Generac 005852-0 - Manuals - manualsarea.com

Page 2 - Table of Contents

Part – Owner’s Manual Introduction ............................................................................. 1 Read This Manual Thoroughly ......................................................... 1 Contents ...........................................................................................

Page 3 - INTRODUCTION; READ T HIS MANUAL THOROUGHLY; Notes contain additional information important to a procedure; C ONTENTS; AUTHORIZED SERVICE; Introduction

INTRODUCTION Thank you for purchasing this model by Generac Power Systems Inc. This model is designed and manufactured to supply electrical power for recreational vehicles. READ T HIS MANUAL THOROUGHLY If any portion of this manual is not understood, contact the near- est Authorized Service Dealer f...

Page 4 - GENERAL HAZARDS; Safety Rules

2 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 fail...

Page 5 - CALIFORNIA PROPOSITION 65 WARNING

3 ELECTRICAL 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 op...

Page 6 - GENERATOR IDENTIFICATION; General Information

4 1. Generator Air Intake 2. Engine Star t/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. Star ter Contactor 9. Fuel Inlet 10. Fuel Pump (Behind Access Panel) 11. Fuel Filter (Side View) 12. Oil...

Page 7 - Figure 1.1 – Connections for 120 Volts Only; SPECIFICATIONS; REQUIREMENTS

5 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 per taining to its application, con...

Page 8 - CONSUMPTION; Model

6 n The 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, and it must be removed from the generator during storage. Do NOT use any gasoline containing methanol. If u...

Page 9 - GENERATOR CONTROL PANEL; Figure 2.1 – Generator Control Panel; PRIMER; AUTOMATIC CHOKE; SOLENOID; BEFORE STARTING THE; Instructions and information in this manual assume the genera-; LUBRICATION; Operation

7 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 Resou...

Page 10 - SUPPLY; STARTING THE GENERATOR

8 n Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in an engine failure. 2.4.3 FUEL SUPPLY The engine must have an adequate supply of proper fuel to oper- ate. Before star ting it, check that sufficient fuel is available. NOTE: Depen...

Page 11 - PROTECTION SYSTEMS; Figure 2.2 – Low Oil Pressure and; BOOST; Figure 2.3 – Field Boost Circuit; PROTECTION

9 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.If electrical loads are applied at reduced operating speeds, such loa...

Page 12 - Figure 2.4 – Solid State Voltage Regulator; ADDITIONAL INFORMATION; ATTENTION REQUIRED AFTER SUBMERSION; Never operate the engine with the oil level; Maintenance

10 Figure 2.4 – Solid State Voltage Regulator The voltage regulator also incorporates a “voltage surge protection circuit.” This circuit prevents troublesome surges in the generator AC output voltage. Voltage surge is a common cause of damage to electronic equipment. 2.10 ADDITIONAL INFORMATION 2.10...

Page 13 - Check the oil level and fill to the “FULL” mark after checking for; Figure 3.2 – Engine Air Cleaner; CLEANING OR REPLACING THE PAPER FILTER; Oil Dipstick/Oil Fill; Figure 3.1 – Oil Maintenance Features

11 9. Install and tighten the oil fill cap and the dipstick before oper- ating the engine. 10. Star t the engine and check for leaks. NOTE: Check the oil level and fill to the “FULL” mark after checking for leaks. The filter will retain some oil. 3.3 MAINTAINING THE ENGINE AIR CLEANER 3.3.1 CLEANING...

Page 14 - CLEAN AIR INTAKE; Figure 3.3 – Cleaning Air Intake; CHECKING THE ENGINE; Figure 3.4 – Setting the Spark Plug Gap; Sparking can occur if the wire terminal does; Figure 3.5 – Fuel Filter; CLEAN SPARK ARRESTOR; If using the generator on any forest-covered, brush-covered or

12 3.4 CLEAN AIR INTAKE Clean all foreign material from the air intake (Figure 3.3) at least once every 100 hours of operation. Clean more often if neces- sary.Inspect the area around the generator exhaust muffler periodically and remove all grass, leaves, dir t, etc., from this area. Figure 3.3 – C...

Page 15 - CLEANING THE GENERATOR; Servicing of the battery is to be performed or supervised by

Figure 3.6 - Spark Arrestor RETAINING SCREW P/N 056892 SPARK ARRRESTOR SCREEN P/N 089680 TAILPIPE P/N 0E0683 3.8 CLEANING THE GENERATOR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dir t, corrosive vapors, road splash, etc. Permitting dir t and moistu...

Page 16 - Using a fuel additive such as STA-BIL fuel stabilizer, or an; ADJUSTING VALVE; Figure 3.7 — 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 - Figure 3.8 — Tightening Jam Nut; RV GENERATOR SERVICE

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 3.8). Figure 3.8 —...

Page 18 - Notes

Page 19 - ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

PART II – INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

Page 20 - NOTICE TO INSTALLER; Installation Instructions

18 NOTICE TO INSTALLER These Installation Instructions have been published by the manu- facturer to aid in the installation of the products described in this manual. The manufacturer assumes that installation personnel are familiar with the procedures for installing such products, or similar product...

Page 22 - Figure 1.1 – 120-volt Single Voltage Connection; Do NOT connect loads in excess of circuit breaker ratings.

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 seri- ous consideration to all information and instructions in th...

Page 24 - LOCATION AND SUPPORT; LOCATION; Figure 2.1 – Typical Horizontal Support Frame; MOUNTING; Figure 2.2 – Typical Suspended Mounting System; RESTRAINT; 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 reinforce.Many recreational vehicles have...

