Page 2 - INTRODUCTION; READ THIS MANUAL THOROUGHLY; After this heading, read explanatory statements; CONTENTS; AUTHORIZED SERVICE
INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc. It has been designed and manu-factured to supply electrical power for recreational vehicles. READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood, con-tact the nearest Authorized Service Dealer for ...
Page 3 - Table of Contents; Recreational Vehicle Generator; Part I – Owner’s Manual
Table of Contents Recreational Vehicle Generator 1 Part I – Owner’s Manual Introduction ........................................Inside Front Cover Read This Manual Thoroughly ................................. IFC Contents .................................................................. IFC Operati...
Page 4 - DANGER; Despite the safe design of this generator, operat-; GENERAL HAZARDS; • For safety reasons, the manufacturer recommends
2 Study these SAFETY RULES carefully before install-ing, operating or servicing this equipment. Become familiar with this Owner’s Manual and with the unit. The generator can operate safely, efficiently and reliably only if it is properly installed, operated and maintained. Many accidents are caused ...
Page 5 - Safety Rules
3 • Adequate, unobstructed flow of cooling and ven- tilating air is critical to correct generator opera-tion and is required to expel toxic fumes and fuel vapors from the generator compartment. Without sufficient cooling airflow, the engine/generator quickly overheats, which causes serious damage to...
Page 6 - Section 1 – General Information; Number; GENERATOR IDENTIFICATION
4 1. Generator Air Intake 2. Engine Start/Stop Switch 3. Fuse 4. Optional Remote Panel Receptacle (Side View) 5. Generator AC Output Leads (Side View) 6. Fuel Primer Switch 7. Circuit Breaker 8. Starter Contactor 9. Fuel Inlet 10. Fuel Pump (Behind Access Panel) 11. LP Regulator/Solenoid 12. Oil Fil...
Page 7 - APPLICABILITY; For fire safety, the generator must have been; CONNECTION SYSTEM; Figure 1.1 – Connections for 120 Volts Only; REQUIREMENTS; Model
5 Section 1 – General Information Recreational Vehicle Generator 1.2 GENERATOR APPLICABILITY These generators have been designed and manufac-tured for supplying electrical power for recreational vehicles. Do not modify the generator or use it for any application other than for what it was designed. ...
Page 8 - • During summer months: SAE 30. An acceptable; • For engines less than 225 cc displacement, Category; GENERATOR CONTROL PANEL; Figure 2.1 – Generator Control Panel; PRIMER; Section 2 – Operation
6 1.5.3 ENGINE OIL REQUIREMENTS Use only high quality detergent oil rated with American Petroleum Institute (API) Service Classification SF, SG or SH. The recommended oil weights include the following: • During summer months: SAE 30. An acceptable substitute is SAE 10W-30. • During winter months: SA...
Page 9 - BREAKER; OPTIONAL REMOTE; LUBRICATION; Have the engine crankcase properly serviced with; Any attempt to crank or start the engine before; SUPPLY; The generator engine releases DEADLY carbon; Never sleep in the vehicle while the genset is; STARTING THE GENERATOR; Read the vehicle manufacturer’s instructions.
7 Section 2 – Operation Recreational Vehicle Generator 2.1.4 MAIN BREAKER The main breaker protects the generator’s AC out-put circuit against overload and provides a method of turning OFF the generator’s 120-volt AC output to the vehicle circuits. This generator has a 30-amp breaker. 2.2 OPTIONAL R...
Page 10 - If the engine does not start after it has been; STOPPING THE GENERATOR
8 Section 2 – Operation Recreational Vehicle Generator To start the generator from either the generator con-trol panel or from the optional remote panel, proceed as follows: 1. Turn OFF electrical loads using the means pro- vided in the vehicle (such as a main line circuit breaker or transfer switch...
Page 11 - Figure 2.2 – Low Oil Pressure and; BOOST; Figure 2.3 – Field Boost Circuit; ADDITIONAL INFORMATION; • Run the unit at varying electrical loads to help seat
9 Section 2 – Operation Recreational Vehicle Generator 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 284º F (140º C), initiating an engine shutdown. Fi...
Page 12 - Oil Dipstick/Oil Fill; Section 3 – Maintenance
10 2.9.2 25-HOUR CHECK-UP After the 25-hour break-in period, contact an Authorized Service Dealer for the following main-tenance. The vehicle owner is responsible for any charges: • Change the engine crankcase oil and oil filter.• Check the oil level.• Inspect the cooling and ventilation openings.• ...
Page 13 - Never operate the engine with the oil level; CHANGING THE ENGINE OIL; engine oil; MAINTAINING THE ENGINE; Figure 3.2 – Engine Air Cleaner
11 Section 3 – Maintenance Recreational Vehicle Generator 4. If necessary, remove the oil fill cap on the rocker cover and slowly add oil until it reaches the dip-stick “Full” mark. DO NOT FILL ABOVE THE “FULL” MARK. Never operate the engine with the oil level below the “Add” mark on the dipstick....
