Owner's Manual and
Installation Instructions
Air-cooled Recreational Vehicle Generators
• Model: 05754-0
PRIMEPACT 50
• Model: 04164-3
PRIMEPACT 50LP
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Table of Contents
Recreational Vehicle Generator
Part I – Owner’s Manual
Part II – Installation Instructions
Safety Rules .............................................................18
Notice to Installer...............................................................................18
Section 1 – General Information .............................20
Introduction .................................. Inside Front Cover
Read This Manual Thoroughly.......................................................IFC
Contents.......................................................................................IFC
Operation and Maintenance...........................................................IFC
How to Obtain Service ..................................................................IFC
Authorized Service Dealer Locator Number....................................IFC
Safety Rules ...............................................................2
Section 1 – General Information ...............................4
1.1
1.2
1.3
1.4
1.5
1.6
Purpose and Scope of the Manual..........................................20
Safety....................................................................................20
Standards Booklets................................................................20
Equipment Description ...........................................................20
Generator Engine Operating Speed .........................................20
Generator AC Connection System ..........................................20
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
Generator Identification ............................................................4
Generator Applicability .............................................................5
Safety......................................................................................5
Generator AC Connection System ............................................5
Specifications ..........................................................................5
Evaporative Emissions Information...........................................7
Exhaust Emissions Information (Gasoline)................................7
Exhaust Emissions Information (Propane) ................................7
Section 2 – Installation ............................................22
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Location and Support.............................................................22
Generator Compartments.......................................................23
Cooling and Ventilating Air......................................................25
Gasoline Fuel System.............................................................27
LP Gas Fuel System...............................................................28
Exhaust System .....................................................................30
Electrical Connections............................................................31
Battery Installation .................................................................32
Optional Accessories .............................................................34
Section 2 – Operation ................................................8
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Generator Control Panel ...........................................................8
Optional Remote Start/Stop Panel.............................................8
Automatic Choke (Gasoline Only).............................................8
Before Starting the Engine........................................................9
Starting the Generator..............................................................9
Stopping the Generator ..........................................................10
Applying Loads to Generator..................................................10
Summer/Winter Heat Riser System ........................................10
Protection Systems................................................................11
Section 3 – Post-installation Start-up
Adjustments..........................................34
3.1
3.2
3.3
3.4
3.5
Post Installation Tests.............................................................34
Before Initial Start-up .............................................................34
Initial Start .............................................................................34
Testing Under Load ................................................................35
Installation Checklist ..............................................................36
Section 4 – Troubleshooting....................................37
Troubleshooting Guide........................................................................37
Section 5 – Electrical Data.......................................38
Section 6 – Exploded Views and Parts Lists ..........40
Section 7 – Notes.....................................................54
Section 8 – Warranty................................................56
2.10 Additional Information ............................................................12
Section 3 – Maintenance..........................................12
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Checking the Engine Oil Level.................................................12
Changing the Engine Oil and/or Oil Filter.................................12
Maintaining the Engine Air Cleaner .........................................13
Clean Air Intake......................................................................13
Checking the Engine Spark Plug.............................................14
Fuel Filter (Gasoline Only).......................................................14
Spark Arrestor Muffler............................................................14
Cleaning the Generator...........................................................14
Battery Maintenance ..............................................................15
3.10 Major Service Manual ............................................................15
3.11 Drive Belt...............................................................................15
3.12 Exercising the Generator ........................................................15
3.13 Out of Service Procedure .......................................................16
1
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Safety Rules
Recreational Vehicle Generator
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be copied and posted in
potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of
this equipment.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
WARNING:
The engine exhaust from this product contains
chemicals known to the state of California to cause
cancer, birth defects or other reproductive harm.
Generator exhaust gases contain DEADLY
carbon monoxide gas. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death.
WARNING:
This product contains or emits chemicals
known to the state of California to cause
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.
cancer, birth defects or other reproductive harm.
• 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.
• When working on this equipment, remain alert at all times.
Never work on the equipment when physically or mentally
fatigued.
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.
• Inspect the generator regularly, and contact the nearest
Authorized Service Dealer immediately for parts needing repair
or replacement.
• Inspect the generator regularly, and contact the nearest
Authorized Service Dealer immediately for parts needing repair
or replacement.
• 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.
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.
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.
ENGINE EXHAUST HAZARDS
• Generator engine exhaust contains DEADLY carbon monox-
ide, an odorless, colorless poisonous gas. Breathing carbon
monoxide can cause: dizziness, throbbing temples, nausea,
muscular twitching, headache, vomiting, weakness and sleepi-
ness, inability to think clearly, fainting, unconsciousness or
even death. If you experience any carbon monoxide poisoning
symptoms, move into fresh air and immediately seek medical
attention.
DANGER
Despite 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.
• Never operate the generator set with the vehicle inside any
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
garage or other enclosed area.
render the machine safe before attempting to
work on the generator.
2
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Safety Rules
Recreational Vehicle Generator
• Adequate, unobstructed flow of cooling and ventilating air
is critical for expelling toxic carbon monoxide gas and fuel
vapors from the generator compartment and for proper genera-
tor operation. Without sufficient cooling airflow, deadly carbon
monoxide gas can accumulate and the engine/generator may
quickly overheat, causing serious damage to the generator. Do
not operate the genset in any confined space.
• 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.
FIRE HAZARDS
• The exhaust system must be installed in accordance with the
genset installation manual. Do not alter the installation or permit
even partial blockage of ventilation systems, as this can seri-
ously affect the safe and proper operation of the generator.
• Do not operate the generator if the exhaust system is leaking or
has been damaged or if you have experienced carbon monoxide
poisoning symptoms during use. Shut down the generator and
do not operate it until it has been inspected and/or repaired.
• Never sleep in the vehicle while the genset is running unless the
vehicle has a working carbon monoxide detector.
• 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.
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 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.
• 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.
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.
• 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.
• 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.
3
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Section 1 – General Information
Recreational Vehicle Generator
1.1 GENERATOR IDENTIFICATION
Please record the following information from the generator DATA DECAL or information decal.
1. Model Number _____________________
3. kW Rating _________________________
2. Serial Number__________________
4. Rated Voltage __________________
Model: 05754-0
1. Generator Air Intake
2. Engine Start/Stop Switch
3. Fuse
4. Optional Remote Panel Receptacle
(behind control panel)
5. Generator AC Output Leads (behind
control panel)
6. Fuel Primer Switch
7. Circuit Breaker
18
8. Circuit Breaker
9. Starter Contactor
10. Fuel Inlet
11. Fuel Pump
19
12. Fuel Filter
13. Oil Filter
14. Oil Drain Cap
15. Oil Dipstick
16. Data Decal
17. Oil Fill
18. Spark Plug
19. External Vacuum Port
Model: 04164-3
1. Generator Air Intake
2. Engine Start/Stop Switch
3. Fuse
4. Optional Remote Panel Receptacle
(behind
control panel)
5. Generator AC Output Leads (behind
control panel)
6. Fuel Primer Switch
7. Circuit Breaker
8. Circuit Breaker
9. Starter Contactor
10. Fuel Solenoid
11. Demand Regulator
12. Oil Filter
17
13. Oil Drain Cap
14. Oil Dipstick
15. Data Decal
16. Oil Fill
17. Spark Plug
4
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Section 1 – General Information
Recreational Vehicle Generator
1.2 GENERATOR APPLICABILITY
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 application,
write or call the factory. Do not use the unit until advised by a
competent authority.
1.4 GENERATOR AC
CONNECTION SYSTEM
This generator set is equipped with dual stator AC power windings.
These two-stator windings supply electrical power to customer
electrical loads by means of a dual two-wire connection system.
Note, however, that the neutral is grounded.
The generator may have been installed so that it powers 120-volt
AC loads (Figure 1.1). It can be wired to connect both 120- and/or
240-volt AC electrical loads. This procedure should be done by an
Authorized Service Dealer or other qualified installer.
DANGER
For fire safety, the generator must have been
properly installed in compliance with ANSI
119.2-1975/NFPA 501C-1974, “Standard for
Recreational Vehicles, Part III – Installation of
Electrical Systems.” The generator also must
have been installed in strict compliance with the
manufacturer’s detailed installation instructions.
After installation, do nothing that might render
the unit in noncompliance with such codes, stan-
dards and instructions.
Figure 1.1 – Connections for 120 Volts Only
Use this generator to supply electrical power for operating
120/240-volt, single-phase, 60 Hertz, AC electrical loads. These
loads can require up to 4,800 watts (4.8 kW) of power, but cannot
exceed 40 AC amperes of current at 120 volts, or 20 AC amperes
at 240 volts for model 05754-0. For model 04164-3, the loads can
require up to 4,500 watts (4.5 kW) of power, but cannot exceed
37.5 amperes of current at 120 volts, or 18.8 amperes at 240
volts.
1.5 SPECIFICATIONS
1.5.1 FUEL REQUIREMENTS
This generator is equipped with a gasoline fuel system. Depending
on the installation, the generator may have either a separate fuel
tank, or it may “share” the vehicle engine’s fuel tank.
Do not overload the generator. Some installations
may require that electrical loads be alternated
to avoid overloading. Applying excessively high
electrical loads may damage the generator and
may shorten its life. Add up the rated watts of
all electrical lighting, appliance, tool and motor
loads the generator will power at one time. This
total should not be greater than the wattage
capacity of the generator. If an electrical device
nameplate gives only volts and amps, multiply
volts times amps to obtain watts (volts x amps =
watts). Some electric motors require more watts
of power (or amps of current) for starting than
for continuous operation.
NOTE:
Some installations using a “shared” fuel tank may have a 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.