Page 25 - Figure 2.3 – Typical Generator Restraint; GENERATOR COMPARTMENTS; SIZE; Figure 2.4 – Clearances; CONSTRUCTION; Figure 2.5 – Typical Compartment Construction

23 Figure 2.3 – Typical Generator Restraint 2.2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compar tment specifically manufactured to house a generator or inside a com- par tment that the installer constructs, the compar tment must meet cer tain specifications as out...

Page 26 - Figure 2.6 – Types of Lock Seams; Any method used to reduce noise must not adversely affect the; Figure 2.7 – Typical Noise Abatement

24 Figure 2.6 – Types of Lock Seams After the compar tment has been metal lined and vapor • sealed, line the compar tment interior walls and ceiling with an approved, nonflammable sound insulating material (see "Sound Insulating Materials").  Do not install any flammable material directly ...

Page 28 - AIRFLOW; Figure 2.9 – Airflow Through Engine/Generator; GASOLINE FUEL SYSTEM; Figure 2.10 – Generator Fuel System

26 n 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/genera...

Page 29 - TANK; EXHAUST SYSTEM; ARRESTOR

27 2.4.1 FUEL TANK Either the generator must share the vehicle engine's fuel tank, or install a separate fuel tank for the generator set. All fuel tanks installed on the vehicle must be constructed, installed and restrained so they comply with applicable codes, standards and regulations.If the gener...

Page 30 - Figure 2.12 — Spark Arrestor Installation; ELECTRICAL CONNECTIONS

28 Figure 2.11 - Spark Arrestor RETAINING SCREW P/N 056892 SPARK ARRRESTOR SCREEN P/N 089680 TAILPIPE P/N 0E0683 Figure 2.12 — Spark Arrestor Installation 40 [1.58"] 5.5 [7/32"] DRILLBOTTOM SIDE ONLY 27.4 [1.08"] I.D. 2.5.2 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches ...

Page 31 - Figure 2.13 – Generator AC Output Leads; BATTERY INSTALLATION; BATTERY; If the battery is to be used to power other vehicle accessories,

29 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 ...

Page 33 - CABLES; CABLE LENGTH; Figure 2.16 – Connecting Battery Cables; COMPARTMENT; OPTIONAL ACCESSORIES; Figure 2.17 – Remote Panel Plug-in Receptacle

31 2.7.2 BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage, which causes star ting problems. For the best cold weather star ting, the voltage drop between battery terminals and the generator connection point should not exceed 0.12 volts per 10...

Page 34 - Post Installation Start-up Adjustments

32 3.1 POST INSTALLATION TESTS The air-cooled generator set was factory tested and adjusted. It should not be required to adjust the unit any fur ther except under special circumstances. n Do not make any unnecessary adjustments. Factory settings are correct for most appli- cations. When making adju...

Page 35 - INSTALLATION CHECKLIST; DATE OF INSTALLATION

33 3.5 INSTALLATION CHECKLIST LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly suppor ted. ❑ Generator is properly restrained. GENERATOR COMPARTMENT ❑ Compar tment construction is proper. ❑ Holes/Openings are vapor-sealed. ❑ Compar tment size is correct. ❑ Compar tment i...

Page 36 - TROUBLESHOOTING GUIDE; Problem Cause; Troubleshooting

TROUBLESHOOTING GUIDE Problem Cause Correction The engine will not crank. 1. Fuse blown 1. Replace fuse. 2. Loose, corroded or defective 2. Tighten, clean or replace as necessary. battery cables. 3. Defective engine Star t/Stop switch 3. Replace Star t/Stop switch. 4. Defective star ter contactor 4....

Page 38 - Electrical Data

RED BLUE ORANGE BR O W N 7 7 YELLO W WHITE 15 BATTERY CHARGE WINDING NEUTRAL CONNECTION GREEN BY CUSTOMER WHITE T2 FIELD 120V 30A 44 0F 0N 0K 22P DPE WINDING 2 CB3 6 ELECTRONIC REGULATOR VOLTAGE 2A 0N 0N R1 POWER WINDING 22S 11S 77 55 BLACK FUEL PRIME 11P 4 4 T1 4 CB1 REMOTE PANEL(OPTIONAL) 33 4 66 ...

Page 39 - Electrical

37 0 CONN. 2 PIN# 0 90 14 14 CH 18A 90 85 LOP CS 0 18 RED 18 85 17 18A 85 PCB J1-7 J1-9 J1-12 J1-11 J1-10 J1-8 J1-15 J1-14 J1-13 J1-2 J1-5 J1-4 J1-3 J1-1 J2 J1-6 J3 18 1 FS 14 2 3 18 18A 18 CONN. 1 PIN# 0 0 FP 90 14 2 1 2A 2 17 18 4 16 CB3 66 0 56 14 15 90 0 90 16 56 IM1 18A HTO SP1 85 13 14A 15 18 ...

Page 40 - Exploded Views & Parts Lists

38 Exploded Views & Parts Lists Enclosure Drawing No. 0D8352-N

Page 50 - CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT; YOUR WARRANTY RIGHTS AND OBLIGATIONS; ATTENTION WARRANTY DEPARTMENT; Warranty

48 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 51 - EMISSION CONTROL SYSTEM WARRANTY; EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

49 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equip- ment is purchased by/...

Page 52 - GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY; WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS

Part No. 0D8351 Revision AA (06/02/10) Printed in U.S.A. Warranty GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE GENERATORS PURCHASED IN THE U.S.A. AND CANADA NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (thr...