Page 14 - CLEAN AIR INTAKE; Figure 3.3 – Cleaning Air Intake; CHECKING THE ENGINE; Sparking can occur if the wire terminal does not; Figure 3.4 – Setting the Spark Plug Gap; CLEAN SPARK ARRESTOR; Clean and inspect the spark arrestor as follows:
12 Section 3 – Maintenance Recreational Vehicle Generator 3.3.2 CLEANING OR REPLACING THE PAPER FILTER Once each year or every 100 hours of operation (whichever comes first), clean or replace the paper filter. The new replacement filter must be flame retardant. Service the paper filter more frequent...
Page 15 - CLEANING THE GENERATOR; • Inspect the battery posts and cables for tightness
Section 3 – Maintenance Recreational Vehicle Generator Figure 3.5 - Spark Arrestor RETAINING SCREW P/N 056892 SPARK ARRRESTOR SCREEN P/N 089680 TAILPIPE P/N 0E0683 3.7 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dirt, corrosive...
Page 16 - MAJOR SERVICE MANUAL; Figure 3.6 — Adjusting Valve Clearance
14 • 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) o...
Page 17 - When valve clearance is correct, hold the pivot; Figure 3.7 — Tightening Jam Nut
15 2. When valve clearance is correct, hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut with a crows foot. Tighten the jam nut to 65-85 inch-pounds torque. After tightening the jam nut, recheck valve clearance to make sure it did not change (Figure 3.7). Figure 3.7 —...
Page 18 - Section 4 – Notes
16 Section 4 – Notes Recreational Vehicle Generator
Page 19 - ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
PART II – INSTALLATION INSTRUCTIONS DANGER ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!!
Page 20 - NOTICE TO INSTALLER; Installation Instructions; Despite the safe design of this generator,
18 NOTICE TO INSTALLER These Installation Instructions have been published by the manufacturer to aid in the installation of the products described in this manual. The manufac-turer assumes that installation personnel are familiar with the procedures for installing such products, or similar products...
Page 22 - Figure 1.1 – 120-volt Single Voltage Connection
20 1.1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to all information and instructions in the ...
Page 24 - LOCATION AND SUPPORT; LOCATION; Figure 2.1 – Typical Horizontal Support Frame; RESTRAINT; Figure 2.2 – Typical Generator Restraint; Section 2 – Installation
22 2.1 LOCATION AND SUPPORT 2.1.1 GENERATOR LOCATION The most desirable location for the generator set is between the vehicle's main frame members. However, this is seldom possible. Most units must be installed on the side of the vehicle and are difficult to rein-force. Many recreational vehicles ha...
Page 25 - GENERATOR COMPARTMENTS; SIZE; Figure 2.3 – Clearances; CONSTRUCTION; Figure 2.4 – Typical Compartment Construction
23 2.2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compartment that the installer constructs, the compartment must meet certain spec-ifications as outlined in the following sections: 2.2.1 COMPART...
Page 26 - Figure 2.5 – Types of Lock Seams; Do not install any flammable material directly; Do not install sound insulation or any absorbent; To prevent fire or explosion, do not install any; Figure 2.6 – Typical Noise Abatement; FLOOR
24 Figure 2.5 – Types of Lock Seams DANGER Do not install any flammable material directly above or around the compartment. Heat, trans-ferred through the compartment structure, may be sufficient to ignite, char or discolor seat cush-ions, fiberboard and other flammable materials. Use approved nonf...
Page 28 - Fuel lines and exhaust piping must not pen-; COOLING AND VENTILATING AIR; Never use discharged cooling air for heating or; AIRFLOW; Figure 2.8 – Airflow Through Engine/Generator; LP GAS FUEL SYSTEM; LP gas is highly EXPLOSIVE. The gas is heavier; Use only approved components in the fuel sup-
26 DANGER Fuel lines and exhaust piping must not pen- etrate into the vehicle living area. 2.3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. Without sufficient airflow, the engine...
Page 29 - Figure 2.9 – Typical Propane Gas Fuel System; WITHDRAWAL; Figure 2.10 – LP Gas Carburetion Diagram
27 Figure 2.9 – Typical Propane Gas Fuel System 2.4.2 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system, consider seriously the following items: • All fittings, lines, hoses and clamps must be tight and free of leaks. Apply a pipe sealant to threads when assembling threaded connections....
Page 30 - Gaseous fuel lines between the tank and the; The generator engine gives off DEADLY carbon
28 The greater the airflow through the carburetor ven-turi, the lower the pressure at the venturi throat. The lower the pressure at the venturi throat, the greater the diaphragm movement, and the greater the move-ment of the regulator valve. The more the regulator valve opens, the greater the gas fl...
Page 31 - ARRESTOR; Figure 2.12 — Spark Arrestor Installation; SYSTEM SAFETY; ELECTRICAL CONNECTIONS
29 2.5.1 SPARK ARRESTOR This spark arrestor assembly meets code and stan-dard requirements of the U.S. Forest Service. Use only mufflers and parts approved by the manufactur-er. Any person(s) installing an unapproved muffler, or an unapproved exhaust system part, or modifying an exhaust system in an...