NOTE:
1.3 SAFETY
Before attempting to use the generator set, carefully read the
“Safety Rules” section of this manual. Comply strictly with these
rules to prevent accidents and damage to equipment and/or
property. We suggest copying and posting the “Safety Rules” in
potential hazard areas of the vehicle. Stress safety to all operators
and potential operators of this equipment.
Using unleaded gasoline contributes to longer engine valve life
by reducing lead and carbon deposits.
5
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Section 1 – General Information
Recreational Vehicle Generator
1.5.5 ENGINE
Type of Engine ............................................................GN-410, Single-cylinder
Cooling Method ................................................................................Air-cooled
Rated Horsepower................................................................15 @ 4,200 rpm
Displacement......................................................................................... 407cc
Cylinder Block....................................................Aluminum w/Cast Iron Sleeve
Type of Governor ...................................................... Mechanical, Fixed Speed
Air Cleaner ................................................. Paper Element w/Foam Precleaner
Starter.................................................................................12-volt DC Electric
Ignition System..............................................Solid-state w/Flywheel Magneto
Recommended Spark Plug
The manufacturer does not recommend using
any gasoline containing alcohol (such as “gaso-
hol”). If using any gasoline containing alcohol, it
must not contain more than 10 percent ethanol,
and it must be removed from the generator dur-
ing storage. Do NOT use any gasoline contain-
ing methanol. If using gasoline with alcohol,
inspect more frequently for fuel leaks and other
abnormalities.
Champion......................................................................................... RC14YC
AC..........................................................................................................R45S
Fram Autolite.............................................................................................. 65
Spark Plug Gap................................................................0.030 inch (76 mm)
Recommended Minimum Battery....................................... 400 Cold-cranking
Amperes
1.5.2 OPTIONAL PROPANE FUEL SYSTEM
This generator is equipped with a liquid propane (LP) gas fuel sys-
tem. LP gas is usually supplied as a liquid in pressure tanks.
The generator requires a vapor withdrawal type fuel system. This
type of gaseous fuel system uses the vapors forming above the liq-
uid fuel in the storage tank. Air temperature around the storage tank
must be high enough to sustain adequate fuel vaporization. In colder
climates, it may be necessary to use an independent heat source to
be sure the fuel sufficiently vaporizes in the storage tank.
ClassII Emission Compliant
1.5.6 GENERATOR
Rated Maximum Continuous
AC Output (Gasoline)...................................................4,800 Watts (4.8 kW)
AC Output (LP Fuel).....................................................4,500 Watts (4.5 kW)
Rated Voltage.............................................................................120 Volts AC*
Rated Maximum Continuous
LP gas may consist of propane, butane or a mixture of the two
gases. Propane vaporizes at temperatures as low as -20° F (-29°
C), but butane returns to its liquid state when the temperature
drops below about 32° F (0° C). For that reason, a higher ratio
of propane is desired in the gas mixture when temperatures drop
below freezing.
AC Current (Gasoline).............................................................40 Amperes**
AC Current (LP Fuel)............................................................37.5 Amperes**
Phase......................................................................................................Single
Rotor RPM.............................................................................................. 3,600
Number of Rotor Poles...................................................................................2
Engine RPM............................................................................................ 2,571
Rated AC Frequency............................................................................... 60 Hz
Battery Charge Voltage ..................................................................14 Volts DC
Battery Charge Current .........................................................2 Amperes (max)
1.5.3 FUEL CONSUMPTION
Model
05754-0
No Load
0.32
1/2 Load
0.46
Full Load
0.76
04164-3
0.47/17.05
0.72/3.06
1.25/45.35
Gasoline is in gal/h.
LP is in gal/h and cf/h.
Weight
Gasoline...................................................................................... 198 Pounds
1.5.4 ENGINE OIL REQUIREMENTS
Use only high quality detergent oil rated with American Petroleum
Institute (API) Service Classification SF, SG or SH. The recom-
mended oil weights include the following:
LP Fuel........................................................................................ 200 Pounds
Length.......................................................................... 25.5 inches (648 mm)
Width ......................................................................... 18.88 inches (479 mm)
Height ........................................................................ 16.75 inches (425 mm)
• During summer months: SAE 30. An acceptable substitute is
SAE 10W-30.
* All units are reconnectable to 120- and/or 240-volt, dual voltage output. Units
are no longer listed per RVIA/ANSI when reconnected for dual voltage output.
• During winter months: SAE 5W-30. DO NOT USE SAE
** If reconnected for dual voltage, the ampere rating for 240 volts is 20 AC
amperes for model 05754-0, and 18.8 AC amperes for model 04164-3.
10-W40.
*** 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.
Crankcase and oil filter capacity is approximately 1,400 mL or
1.5 U.S. quarts. Do NOT use special additives. See "Checking the
Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter"
sections for oil level check and fill procedures.
6
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Section 1 – General Information
Recreational Vehicle Generator
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.
1.6 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.
Displacement
Category
Compliance Period
500 Hours
A
B
C
A
B
C
> 66 cc - < 225 cc
250 Hours
125 HOurs
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.
1000 Hours
500 Hours
≥ 225 cc
250 Hours
1.8 EXHAUST EMISSIONS
INFORMATION (PROPANE)
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 propane fuel (LP). The emission
control system on the generator consists of the following:
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-permeation
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.
• Fuel Metering System
~Mixer assembly
~Fuel regulator and lines
• Air Induction System
~Intake pipe / manifold
~Air cleaner
1.7 EXHAUST EMISSIONS
INFORMATION (GASOLINE)
• Ignition System
~Spark plug
~Ignition module
• Catalytic Converter (if equipped)
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.
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:
• 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)
Displacement
Category
Compliance Period
500 Hours
A
B
C
A
B
C
> 66 cc - < 225 cc
250 Hours
125 HOurs
1000 Hours
500 Hours
≥ 225 cc
250 Hours
7
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Section 2 – Operation
Recreational Vehicle Generator
NOTE:
2.1 GENERATOR CONTROL PANEL
The following features are mounted on the generator control panel
(Figure 2.1):
If the generator has been reconnected for dual voltage AC out-
put (120/240 volts), install line breakers having an amperage
rating that is different than that stated in the "Generator AC
Connection System" section. The replacement line breakers
consist of two separate breakers (one 20 amp, and one 30
amp) with a connecting piece between the breaker handles (so
that both breakers will operate at the same time). If the unit is
reconnected for dual voltage, it is no longer RVIA listed.
Figure 2.1 – Generator Control Panel
2.2 OPTIONAL REMOTE
START/STOP PANEL
A remote mounted Start/Stop Panel (Figure 2.2) is available that
allows starting and stopping the generator engine conveniently
from inside the vehicle. The remote panel includes a Start/Stop
switch, hourmeter, generator run lamp and a wire harness. The
Prime switch is not connected, it must be used with jumper wire
0G7666.
Figure 2.2 — Optional Remote Panel
(Models 0H3068)
2.1.1 FUEL PRIMER
Before starting a cold engine (if it has not been started in more
than two weeks), this switch must be pressed for approximately
10 to 15 seconds to bring fuel from the tank to the carburetor.
This rocker type switch springs back into its original position
when released. It is not necessary to press the primer switch for
LP units.
2.1.2 START/STOP SWITCH
To crank and start the engine, hold this switch in the START posi-
tion. Release the switch when the engine starts. To stop an operat-
ing engine, press and hold the switch in the STOP position until the
engine shuts off. The switch center position is the RUN position.
2.3 AUTOMATIC CHOKE (GASOLINE
ONLY)
The engine is equipped with an automatic choke that consists of
two main components: a choke solenoid and prechoke.
2.1.3 FUSE
The fuse protects the engine’s DC control circuit against electrical
overload. If the fuse element has melted open due to overloading,
the engine cannot be cranked. If the fuse must be replaxed, use
only an identical replacement.
2.3.1 CHOKE SOLENOID
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.
2.1.4 MAIN BREAKER
The main breaker protects the generator’s AC output circuit against
overload and provides a method of turning OFF the generator’s
120/240-volt AC output to the vehicle circuits. The generator has
one 20-amp breaker and one 30-amp breaker.
2.3.2 PRECHOKE
The choke system also has a temperature-sensitive metal strip that
adjusts choke valve angle according to ambient temperatures (i.e.,
in cold ambient 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.
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Section 2 – Operation
Recreational Vehicle Generator
2.4 BEFORE STARTING THE ENGINE
DANGER
NOTE:
Generator engine exhaust contains DEADLY
carbon Monoxide, an odorless, colorless poi-
sonous gas. Breathing carbon monoxide can
cause: dizziness, throbbing temples, nausea,
muscular twitching, headache, vomiting, weak-
ness and sleepiness, inability to think clearly,
fainting, unconsciousness or even death. If you
experience any carbon monoxide poisoning
symptoms, move into fresh air and immediately
seek medical attention.
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.
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.
Never operate the generator set with the vehicle
inside any garage or other enclosed area.
NOTE
Be sure the installation complies with all standards and codes
listed in the "Standards Booklets" section of this manual.
Adequate, unobstructed flow of cooling and
ventilating air is critical for expelling toxic car-
bon monoxide gas and fuel vapors from the
generator compartment and for proper genera-
tor operation. Without sufficient cooling airflow,
deadly carbon monoxide gas can accumulate
and the engine/generator may quickly overheat,
causing serious damage to the generator. Do
not operate the genset in any confined space.
2.4.2 ENGINE LUBRICATION
Have the engine crankcase properly serviced with the recom-
mended oil before starting. Refer to the "Engine Oil Requirements"
section and "Checking the Engine Oil Level" and "Changine the
Engine Oil and/or Oil Filter" sections for oil servicing procedures
and recommendations.
The exhaust system must be installed in accor-
dance with the genset installation manual. Do
not alter the installation or permit even partial
blockage of ventilation systems, as this can
seriously affect the safe and proper operation of
the generator.
