, Inc.," which is enclosed herewith on a separate sheet, also provided to you by Generac. Note that this warranty shall not  
apply to any incidental, consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replace-  
ment of the defective part(s). This warranty is in place of all other warranties, expressed or implied. Specifically, Generac makes no other  
warranties as to the merchantability or fitness for a particular purpose. Some states do not allow limitations on how long an implied warranty  
lasts, so the above limitation may not apply to you.  
The ECS Warranty applies only to the emission control system of your new equipment. If there is any conflict in terms between the ECS  
Warranty and the Generac Warranty, the Generac Warranty shall apply. Both the ECS Warranty and the Generac Warranty describe important  
rights and obligations with respect to your new engine.  
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence  
must be presented showing the date of the sale to the original purchaser/owner.  
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following address:  
ATTENTION WARRANTY DEPARTMENT  
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 297 • WHITEWATER, WI 53190  
Part 1  
Part No. 0H1912 Rev. A 05/09  
52  
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Warranty  
EMISSION CONTROL SYSTEM WARRANTY  
Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines:  
(a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin on the date the new equip-  
ment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.  
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or equipment and to each sub-  
sequent purchaser/owner that the ECS when installed was:  
(1) Designed, built and equipped so as to conform with all applicable regulations; and  
(2) Free from defects in materials and workmanship which cause the failure of a warranted part at any time during the ECS Warranty Period.  
(c) The warranty on emissions-related parts will be interpreted as follows:  
(1) Any warranted part that is not scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the ECS Warranty  
Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4) below. Any  
such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.  
(2) Any warranted part that is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for the ECS Warranty  
Period. A statement in the Owner’s Manual to the effect of "repair or replace as necessary" shall not reduce the ECS Warranty Period. Any such  
part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.  
(3) Any warranted part that is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the period of time prior  
to first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by  
Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS warranty shall be warranted for  
the remainder of the period prior to the first scheduled replacement point for that part.  
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a  
Generac Authorized Warranty Service Facility.  
(5) Notwithstanding the provisions of subsection (4) above, warranty services or repairs must be provided at Generac Authorized Service Facilities.  
(6) When the engine is inspected by a Generac Authorized Warranty Service Facility, the purchaser/owner shall not be held responsible for diagnostic  
costs if the repair is deemed warrantable.  
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand  
for such parts.  
(8) Any Generac authorized and approved emission-related replacement parts may be used in the performance of any ECS warranty maintenance or  
repairs and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac ECS Warranty obligations.  
(9) Unapproved, add-on, modified, counterfeit and/or "grey market" parts may not be used to modify or repair a Generac engine. Such use voids this  
ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any  
warranted parts of Generac equipment caused by the use of such an unapproved, add-on, modified, counterfeit and/or "grey market" part.  
EMISSION RELATED PARTS MAY INCLUDE THE FOLLOWING (IF EQUIPPED):  
1) FUEL METERING SYSTEM  
A. CARBURETOR AND INTERNAL PARTS  
B. PRESSURE REGULATOR  
2) AIR INDUCTION SYSTEM  
A. INTAKE MANIFOLD  
4) AIR INJECTION SYSTEM  
A. PULSE AIR VALVE  
5) EXHAUST SYSTEM  
A. CATALYST  
B. THERMAL REACTOR  
C. EXHAUST MANIFOLD  
B. AIR FILTER  
3) IGNITION SYSTEM  
A. SPARK PLUGS  
B. IGNITION COILS / MODULE  
Part 2  
Part No. 0H1912 Rev. A 05/09  
53  
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Warranty  
GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY  
FOR GENERAC RECREATIONAL VEHICLE GENERATORS  
NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3  
(three) years of operation from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part  
which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective  
under normal use and service, in accordance with the warranty schedule set forth below. Any equipment that the purchaser/owner claims to  
be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility. All transportation costs under  
the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac  
generators sold and rated for “Recreational Vehicle” (RV) applications, as Generac has defined Recreational Vehicle generator applications.  
The factory recommends exercising the unit one half-hour every month.  
WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS  
YEAR ONE – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:  
• Engine All components  
• Alternator All components  
WARRANTY SCHEDULE – CONSUMER/PERSONAL APPLICATIONS  
YEARS ONE AND TWO – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:  
• Engine All components  
• Alternator All components  
YEAR THREE – 100% (one hundred percent) only on selected part(s) and labor listed [Any labor and part(s) not listed, and removal and  
reinstallation are the owner’s responsibility]:  
Rotor, Stator, Computer Control Board (part numbers 0A6060 and 0A3369) and inverter, (if applicable with regard to the generator) Cylinder  
Block, Cylinder Head, Crankshaft, Piston(s), Valve, Valve Lifter(s), Intake and Exhaust Manifolds  
Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators manu-  
factured after January 1, 1998, have a transferable warranty to the second owner ONLY for the remainder of the three-year limited warranty.  
Proof-of-purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to the performance of any  
warranty service.  
All warranty expense allowances are subject to the conditions defined in Guardian’s Warranty Policies and Procedures Guide.  
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:  
• Generac Guardian generators that utilize non-Generac replacement parts.  
• Costs of normal maintenance, adjustments, installation and start-up.  
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac  
Power Systems.  
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.  
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all mechani-  
cal devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not cover repair when  
normal use has exhausted the life of a part(s) or engine.  
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing,  
lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.  
• Damage related to rodent and/or insect infestation.  
• Products that are modified or altered in a manner not authorized by Generac in writing.  
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement  
of the defective part(s).  
• Failure due to misapplication.  
Telephone, cellular phone, facsimile, internet access or other communication expenses.  
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty  
period.  
• Expenses related to "customer instruction" or troubleshooting where no manufacturing defect is found.  
• Rental equipment used while warranty repairs are being performed.  
• Overnight freight costs for replacement part(s).  
• Overtime labor.  
• Starting batteries, fuses, light bulbs and engine fluids.  
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES  
AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty  
lasts, so the above limitation may not apply to you.  
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE  
LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC'S NEGLIGENCE.  
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.  
This warranty gives you specific legal rights. You also have other rights from state to state.  
GENERAC® POWER SYSTEMS, INC.  
P.O. BOX 297  
WHITEWATER, WI 53190  
Rev. A 06.09  
Part No. 0H3467  
Revision B (04/15/10)  
Printed in U.S.A.  
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