Page 32 - Figure 2.13 – Generator AC Output Leads; Do NOT connect electrical loads in excess of any
30 • Wiring must be of adequate size, have approved insulative qualities and be properly supported. • Conduit and wire openings into the generator com- partment (if used) must be vapor-sealed to prevent entry of flammable, explosive or poisonous gases into the vehicle. 2.6.1 ELECTRICAL JUNCTION BOX ...
Page 33 - Figure 2.14 – Transfer Switch Isolation Method
31 Section 2 – Installation Recreational Vehicle Generator Figure 2.14 – Transfer Switch Isolation Method Figure 2.15 – Installation With Isolation Receptacle
Page 34 - BATTERY INSTALLATION; BATTERY; Figure 2.16 – Connecting Battery Cables; COMPARTMENT; OPTIONAL ACCESSORIES; CABLE
32 2.6.6 POWER SUPPLY CORD The power supply cord must comply with all appli-cable codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected. 2.6.7 GROUND FAULT CIRCUITINTERRUPTERS The National Electrical Code (NFPA 70, 551-7) requires that a ...
Page 35 - Section 3 – Post-installation Start-up Adjustments; Figure 2.17 – Remote Panel Plug-in Receptacle; FUNCTION; Figure 2.18 – Optional Remote Panel; POST INSTALLATION TESTS; Do not make any unnecessary adjustments.; Check the fuel supply. Gas fuel lines must have; If a liquid propane (LP) gas fuel system has been; Turn off all electrical loads. Do this by setting the
33 Section 3 – Post-installation Start-up Adjustments Recreational Vehicle Generator Figure 2.17 – Remote Panel Plug-in Receptacle 12.00" 14 0 17 15 18 14A 1 3 2 5 4 6 0 14 17 18 14A 15 1517 14A 18 14 0 No. WIRE WIRE COLOR RED YELLOW ORANGE WHITE BLUE BROWN 12.0 (305) LENGTH (mm) 12.0 (305)12.0 ...
Page 36 - TESTING UNDER LOAD
34 6. Turn off all electrical loads by setting the gener- ator’s main circuit breakers to their “OFF” (or open) position. 7. Let the unit run at no-load for a few minutes to stabilize internal engine/generator temperatures. Then, shut down the engine. NOTE: The generator set was thoroughly tested an...
Page 37 - INSTALLATION CHECKLIST
35 Section 3 – Post-installation Start-up Adjustments Recreational Vehicle Generator 3.5 INSTALLATION CHECKLIST LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GENERATOR COMPARTMENT ❑ Compartment construction is proper. ❑ H...
Page 38 - TROUBLESHOOTING GUIDE; Problem Cause; Section 4 – Troubleshooting
36 TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace battery cables as necessary. 3. Defective engine Start/Stop 3. Replace Start/Stop switch. switch 4. Defective starter contactor 4. ...
Page 39 - Section 5 – Notes
37 Section 5 – Notes Recreational Vehicle Generator
Page 40 - Section 6 — Electrical Data
RED BLUE ORANGE BR O W N 7 7 YELLO W WHITE 15 BATTERY CHARGE WINDING NEUTRAL CONNECTION GREEN BY CU S TOMER WHITE T2 FIELD 120V 30A 44 0F 0N 0K 22P DPE WINDING 2 CB3 6 ELECTRONIC REGULATOR VOLTAGE 2A 0N 0N R1 POWER WINDING 22 S 11 S 77 55 BLACK FUEL PRIME 11P 4 4 T1 4 CB1 REMOTE PANEL(OPTIONAL) 33 4...
Page 42 - Section 7 — Exploded Views and Parts Lists
40 Section 7 — Exploded Views and Parts Lists Recreational Vehicle GeneratorEnclosure – Drawing No. 0F4589-B
Page 45 - ITEM PART
43 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generator Generator – Drawing No. 0F4590-C ITEM PART NO. QTY. DESCRIPTION 1 029092 1 S CREW IHHC 5/16”-24 X 11-1/4” G5 2 022129 22 WA S HER LOCK M8-5/16” 3 049451 1 WA S HER FLAT .406” I.D. X 1.62” O.D. 4 0C8096A 1 FAN, 8" CURVE ...
Page 54 - CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT
52 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 S...
Page 55 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:; Section 8 – Warranty
53 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/de...
Page 56 - GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY
Part No. 0F4594 Revision D (10/22/07) Printed in U.S.A. Section 8 – Warranty Recreational Vehicle Generator GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a ...
Generac 005793-3
User Manual
Generac 5943-3
User Manual
Generac XG8000E-5747-0
User Manual
Generac GP5500-5939-5
User Manual
Generac 005939-2
User Manual
Generac XG4000-5778-1
User Manual
Generac 005939-6
User Manual
Generac GP6500-5940-0
User Manual
Generac XG7000E-5798-2
User Manual
Generac 006673-0
User Manual
Generac 5939-6
User Manual
Generac 006230-0
User Manual