Any attempt to crank or start the engine before
it hase been properly serviced with the recom-
mended oil may result in an engine failure.
Do not operate the generator if the exhaust sys-
tem is leaking or has been damaged or if you
have experienced carbon monoxide poisoning
symptoms during use. Shut down the generator
and do not operate it until it has been inspected
and/or repaired.
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:
Never sleep in the vehicle while the genset is
running unless the vehicle has a working carbon
monoxide detector.
Depending on the installation, the generator may have either a
separate fuel tank, or it may “share” the vehicle engine’s fuel
tank.
2.5 STARTING THE GENERATOR
2.4.4 COOLING AND VENTILATING AIR
NOTE:
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.
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 cer-
tain DC lighting and other DC loads.
2.4.5 ENGINE EXHAUST GAS
Before starting the generator engine, be sure there is no way for
Before starting the generator engine, inspect for exhaust leaks and
ensure there is no way for exhaust gases to enter the vehicle inte-
rior 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.
To start the generator from either the generator control panel or
from the optional remote panel, proceed as follows:
1. Turn OFF electrical loads using the means provided in the
vehicle (such as a main line circuit breaker or transfer
switch).
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Section 2 – Operation
Recreational Vehicle Generator
NOTE:
2.8 SUMMER/WINTER HEAT
If starting from the generator control panel, turn OFF loads
by setting the generator’s main circuit breaker to the OFF (or
OPEN) position. If starting from a remote panel, turn OFF loads
using the means provided in the vehicle (such as a main circuit
breaker). Electrical load circuits will be turned ON after the
generator has started, stabilized and warmed up.
RISER SYSTEM
Under certain weather conditions, it is possible for ice to form
in the venturi area of the carburetor. This condition can be very
dangerous because it can prevent the governor system from func-
tioning properly, which results in a “runaway” engine.
The most common weather conditions leading to this problem are
temperatures in the range of 25° F to 35° F (-4° C to 1.7° C), along
with high humidity. This ice formation also can be attributed to the
load being applied during these weather conditions. Generators
running with no-load or light loads applied usually have the most
problems.
2. If the engine has not been started in more than two weeks,
press the Fuel Pump Primer switch and hold it for about 10 to
15 seconds to prime the fuel system. However, if the engine
is warm, skip Step 2.
3. Hold the engine Start/Stop switch in the START position to
crank the engine. Release the switch when the engine starts.
The Summer/Winter Lever (Figure 2.3) should be in the WINTER
position for ambient temperatures below 40° F (4.4° C) and in the
SUMMER position for ambient temperatures above 40° F (4.4°
C).
If the engine does not start after it has been
cranking for 15 seconds, release the Start/Stop
switch and try again. Holding the switch for
longer than 15 seconds can damage the starter
motor.
Figure 2.3 – Heat Riser System
4. Let the engine run at no-load for a few minutes to stabilize and
warm up.
5. Turn ON electrical loads using the means provided (such as a
main circuit breaker or transfer switch).
2.6 STOPPING THE GENERATOR
1. Turn OFF all electrical loads using the means provided (such
as a main circuit breaker or transfer switch).
2. Let generator run at no-load for a few minutes, to stabilize inter-
nal engine generator temperatures.
3. Place the Start/Stop switch in its STOP position.
2.7 APPLYING LOADS TO
GENERATOR
When applying electrical loads to the generator, observe these
guidelines:
• Before applying electrical loads, let the generator stabilize and
warm up for a minute or two.
• DO NOT overload the generator.
When the heat riser is in the SUMMER (down) position (Figure
2.2), air is drawn into the air cleaner from the upper intake tube.
2.7.1 LETTING THE ENGINE STABILIZE
When the heat riser is in the WINTER (up) position, air is drawn
from the lower intake tube, which is positioned to draw the heated
air near the exhaust manifold.
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.
To prevent carburetor icing, the owner/operator should physically
position the heat riser to the proper position dependent on the
temperature.
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.
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Section 3 – Maintenance
Recreational Vehicle Generator
2.8.1 DO NOT OVERLOAD THE GENERATOR
2.9.3 FIELD BOOST
Read the rated wattage/amperage capacity of the generator on the
generator data decal (see "Generator Identification").
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 2.5). During engine
cranking only, a positive DC (battery) voltage is delivered through
the diode, resistor, brushes and slip rings, and the generator rotor.
Application of this voltage to the rotor “flashes the field” whenever
it is started. Flashing of the field each time the generator starts
makes sure that a sufficiently strong magnetic field is available to
produce “pickup” voltage in the stator windings.
Applying electrical loads in excess of the unit’s rated capacity will
cause the engine/generator to automatically shut down.
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.
• 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.
Figure 2.5 – Field Boost Circuit
• If a load does not show its rated wattage, multiply that load’s
rated VOLTS times AMPS to obtain WATTS.
• Induction type motors (such as those that run the vehicle’s
furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2
time more watts of power for starting than for running (for a
few seconds 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.
• Do not apply heavy electrical loads for the first two or three
hours of operation.
2.9 PROTECTION SYSTEMS
2.9.
LOW OIL PRESSURE SWITCH
2.9.4 OVERVOLTAGE PROTECTION
This switch (Figure 2.4) has normally closed (N.C.) contacts that
are held open by engine oil pressure during cranking and operating.
Should oil pressure drop below a preset level, switch contacts close,
and the engine automatically shuts down. The unit should not be
restarted until oil is added.
A solid-state voltage regulator (Figure 2.6) 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 120 volts (voltage-to-frequency
ratio is 2-to-1).
2.9.2 HIGH TEMPERATURE SWITCH
This switch (Figure 2.4), which has normally open (N.O.) contacts,
is mounted near the oil filter. The contacts close if the temperature
should exceed approximately 293º F (145º C), initiating an engine
shutdown.
Figure 2.6 – Solid State Voltage Regulator
Figure 2.4 – Low Oil Pressure and
High Temperature Switches
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.
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Section 3 – Maintenance
Recreational Vehicle Generator
2.10 ADDITIONAL INFORMATION
3.1 CHECKING THE ENGINE OIL
LEVEL
2.10.1 ATTENTION REQUIRED AFTER SUBMERSION
For oil capacities and requirements, see section “Engine Oil
Requirements”. Check the engine crankcase oil level at least every
eight hours of operation, or before use. To check the engine oil
level, proceed as follows (see Figure 3.1):
If the recreational vehicle generator has been submerged in water,
it MUST NOT be started and operated. Following any submersion
in water, have an Authorized Service Dealer thoroughly clean and
dry the generator.
1. Be sure the generator is as level as possible.
2. Remove the dipstick and wipe it dry with a clean, lint-free
cloth.
2.10.2 OPERATION IN HIGH GRASS OR BRUSH
Never operate the generator while the vehicle is parked over high
grass, weeds, brush, leaves or any other combustible substance.
Such materials can ignite and burn from the heat of the exhaust
system. The generator exhaust system becomes extremely hot
during operation and remains hot for a long time after it has shut
down.
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 “FULL” MARK.
2.10.3 EFFECTS OF MOISTURE AND DIRT
Never operate the engine with the oil level below
the “Add” mark on the dipstick. Doing this could
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.
damage the engine.
5. Install and tighten the oil fill cap and the dipstick before oper-
ating the engine.
3.2 CHANGING THE ENGINE OIL
AND/OR OIL FILTER
When moisture is allowed to remain in contact with windings,
some of the moisture will be retained in voids and cracks in the
insulation. This causes a reduced insulation resistance and will
eventually cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with windings. Salt (as
from sea air) also will worsen the problem since it tends to absorb
moisture from the air. Salt and moisture, when combined, form a
good electrical conductor.
Hot oil may cause burns. Allow engine to cool
before draining oil. Avoid prolonged or repeated
skin exposure with used oil. Thoroughly wash
exposed areas with soap.
• Change the engine oil after the first 25 hours of operation.
Thereafter, change the oil every 100 operating hours. Change
the oil more frequently if operating consistently under heavy
load or at high ambient temperatures.
Figure 3.1 – Oil Maintenance Features
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Section 3 – Maintenance
Recreational Vehicle Generator
• Change the engine oil filter after the first 25 hours of operation,
and every 100 operating hours thereafter.
8. Install the cover, foam precleaner and paper filter.
9. Tighten the two screws to retain the filter in place.
• To change the oil and/or oil filter, proceed as follows (see Figure
Figure 3.2 – Engine Air Cleaner
3.1):
1. Run the engine until it is thoroughly warmed up (at least five
minutes) then shut OFF the engine.
2. Immediately after the engine shuts OFF, pull the oil drain hose
free of its retaining clip. Remove the cap from the hose and
drain the oil into a suitable container. Loosening the oil fill cap
will allow the crankcase to drain faster.
PAPER
AIR FILTER
FOAM
PRECLEANER
AIR CLEANER
COVER
3. After the oil has drained, replace the cap onto the end of the oil
drain hose. Retain the hose in the clip.
4. With the oil drained, remove the old oil filter by turning it
counterclockwise.
5. Apply a light coating of clean engine oil to the gasket of the
new filter.
SCREWS
6. Screw the new filter on by hand until its gasket lightly contacts
the oil filter adapter. Then, tighten the filter an additional 3/4 to
one turn.
3.3.2 CLEANING OR REPLACING
7. Remove the dipstick and wipe it dry with a clean, lint-free
cloth. This will be used later to check the oil level.
8. Remove the oil fill cap on the rocker cover and slowly add
the proper type and amount of recommended oil (see section
"Engine Oil Requirements"). Periodically use the dipstick to
check the oil level and continue to fill the crankcase until the
oil reaches the dipstick “Full” mark. DO NOT FILL ABOVE THE
“FULL” MARK.
THE PAPER FILTER
Once each year or every 100 hours of operation (whichever comes
first), clean or replace the paper filter. The new replacement filter
must be flame retardant. Service the paper filter more frequently if
operating the generator in extremely dusty or dirty conditions. Use
the following procedure (Figure 3.2):
1. Follow steps 1-3 in the "Cleaning the Foam Precleaner" sec-
tion; service the foam precleaner if necessary.
2. Remove the paper filter.
3. Clean the air filter by tapping it gently on a solid surface. If the
filter is too dirty, replace it with a new one. Dispose of the old
filter properly.
9. Install and tighten the oil fill cap and the dipstick before oper-
ating the engine.
10. Start 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.
4. Clean the air cleaner cover then reassemble following steps
7-9 in the "Cleaning the Foam Precleaner" section.
3.3 MAINTAINING THE ENGINE
AIR CLEANER
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.
3.3.1 CLEANING THE FOAM PRECLEANER
Clean and re-oil the foam precleaner every three months or every
25 hours of operation, whichever occurs first. Service the foam
precleaner more frequently if operating the generator in extremely
dusty or dirty conditions. Use the following procedure (Figure
3.2):
Inspect the area around the generator exhaust muffler periodically
and remove all grass, leaves, dirt, etc., from this area.
Figure 3.3 – Cleaning Air Intake
1. Turn the two screws counterclockwise to loosen.
2. Remove the cover, foam precleaner and paper filter.
3. Remove the foam precleaner from the cover.
4. Wash the foam precleaner in liquid detergent and water.
5. Wrap the foam precleaner in a clean cloth and gently squeeze
it dry.
6. Saturate the foam precleaner in clean engine oil. Gently
squeeze it in a clean cloth to remove excess oil and to distrib-
ute oil (DO NOT TWIST).
7. Install the foam precleaner into the cover, followed by the
paper filter.
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Section 3 – Maintenance
Recreational Vehicle Generator
3.5 CHECKING THE ENGINE
3.7 SPARK ARRESTOR MUFFLER
If the generator is not equipped with a spark arrestor exhaust
muffler and is to be used on any forest covered, brush covered or
grass covered unimproved land, a spark arrestor may need to be
installed. The spark arrestor must be maintained in effective work-
ing order by the vehicle owner/operator.
SPARK PLUG
Clean the spark plug and reset the spark plug gap every 100 hours
of operation.
1. Clean the area around the base of the spark plug to keep dirt
and debris out of the engine. Clean by scraping or washing
using a wire brush and commercial solvent. Do not blast the
spark plug to clean.
For assistance in ordering, installing and maintaining spark arrestor
exhaust mufflers, contact the nearest Authorized Service Dealer.
Exhaust mufflers supplied by the manufacturer are spark arrestor
types. The manufacturer's exhaust mufflers for recreational vehicle
generators do not have a spark arrestor screen, but are of the more
efficient “toroid” or “swirl” type. To remove carbon and combus-
tion deposits from such mufflers, remove the plug from the muffler
and run the engine for approximately 15 minutes. Shut down the
engine, let the muffler cool and install the plug.
2. Remove the spark plug and check the condition. Replace the
spark plug if worn or if reuse is questionable.
3. Check the spark plug gap using a wire feeler gauge. Adjust the
gap to 0.030 inch (0.76 mm) by carefully bending the ground
electrode (Figure 3.4).
Sparking can occur if the wire terminal does not
fit firmly on the spark plug terminal end. If nec-
essary, re-form the wire terminal to obtain a
tight fit.
Be sure to reinstall the muffler plug tightly.
Engine vibration could cause a loose plug to
fall out. Without the plug in place, hot engine
exhaust is directed out the opening. This hot
exhaust, depending on the installation, could
be directed to areas not able to withstand the
extreme heat such as wooden floor boards or
other flammable material. This could result in a
fire.
Figure 3.4 – Setting the Spark Plug Gap
3.8 CLEANING THE GENERATOR
Keep the generator set as clean and dry as possible. Protect the
unit against excessive dust, dirt, corrosive vapors, road splash,
etc. Permitting dirt and moisture to accumulate on generator
windings will have an adverse effect on the insulation resistance
of those windings.
3.6 FUEL FILTER (GASOLINE ONLY)
Remove and replace the fuel filter (Figure 3.5) once each year or
every 100 hours of operation, whichever comes first.
When moisture is allowed to remain in contact with windings,
some of the moisture will be retained in voids and cracks in the
insulation. This causes a reduced insulation resistance and will
eventually cause problems. Dirt will make the problem worse,
since dirt tends to hold moisture in contact with windings. Salt (as
from sea air) also will worsen the problem since it tends to absorb
moisture from the air. Salt and moisture, when combined, form a
good electrical conductor.
Figure 3.5 – Fuel Filter
Fuel Filter
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
interior and cause problems, and may also con-
taminate the generator fuel system.
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Section 3 – Maintenance
Recreational Vehicle Generator
3.9 BATTERY MAINTENANCE
All lead-acid batteries will discharge when not in use. The genera-
tor battery should be inspected as follows:
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
3.9.1 WEEKLY
• Inspect the battery posts and cables for tightness and corro-
sion. Tighten and clean as necessary.
• Check the battery fluid level of unsealed batteries and, if nec-
essary, fill with Distilled Water Only. Do not use tap water in
batteries.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following
procedures are to be observed:
• Wear full eye protection and protective clothing;
• Where electrolyte contacts the skin, wash it off
immediately with water;
• Where electrolyte contacts the eyes, flush
thoroughly and immediately with water and seek
medical attention; and
• Spilled electrolyte is to be washed down with an
acid neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) or water. The bicar-
bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
3.9.2 EVERY SIX MONTHS
• Have the state of charge and condition checked. This should be
done with an automotive-type battery hydrometer.
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.
Damage will result if the battery connections are made in
reverse.
DANGER
Do not dispose of the battery in a fire. The
3.10 MAJOR SERVICE MANUAL
To obtain a service manual for the generator, contact the nearest
to identify the MODEL NUMBER and SERIES.
battery is capable of exploding. Stored batteries
give off explosive hydrogen gas. This gas can
form an explosive mixture around the battery for
several hours after charging. The slightest spark
can ignite the gas and cause an explosion. Such
an explosion can shatter the battery and cause
blindness or other injury. Any area that houses a
storage battery must be properly 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.
3.11 DRIVE BELT
The engine drives the generator rotor by means of a pulley and drive
belt arrangement. The drive belt and pulleys are warranted for the life
of the generator. Drive belt tension was properly adjusted before the
unit was shipped from the factory. If suspecting that the drive belt
tension is incorrect, contact an Authorized Service Dealer.
3.12 EXERCISING THE GENERATOR
The manufacturer recommends starting and operating the genera-
tor at least once every seven days. Let the unit run for at least 30
minutes to “exercise” the engine.
A battery presents a risk of electrical shock
and high short circuit current. The following pre-
cautions are to be observed when working on
batteries:
• Remove watches, rings or other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery;
• Disconnect any charging source prior to connecting
or disconnecting battery terminals; and
• Do not use any jumper cables or booster battery to
crank and start the generator engine. If any battery
has discharged, remove it for recharging.
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Section 3 – Maintenance
Recreational Vehicle Generator
3.13.2 RETURN TO SERVICE
To return the unit to service after storage, proceed as follows:
3.13 OUT OF SERVICE PROCEDURE
3.13.1 REMOVAL FROM SERVICE
If the generator cannot be exercised every seven days, and it is to
be out of service longer than 30 days, prepare the generator for
storage as follows:
1. Check the tag on the engine for oil viscosity and classification.
Verify that the correct recommended oil is used in the engine
(see the "Engine Oil Requirements" section). If necessary,
drain and refill with the proper oil.
2. Check the state of the battery. Fill all cells of unsealed batteries
to the proper level with 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.
1. Start the engine and let it warm up.
2. Close the fuel shutoff valve in the fuel supply line and allow
the unit to shut down.
3. While the engine is still warm from running, drain the oil com-
pletely. Refill the crankcase with SAE 10W-30 oil having API
classification “For Service SF.”
3. Clean and wipe the entire generator.
4. Reconnect the battery. Observe battery polarity. Damage may
occur if the battery is connected incorrectly.
4. Attach a tag to the engine indicating the viscosity and clas-
5. Turn OFF all electrical loads. Add fuel if necessary and then
start the engine.
6. Allow the unit to warm up thoroughly.
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. Apply electrical loads to at least 50 percent of the unit’s rated
wattage capacity.
8. When the engine is thoroughly warmed up, shut it down.
9. The generator is now ready for service.
7. Clean and wipe the entire generator.
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PART II –
INSTALLATION
INSTRUCTIONS
DANGER
ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS
SHOULD ATTEMPT INSTALLATION!
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Safety Rules
Recreational Vehicle Generator
DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strict-
ly 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 com-
ply with the manufacturer’s instructions and recommendations.
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 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.
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.
• 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.
• 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.
• Inspect the generator regularly, and contact the nearest
Authorized Service Dealer immediately for parts needing repair
or replacement.
• 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.
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.
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.
DANGER
ENGINE EXHAUST HAZARDS
Despite the safe design of this generator,
• Generator engine exhaust contains DEADLY carbon monox-
ide, an odorless, colorless poisonous gas. Breathing carbon
monoxide can cause: dizziness, throbbing temples, nausea,
muscular twitching, headache, vomiting, weakness and sleepi-
ness, inability to think clearly, fainting, unconsciousness or
even death. If you experience any carbon monoxide poisoning
symptoms, move into fresh air and immediately seek medical
attention.
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.
• Never operate the generator set with the vehicle inside any
garage or other enclosed area.
• Adequate, unobstructed flow of cooling and ventilating air
is critical for expelling toxic carbon monoxide gas and fuel
vapors from the generator compartment and for proper genera-
tor operation. Without sufficient cooling airflow, deadly carbon
monoxide gas can accumulate and the engine/generator may
quickly overheat, causing serious damage to the generator. Do
not operate the genset in any confined space.
• The exhaust system must be installed in accordance with the
genset installation manual. Do not alter the installation or permit
even partial blockage of ventilation systems, as this can seri-
ously affect the safe and proper operation of the generator.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
Generator exhaust gases contain DEADLY
carbon monoxide gas. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death.
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Safety Rules
Recreational Vehicle Generator
• Do not operate the generator if the exhaust system is leaking or
has been damaged or if you have experienced carbon monoxide
poisoning symptoms during use. Shut down the generator and
do not operate it until it has been inspected and/or repaired.
• Never sleep in the vehicle while the genset is running unless the
vehicle has a working carbon monoxide detector.
FIRE HAZARDS
• For fire safety, the generator must be installed and maintained
properly. Installation always must comply with applicable
codes, standards, laws and regulations. Adhere strictly to local,
state and national electrical and building codes. Comply with
regulations the Occupational Safety and Health Administration
(OSHA) has established. Also, ensure that the generator is
installed in accordance with the manufacturer’s instructions
and recommendations. Following proper 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.
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 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.
• 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.
• 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.
• 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.
• 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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Section 1 – General Information
Recreational Vehicle Generator
1.1 PURPOSE AND SCOPE
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 that require 40.0 amps (gasoline) or
37.5 amps (LP fuel) at 120 volts.
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 the manual,
both for safety and for continued reliable operation of the equip-
ment.
1.5 GENERATOR ENGINE
OPERATING SPEED
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.
The generator’s revolving field (rotor) is driven by a single-cylinder,
four-cycle engine through a pulley and drive belt arrangement. The
generator supplies 120 volts AC at 60 Hertz when the rotor is oper-
ating at 3,600 rpm.The drive belt arrangement allows the engine to
operate at a lower speed than the rotor.
The installation should comply strictly with all 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.
1.6 GENERATOR AC
CONNECTION SYSTEM
The generator is equipped with dual stator power windings as
shown in Figure 1.1.
1.2 SAFETY
Figure 1.1 – 120-volt Single Voltage Connection
Before handling, installing, operating or servicing this equipment,
carefully read the “Notice to Installer” and “Safety Rules” on pages
18 and 19. Comply with all safety rules to prevent death, personal
injury or damage to equipment and/or property. Stress safety to
all installers, operators and service technicians who work on this
equipment.
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:
1. NFPA Standard 501C, “Standard for Recreational Vehicles,”
available from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
• The AC connection system on all air-cooled generators uses a
GROUNDED neutral.
2. NFPA 70, “NFPA Handbook of the National Electric Code,”
available same as Item 1.
• A separate green ground wire is connected to the recreational
3. ANSI C1-1975 and ANSI 119.2-1975, available from the
American National Standards Institute, 1430 Broadway, New
York, NY 10018.
4. ANSI A119.2/NFPA 501C, available from the Recreational
Vehicle Association, 1896 Preston White Drive, Reston, VA
22090.
5. California Administrative Code, Title 25, available from the
State of California, Documents Section, P.O. Box 1015, North
Highlands, CA 95660.
vehicle’s junction box.
• For these units, loads connected across T1 (red) to T2 (white),
MUST NOT exceed 30 amperes or 3,600 watts, and loads con-
nected across T3 (black) and T2 (white) MUST NOT exceed 20
amperes or 2,400 watts each at 120 volts. The combined load-
ing of the two breakers should not exceed 5,500 watts.
NOTE:
Do NOT connect loads in excess of circuit breaker ratings.
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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Section 1 – General Information
Recreational Vehicle Generator
Figure 1.2 – Major Features and Dimensions (Drawing 0F1127-A)
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Section 2 – Installation
Recreational Vehicle Generator
Figure 2.1 – Typical Horizontal Support Frame
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 been factory equipped with an
area for the generator set. Some vehicles may even have a genera-
tor compartment provided by the vehicle manufacturer.
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.
• The location must provide sufficient room to allow minimum
clearances as outlined in the "Generator Compartment" section.
If sound insulation is to be used on the compartment walls
and ceiling, the minimum recommended applies to the space
between the generator and such insulation.
2.1.3 SUSPENDED MOUNTING
If the generator will be suspended below the horizontal support
tubing, the suspension method used with the vehicle frame mem-
bers must (a) be able to support the weight of the generator AND
(b) provide sufficient restraint for the generator. One typical sus-
pended mounting system is shown in Figure 2.2. The location of
a suspended mounting system must be carefully planned, keeping
the following general rules in mind:
• Protect the generator against road splash and debris. Baffles or
splash guards may be required to protect certain areas of the
generator. To make sure the generator is adequately protected,
road test the installation through mud, water and slush.
• The location must provide adequate cooling and ventilating
airflow for the generator without a great deal of work and
expense.
Figure 2.2 – Typical Suspended Mounting System
2.1.2 GENERATOR SUPPORT
The generator must be securely attached to a metal framework that
has been made part of the vehicle frame structure by bolting or
welding. The metal framework on which the generator will rest and
which will restrain the generator set should consist of at least two
horizontal beams. These beams should consist of (a) 1-1/2-inch
square, 11-gauge steel 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.
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:
• The installer must make certain that the selected location will
permit adequate cooling and ventilating airflow to be supplied.
• 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.
2.1.4 GENERATOR RESTRAINT
Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the genera-
tor to the supporting frame or the support tubing. These bolts must
pass through (a) the generator mounting base, (b) the compartment
floor (if a compartment is used) and (c) the supporting framework
(Figure 2.3). All bolts must be long enough so that when tight, at
least three threads are visible past the retaining lock nuts. Refer to
the "Generator Compartment" section for the location of the generator
mounting holes.
•
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Section 2 – Installation
Recreational Vehicle Generator
• 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).
Figure 2.3 – Typical Generator Restraint
Figure 2.5 – Typical Compartment Construction
2.2 GENERATOR COMPARTMENTS
Whether the generator set is being installed inside a compartment
specifically manufactured to house a generator or inside a compart-
ment that the installer constructs, the compartment MUST meet
certain specifications as outlined in the following sections:
2.2.1 COMPARTMENT SIZE
Plan the compartment size carefully. Provide a minimum clearance
of 1/2 inch (13 mm) on the front, 1-1/2 inches (38 mm) on the
top, and 1 inch (25 mm) on the sides and back for air circulation
AFTER the compartment has been lined with metal and sound
insulation (Figure 2.4).
• If constructing a compartment, line the exterior (underside) of
the compartment floor with 26-gauge galvanized steel.
• All seams, splices and joints of the compart-
ment walls (unless vapor tight by design) should
be caulked to prevent poisonous, flammable or explosive vapors
from entering the vehicle interior.
NOTE:
Refer to “Figure 1.2 – Major Features and Dimensions”.
Figure 2.4 – Clearances
NOTE:
Plywood
Compartment
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 rubber
base sealant is recommended.
1-1/2" Clearance on Top
1" Clearance
in Back
• 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.
1" Each Side
1/2"
Insulation
in Front
NOTE:
Flexible metal conduit, due to its unique construction, is NOT
vapor tight along its entire length.
2.2.2 COMPARTMENT CONSTRUCTION
• 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.
• The generator compartment should be either constructed of, or
lined with, 26-gauge galvanized steel.
NOTE:
Aluminum is NOT an acceptable alternative to galvanized steel
due to aluminum’s low melting point.
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Section 2 – Installation
Recreational Vehicle Generator
Figure 2.6 – Types of Lock Seams
2.2.4 ACOUSTICS
For additional noise abatement, the installer may wish to consider
the following:
• Using special sound insulating materials.
• Construction of a special noise abatement compartment.
NOTE:
Any method used to reduce noise must not adversely affect the
flow of cooling and ventilating air into or out of the compart-
ment.
In addition to the effective use of sound insulating materials,
construction of a special noise abatement compartment might be
considered to reduce noise levels. Such a compartment might be
constructed as follows (Figure 2.7):
• After the compartment has been metal lined and vapor
sealed, line the compartment interior walls and ceiling with an
approved, nonflammable sound insulating material. See the
"Sound Insulating Materials" section.
• Use 5/8-inch thick or 3/4-inch thick plywood in the compart-
ment.
• 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 the "Sound Insulating Materials"
section.
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
cushions, fiberboard and other flammable mate-
rials. Use approved nonflammable insulating
materials in high temperature areas.
DANGER
To prevent fire or explosion, do not install any
insulation or other absorbent materials on the
2.2.3 SOUND INSULATING MATERIALS
interior or underside of the compartment floor.
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.
• Seal all compartment door edges to prevent noise leakage
around the door perimeter.
• Line the compartment door interior (except for air openings)
with suitable, fireproof sound insulation (such as 1-inch (25
mm) thick fiberglass with a 2-pound density).
Sound insulating materials should be of a 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.
Figure 2.7 – Typical Noise Abatement
DANGER
Do not install sound insulation or any absorbent
material on the compartment floor interior. Such
materials will become soaked with combustible
or explosive vapors and liquids and will become
a fire hazard.
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.
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Section 2 – Installation
Recreational Vehicle Generator
2.2.5 COMPARTMENT FLOOR CUTOUTS
Provide openings in the generator compartment for the following
items (Figure 2.8):
2.3 COOLING AND VENTILATING
AIR
It is absolutely essential that an adequate flow of air for cooling,
ventilating and engine combustion be supplied to the generator set.
Without sufficient airflow, the engine/generator quickly overheats.
Such overheating can cause serious operating difficulties and also
may cause fire and personal injury. The installer must make sure
that sufficient air is 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.
• Engine exhaust and cooling air outlets
• Generator cooling air inlet
• Four holes for passage of generator mounting bolts. See the
"Generator Restraint" section.
DANGER
Fuel lines and exhaust piping must not penetrate
into the vehicle living area.
Figure 2.8 – Compartment Floor Cutout
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Section 2 – Installation
Recreational Vehicle Generator
NOTE:
DANGER
Screening, louvers or expanded metal that cover air open-
ings restrict airflow. Compensate for this by making the actual
air opening proportionately larger. See the "Compensating for
Restrictions" section.
Never use discharged cooling air for heating or
permit such air to enter the vehicle interior. This
air contains deadly carbon monoxide gas and
other poisonous, flammable or explosive gases.
NOTE:
Be sure to meet the minimum clearances illustrated in Figure
2.4.
2.3.1 GENERATOR AIRFLOW
Engine operation drives cooling fans for the two-stage cooling air
system. A pressure fan draws cooling air into the top of the generator
(Figure 2.9). This airflow cools the engine/generator and electronic
components. The second part of the cooling system, a suction fan,
draws air that is heated from a hot engine into a collector pan at the
base of the unit. This heated air (although cooler than exhaust muf-
fler) is then deflected out the bottom toward the ground.
When the unit is installed on a suspended mounting system, one
of several different methods of supplying airflow may be used as
follows:
• Provide a door in the vehicle skirt having an air inlet opening
(Figure 2.11).
Figure 2.11 – Suspended Mount: Inlet Door
Figure 2.9 – Airflow Through Engine/Generator
• Using ductwork (Figure 2.12). The installer must be sure air is
available to the top of the generator since air inlets are located
at the top.
• By providing an opening in the vehicle skirt and space behind
the generator for cooling airflow (Figure 2.13). Recommended
clearance behind the back of the generator is at least 1/2 inch
(13 mm).
2.3.2 COOLING AIR INLET OPENINGS
The minimum size of the air inlet opening, whether the generator
is housed in a conventional compartment or not, is at least 100
square inches (see Figure 2.10). This rule applies whether inlet
air is brought in through an opening in the compartment door, an
opening in the vehicle skirt, through ductwork, or by any other
means.
Figure 2.12 – Air Inlet Using Ductwork
Figure 2.10 – Air Inlet in Compartment Door
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Section 2 – Installation
Recreational Vehicle Generator
Figure 2.13 – Air Inlet in Vehicle Skirt
Figure 2.14 – Generator Fuel System
VEHICLE FLOOR
VEHICLE
SKIRT
FUEL LINE
AIR
INLET
MINIMUM
CLEARANCE
1-1/2"
FUEL PUMP
FUEL FILTER
DANGER
Gasoline is highly flammable, and its vapors are
explosive. Comply with all codes, standards and
regulations pertaining to gasoline fuel systems
used in recreational vehicle generators. Properly
install and maintain the fuel system and keep it
entirely free of leaks. Gasoline vapors must not
enter the vehicle interior.
2.3.3 COMPENSATING FOR RESTRICTIONS
Such materials as screening, louvers or expanded metal can
restrict the free flow of air. Compensate for this restriction by mak-
ing the actual air opening proportionately larger.
Factory installed generator fuel system components include (a)
fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and
(d) interconnecting lines and fittings. Connect a fuel supply line
to the fuel filter inlet. Use a flexible length of approved fuel hose
between the fuel filter inlet connection and rigid fuel lines.
Some materials may offer only a 60 percent “free air inlet area.”
Other more efficient materials may provide up to a 90 percent free
air inlet area. The percentage of free air inlet opening is usually
available from the material supplier or manufacturer.
To determine the actual air inlet opening size required, divide
100 square inches by the percentage of free air inlet area for
the material being used.
2.4.1 FUEL TANK
Either the generator must share the vehicle engine's fuel tank, or a
separate fuel tank must be installed for the generator set. All fuel
tanks installed on the vehicle must be constructed, installed and
restrained so they comply with applicable codes, standards and
regulations. The generator has an evaporative emissions port to
evacuate accumulated gasoline vapors when necessary.
For example: If planning to use screening with an 80 percent free
air inlet area, divide 100 by 0.8, which results in 125 square inches.
Minimum actual size of air inlet opening in this case is 125 square
inches.
2.3.4 TESTING THE 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.
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.
NOTE:
The installation must be tested, especially if air is brought in
from below the generator set.
Do NOT tie the generator fuel supply line into
the vehicle engine fuel supply line. If this is
done, the generator will be starved of fuel
when both engines are operating at the same
time. Also, while the vehicle engine is not run-
ning, generator operation may drain the vehicle
engine supply line, making it difficult to start the
vehicle engine.
2.4 GASOLINE FUEL SYSTEM
The installation of a gasoline fuel system (Figure 2.14) for a
recreational vehicle generator set must comply with applicable
codes, standards and regulations. The entire fuel system must be
completely free of leaks. There must be no possibility of gasoline
vapors entering the vehicle interior.
Gasoline generators are equipped with an evaporative emissions
vacuum port that may be used in conjunction with a certified fuel
system where required by law.
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Section 2 – Installation
Recreational Vehicle Generator
2.4.2 GENERATOR FUEL SUPPLY LINE
2.5.1 PARTS NOT INCLUDED IN FUEL SYSTEM
The propane fuel system does NOT include such items as (a) gas
tank, (b) gas piping, (c) fittings, (d) valves, and (e) primary regula-
tor, used to store the gaseous fuel and deliver it to the gaseous fuel
solenoid (Figure 2.15).
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:
DANGER
• Rigid lines should be of annealed, seamless, drawn aluminum
or steel.
• Lines and fittings must comply with SAE J512F, “Standard
Automotive Fittings,” or with ANSI B126.26 (latest edition).
• Route the fuel line so that at least 2 inches (51 mm) of 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 only approved components in the fuel sup-
ply system. All components must be properly
installed in accordance with applicable codes.
Improper installation or use of unauthorized
components may result in fire or an explosion.
Follow approved methods to test the system for
leaks. No leakage is permitted. Do not allow fuel
vapors to enter the vehicle interior.
Figure 2.15 – Typical Propane Gas Fuel System
• Use nonferrous metal straps without sharp edges to secure
fuel lines.
2.4.2.2 Flexible Fuel Line
Use an approved flexible length of fuel hose between the generator
fuel inlet connection and rigid fuel lines. This prevents breaking of
the line caused by vibration, shifting, settling or movement. The
following rules apply:
• The flexible hose must comply with SAE J1737 (30R7),
“Standard for Fuel and Oil Hose.” It must be approved for use
with gasoline and low 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.
2.5 LP GAS FUEL SYSTEM
DANGER
LP gas is highly EXPLOSIVE. The gas is heavier
than air and tends to settle in low areas. Even
2.5.2 SOME IMPORTANT CONSIDERATIONS
When installing an LP gas system, consider seriously the following
items:
the slightest spark can ignite it and cause and
explosion. Only competent, qualified people
should be allowed to install, test, adjust or ser-
vice an LP gas fuel system. Install the optional
fuel system in compliance with applicable codes,
standards and regulations. After the installation,
do not do anything that might render the system
in noncompliance with applicable codes and
standards.
• All fittings, lines, hoses and clamps must be tight and free of
leaks. Apply a pipe sealant to threads when assembling thread-
ed connections. This reduces the possibility of leakage.
• Test the entire fuel system for leaks using approved test meth-
ods.
• Optimum gas pressure at the inlet to the gaseous fuel solenoid
valve and secondary regulator is 11 inches water column.
• The installer’s fuel supply connection point is at the gaseous
fuel solenoid valve. This is a 3/4-inch (female) connection.
Provide a suitable 3/4-inch NPT (male) connector to attach to
the fuel supply line.
The LP powered range of generators are fitted with a nonadjust-
able, factory set system. These systems are tamper-proof to meet
1997 California Air Resources Board requirements for engine
emission.
• Use a length of approved flexible fuel hose between the gaseous
fuel solenoid valve and rigid gas piping. The flexible line should
be at least six (6) inches longer than necessary.
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Section 2 – Installation
Recreational Vehicle Generator
The greater the airflow through the carburetor venturi, 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
movement of the regulator valve. The more the regulator valve
opens, the greater the gas flow that is proportional to airflow
through the generator.
2.5.3 VAPOR WITHDRAWAL
LP gas is stored in pressure tanks as a liquid. The gas systems
used with these generators were designed only for vapor with-
drawal type systems. Vapor withdrawal systems use the gas
vapors that form above the liquid fuel in the tank. Do NOT attempt
to use the generator with any liquid withdrawal type system.
The following facts about the secondary regulator must be empha-
sized:
2.5.4 PRIMARY REGULATOR
• The regulator must be sensitive to venturi throat pressure
changes throughout the operating range.
• The regulator must be properly adjusted so it will stop the flow
of gas when the engine is not running (no air flow through the
carburetor).
Gas pressure delivered to the solenoid valve must be properly
regulated by means of a primary gas regulator. Mount the primary
regulator at the gas tank outlet or in the supply line from the gas
tank. The following rules apply:
• For best results, the primary regulator supplies gaseous fuel to
the secondary regulator at 11 inches water column. Do NOT
exceed 14 inches water column.
• The slightest airflow (and vacuum in the venturi throat) should
move the regulator valve off its seat and permit gas to flow.
• The installer must be sure the primary regulator is rated at
sufficient gas flow to operate the generator plus all other gas
appliances in the circuit.
2.5.6 FUEL SUPPLY LINES
• LP gas lines must be accessible, but protected against possible
damage.
NOTE:
• Do NOT connect electrical wiring to any LP gas fuel line or run
Recommended MINIMUM gas flow rate for all air-cooled gen-
erators is 67 cubic feet per hour.
wiring alongside the lines.
• Route gas lines away from hot engine exhausts.
• Retain gas lines with metal clamps that do not have sharp
edges.
• Install an approved length of flexible hose between the gaseous
fuel solenoid valve and rigid fuel supply lines. The flexible line
must be nonmetallic, nonorganic and nonconductive. It must be
approved for use with LP gas.
If an existing primary gas regulator does not have a sufficient
flow capacity for the generator and other gas appliances in the
circuit, (a) install a primary regulator with adequate flow rate,
or (b) install a separate regulator only and rated at least 67
cubic feet per hour. The inlet side of any primary regulator that
supplies the generator must connect directly to a gas pressure
tank. Do NOT tee the generator line into a gas circuit feeding
other areas.
2.5.7 EXCESS FLOW VALVE
LP gas tanks should have an excess flow valve, according to
NFPA 501C, Paragraph 3-4.4. This valve and the gas lines must
be carefully sized so the valve will close when a fuel line is severed
or broken. Consult the Natural-LP Gas Association for information
and limitations of excess flow valves.
2.5.5 GASEOUS CARBURETION
LP gas vapors should be supplied to the secondary regulator inlet
at about 11 inches water column (positive pressure). The engine
pistons draw air in during the intake stroke (Figure 2.16). This air
passes through a carburetor venturi, which creates a low pressure
that is proportional to the quantity of air being pumped. The low
pressure from the carburetor venturi acts on the regulator dia-
phragm to pull the diaphragm toward the source of low pressure.
A lever attached to the diaphragm opens a valve to permit gas glow
through the carburetor.
Manual shutoff valves on the supply tank and elsewhere in the sys-
tem must be fully open when operating the generator. The excess
flow valve functions properly only if all valves are fully open.
2.5.8 LEAKAGE TESTS
Do not place the generator into service until the gas system has
been properly tested for leaks. To test the system, a separate
source of 12 volts DC is needed to open the gaseous fuel solenoid
valve.
Figure 2.16 – LP Gas Carburetion Diagram
The leak test must comply fully with NFPA, Paragraph 318. All con-
nections, hoses, valve regulators, fittings, and other fuel system
parts must be tested under gas or air pressure of not less than
90 psi (620 kPa), while using soap and water or an equivalent
solution to check for leaks. Other approved methods of testing for
leaks may be used, if appropriate. DO NOT USE ANY FLAME TO
TEST FOR LEAKS.
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Section 2 – Installation
Recreational Vehicle Generator
Failure to provide and maintain a spark arrestor may be in violation
of the law. If this generator is used on any forest covered, brush
covered or grass covered unimproved land, a spark arrestor must
be installed. The vehicle owner or operator must maintain this
device in good condition. In the state of California, the preceding
is required by law (Section 4442 of the California Public Resources
Code). Other states may have similar laws. Federal laws apply on
federal lands.
DANGER
Gaseous fuel lines between the tank and the
secondary regulator are under a positive pres-
sure (about 11 inches water column). Gas pres-
sure at the outlet side of the secondary regula-
tor, however, is a negative pressure and can
draw flame inside a line or fitting and cause an
explosion.
2.6.2 TYPE OF EXHAUST SYSTEM
Two types of exhaust systems for these generators are available
from the manufacturer. They include the following:
2.6 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.
• “Out-the-bottom” exhaust system dimensions are 15/16” O.D.,
model 9742.
• “Out-the-side” exhaust system dimensions are 1-1/4” O.D., 18
gauge, model 4172.
DANGER
NOTE:
The generator engine gives off DEADLY carbon
No matter what type of exhaust kit best fits the recreational
vehicle, the mounting base has openings for either “bottom-
out” or “side-out” exhaust systems. Use the cover plate pro-
vided with the generator to cover the opening NOT used.
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concen-
trations, can cause unconsciousness or even
death. Never operate the generator set with the
vehicle inside any garage or other enclosed
area. DO NOT OPERATE THE GENERATOR IF
THE EXHAUST SYSTEM IS LEAKING OR HAS
BEEN DAMAGED. SYMPTOMS OF CARBON
MONOXIDE POISONING ARE (a) inability to
think coherently; (b) vomiting; (c) twitching
muscles; (d) throbbing temples; (e) dizziness;
(f) headaches; (g) weakness; and (h) sleepiness.
IF FEELING ANY OF THESE SYMPTOMS, MOVE
INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS
PERSIST, GET MEDICAL HELP. Do not operate
the generator until its exhaust system has been
inspected and properly repaired.
2.6.3 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.
• 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).
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.
• 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.
• 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.
2.6.1 MUFFLERS AND SPARK ARRESTORS
This muffler meets code and standard requirements of the U.S.
Forest Service. Use only mufflers and parts approved by the
manufacturer. Any person(s) installing an unapproved muffler,
or an unapproved exhaust system part, or modifying an exhaust
system in any way that might cause a hazard, is liable for any
damage, injury or warranty expense that might be caused by such
unapproved installation or modification.
• Exhaust piping must be large enough to prevent excessive back
pressure on the generator engine.
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Section 2 – Installation
Recreational Vehicle Generator
• 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.
2.7.3 GENERATOR AC CONNECTIONS
Generator AC output leads T1 (red), T2 (white) and T3 (black)
come out of the generator as shown in Figure 2.17. Leads T1 (red)
and T3 (black) are “hot,” while T2 (white) is the grounded neutral
lead. There is also a green lead that connects to ground in the
junction box of the recreational vehicle.
• Plan exhaust system installation carefully. Comply with all appli-
cable codes, standards and regulations.
2.7 ELECTRICAL CONNECTIONS
Figure 2.17 – Generator AC Output Leads
Be sure to read the "Generator AC Connection System" section.
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.
• 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.
T3
T2
T1
Green
(Ground)
• 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.
2.7.1 ELECTRICAL JUNCTION BOX
Line T1 (red) to T2 (white) is protected against overload by a
30-amp circuit breaker (CB1). Use this line-to-neutral connection
separately to operate 120-volt, single-phase, 60 Hertz, AC loads
requiring up to 3,600 watts (3.6 kW) of power. Line T3 (black) to
T2 (white) also is protected against overload by a 20-amp circuit
breaker (CB2). Use this line-to-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.
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.
2.7.2 WIRING
• Wiring should be of stranded copper to reduce the chance that
vibration may cause breakage.
• Wire gauge size should be large enough to handle at least 115
percent of the installed generator's rated maximum current.
• If neutral conductors are used, they must be the same size as
other leg wires.
• Route power supply conductors from generator AC output leads
T1 (red), T2 (white), T3 (black) and the green ground wire
through approved flexible conduit to the electrical junction box
on the 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.
Do NOT connect electrical loads in excess of any
circuit breaker rating or problems with circuit
breaker tripping will develop, which causes a loss
of AC output. Also, do NOT exceed the genera-
tor's rated wattage capacity. Add the watts or
amperes of all lighting, appliance, tool and motor
loads the generator will operate at one time. This
total should be less than the unit's rated wattage/
amperage capacity.
2.7.4 CONDUIT
• From the junction box, route power supply wires through approved
conduit to either (a) double-pole, double-throw transfer 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).
Route the connections between the generator and the junction box
through approved, flexible conduit. The following general rules
apply:
• Cut wiring to the required length and allow extra wire for junc-
tion box connections.
• Carefully prepare conduit ends to prevent sharp edges from
• Conductors must be rated 221° F (105° C) or must be of a
cutting through wiring insulation.
larger conductor size.
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Section 2 – Installation
Recreational Vehicle Generator
• Route conduit so it does not interfere with generator move-
ment.
2.8 BATTERY INSTALLATION
• 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 vaporproof along its entire length.
2.8.1 RECOMMENDED BATTERY
Install a battery that meets the following requirements:
• 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.
2.7.5 ISOLATING DIFFERENT POWER SOURCES
Connections from the junction box must terminate in a double-
pole, double-throw transfer switch (Figure 2.18). An alternate
method for isolating different power sources is by using an isolat-
ing receptacle (Figure 2.19). Whichever method is use, be certain
that both power sources are NOT connected at the same time.
NOTE:
2.7.6 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.
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.
2.8.2 BATTERY CABLES
2.7.7 GROUND FAULT CIRCUIT INTERRUPTERS
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.
The National Electrical Code (NFPA 70, 551-7) requires that ground
fault circuit interrupters (GFCIs) on all external and some internal
electrical receptacles be installed. Contact the manufacturer or
dealer for recommendations.
Figure 2.18 – Transfer Switch Isolation Method
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Section 2 – Installation
Recreational Vehicle Generator
Figure 2.19 – Installation With Isolation Receptacle
These generators are rated at about 100 DC amperes of cranking
current.
NOTE:
Check to be sure the battery cable boot for the starter cable has
been installed.
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. Connect the battery cable from the battery post indicated by a
NEGATIVE, NEG or (-) to the frame ground connection (Figure
2.20).
3. Connect cables so the connectors are clean and tight.
CABLE LENGTH
CABLE SIZE
in Feet (meters)
Figure 2.20 – Connecting Battery Cables
0 to 10 (0 to 3)
11 to 15 (3.4 to 4.5)
16 to 20 (4.5 to 6)
2*
0
SIDE VIEW OF GENERATOR
000
*For warm weather, use No. 2 cable up to 20 feet.
STARTER
CONTACTOR
2.8.3 BATTERY CABLE CONNECTIONS
1. Connect the battery cable from the battery post or terminal
indicated by a POSITIVE, POS or (+) to the lug on the starter
contactor (Figure 2.20).
GROUND LUG
BATTERY
NEGATIVE CABLE
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Section 3 – Post-installation Start-up Adjustments
Recreational Vehicle Generator
2.8.4 BATTERY COMPARTMENT
Install the generator battery in its own, vented compartment. Place
the battery compartment away from any source of heat, sparks
or flame.
3.1 POST INSTALLATION TESTS
The air-cooled generator set was factory tested and adjusted. It
should not be required to adjust the unit any further except under
special circumstances.
Provide ventilation openings in the battery compartment. The
minimum size of openings should be 2 square inches at the top
of the compartment. Mount the battery on a strong, rigid support-
ing structure, where leaks and spills of battery fluid will not cause
damage.
Do not make any unnecessary adjustments.
Factory settings are correct for most applica-
tions. When making adjustments, however, be
careful to avoid overspeeding the engine.
2.9 OPTIONAL ACCESSORIES
3.2 BEFORE INITIAL START-UP
A plug-in receptacle (Figure 2.21) is provided on the generator
set, above the muffler enclosure. Use this receptacle to connect
an optional remote-mounted start/stop panel to the generator.
Installation of such a panel will permit starting and stoping the
generator engine from any convenient location inside the vehicle.
Before starting, complete the following:
1. Check the engine crankcase oil level and, if necessary, fill to
the dipstick “FULL” mark (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.
Figure 2.21 – Remote Panel Plug-in Receptacle
DANGER
If a liquid propane (LP) gas fuel system has
been installed, it must be properly tested for
leaks before operating the system in compliance
with ANSI A119.2/NFPA 501C. No leakage is per-
mitted. Be sure no gasoline fuel vapors enter the
vehicle interior.
3.3 INITIAL START
When absolutely certain that the unit has been properly installed
and prepared for use, start the engine as follows:
1. Turn off all electrical loads. Do this by setting the generator’s
main circuit breakers to their “OFF” (or open) position.
2. Refer to Part I, section “Starting the Generator”, for cranking
and starting instructions. The engine may require more crank-
ing for initial starting since the fuel lines have to be primed
(use of the primer switch will shorten this time).
2.9.1 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. The Prime switch is not connected,
it must be used with jumper wire 0G7666.
3. Let the engine warm up for about five minutes to allow internal
temperatures to stabilize.
• Model 0F0429 includes the remote panel and a 10 foot long,
5-wire harness.
4. Carefully inspect the engine/generator for fuel, oil and exhaust
system leaks. Before proceeding to the next step, correct any
leakage immediately.
• Model 0F0430 includes the remote panel and a 30 foot long,
5-wire harness.
5. When all tests and adjustments at no-load are completed,
apply electrical loads and check for proper operation under
load. See the "Testing Under Load" section. Run the unit at
least 30 minutes with loads applied.
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.
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Section 3 – Post-installation Start-up Adjustments
Recreational Vehicle Generator
NOTE:
The generator set was thoroughly tested and adjusted at the
factory before shipping. No additional adjustment should be
necessary. Only qualified service technicians who have been
trained should perform adjustments outlined in this manual.
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.
NOTE:
The generator engine is equipped with a high temperature
switch. The switch has normally closed (N.C.) contacts. When
the engine temperature is too high, switch contacts close, and
the engine shuts down automatically.
THE MANUFACTURER RECOMMENDS TESTING THE GENERA-
TOR FOR ADEQUATE COOLING.
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Section 3 – Post-installation Start-up Adjustments
Recreational Vehicle Generator
EXHAUST SYSTEM
❑ Exhaust system complies with all applicable codes.
3.5 INSTALLATION CHECKLIST
LOCATION AND SUPPORT
❑ Generator is properly located.
❑ Generator is properly supported.
❑ Generator is properly restrained.
❑ Exhaust system is properly and safely installed.
ELECTRICAL CONNECTIONS
❑ Connections comply with local code requirements and all
National Electrical Codes.
GENERATOR COMPARTMENT
❑ Compartment construction is proper.
❑ Holes/Openings are vapor-sealed.
❑ Compartment size is correct.
❑ 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.
❑ Compartment is vapor-sealed.
❑ Sound insulation is correct.
BATTERY INSTALLATION
❑ Recommended battery is installed.
❑ Recommended cables are installed.
❑ Cables are clean and tight.
❑ Floor cutouts are properly completed.
COOLING AND VENTILATING AIR
❑ Airflow is adequate.
❑ Air inlet opening is correct.
❑ Cables are connected properly.
❑ Proper ventilation is provided.
❑ Compensate for restrictions.
❑ Check that installation has been tested.
❑ Terminals are coated with anti-corrosion grease, and terminal
covers are positioned.
GASOLINE FUEL SYSTEM
❑ Fuel tank complies with all applicable codes.
OPTIONAL ACCESSORIES
❑ Check that remote start/stop panels (if used) are installed
❑ Fuel system is properly installed and checked for leaks.
properly.
❑ Check that hourmeter kit (if used) is installed properly.
OPTIONAL LP GAS FUEL SYSTEM
❑ Fuel system is properly installed and checked for leaks.
❑ Pressure at regulator inlet is correct.
❑ Check that any other options and accessories (if used) are
installed properly.
❑ Rated flow of primary regulator is correct.
❑ All parts are properly installed.
POST INSTALLATION TESTS
❑ Check that all tests are completed properly.
❑ Fuel system is properly tested/adjusted.
DATE OF INSTALLATION _______________________________________________________
NAME OF INSTALLER__________________________________________________________
SIGNATURE OF INSTALLER ____________________________________________________
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Section 4 – Troubleshooting
Recreational Vehicle Generator
TROUBLESHOOTING GUIDE
Problem
Cause
Correction
The engine will not crank.
1. Fuse blown
1. Replace fuse.
2. Loose, corroded or defective
2. Tighten, clean or replace
battery cables
as necessary.
3. Defective engine Start/Stop
switch
3. Replace Start/Stop switch.
4. Defective starter contactor
5. Defective starter motor
6. Low or defective battery
4. Replace contactor.
5. Replace starter motor.
6. Charge or replace battery.
The engine cranks but
will not start.
1. Out of fuel
1. Replenish fuel.
2. Replace fuel pump.
2. Defective fuel pump
3. Open #14 wire from
engine control board
3. Check connections and.
insulation of #14 wires.
4. Flooded engine
4. Wait 5-10 minutes before trying.
5. Clean, re-gap or replace plug(s).
6. Open fuel line shut-off.
7. Clean or replace fuel filter.
5. Defective spark plug(s)
6. Fuel line shut-off closed
7. Plugged fuel filter
The engine starts hard
and runs rough.
1. Air cleaner
plugged or damaged
2. Defective spark plug(s)
1. Check, clean or replace air cleaner.
2. Clean, re-gap or replace plug(s).
The engine starts, but shuts
down when the Start/Stop
switch is released.
1. Engine oil level low
2. Defective low oil
pressure switch
1. Check oil and add oil as needed.
2. Replace pressure switch.
3. Defective high temperature
switch
3. Replace temperature switch.
4. Defective engine control board
5. Overheated engine
4. Replace control board.
5. Check that the airflow
openings are adequate.
The Start/Stop switch is
set to Stop, but the engine
continues to run.
1. Defective Start/Stop switch
2. Open/Disconnected #18 wire
between Start/Stop switch
1. Replace switch.
2. Reconnect or close wire.
and engine control board
3. Open/Disconnected #0 wire
3. Reconnect or close wire.
4. Replace control board.
between Start/Stop switch
and engine control board
4. Defective engine control board
There is no AC output from
the generator.
1. Main line circuit breaker open
1. Reset circuit breaker
to ON (or CLOSED).
2. Fault with vehicle circuit
breaker and/or fuses
2. Reset and replace if necessary.
3. Transfer switch set to NORMAL
4. Start switch not held long
enough to flash the field
3. Set switch to GENERATOR.
4. Stop, then restart the engine
(Hold Start switch for at least
two (2) seconds).
5. Generator internal failure
5. Contact an Authorized Service Dealer.
37
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Section 5 — Electrical Data
Recreational Vehicle Generator
Electrical Schematic and Wiring Diagram – Drawing No. 0D1754-B
38
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Section 5 — Electrical Data
Recreational Vehicle Generator
Electrical Schematic and Wiring Diagram – Drawing No. 0D1754-B
39
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Base and Pulleys (Model 05754-0) – Drawing No. 0D1759-E
40
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Base and Pulleys (Model 05754-0) – Drawing No. 0D1759-E
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
0C2368
053407
046911
025017
022237
022129
0A6479
077603
022259
052858
051730
029459
075215
073146
075209
0A8341
090239
040976
1
1
4
6
6
9
1
2
2
6
2
2
2
4
2
1
1
2
BASE, MOUNTING
GROUND CABLE
MOUNT, (RUBBER)
CAPSCREW, HEX HD.-3/8"-16 X 1/2"
LOCK WASHER-3/8"
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
0C4006
0A4456
090475
087769
0A7695
0A6922
079246
022145
023897
0A8010A
077643
075237
0D1741A
090859
0F9176
0A8594
0A1658
023152
0A8475
045756
022131
048031C
081105
066849
0D1227
0A8010
0C2824
0742600131
024114
0D1741
022152
022158
0A8531
0A8407
022473
0A2110
1
2
1
1
1
1
2
5
3
1
1
4
1
1
6 IN.
1
2
2
3
2
1
2
2
5
1
1
7
1
2
2
2
2
1
1
CABLE, BATTERY
3/8" SPECIAL LOCK WASHER
FUEL PUMP
FUEL FILTER
FITTING-1/8" PIPE TO 1/4" TUBE
FUEL TUBE, METAL
CAPSCR., HEX HD.-M6-1.0 X 16
FLAT WASHER-M8-5/16"
FLAT WASHER-#10
GASKET, BLOWER HSNG
EXHAUST PIPE GASKET
WASHER, SPRING RETAINER
BOOT, STARTER CONTACTOR
EXHAUST COVER PLATE
HOSE, FUEL
LOCK WASHER-M8
SKID, RUBBER MOUNT
SAFETY BOLT 5/16"-18 X 3 1/2"
NUT, HEX-5/16"-18
NUT, FLANGED LOCK-M8-1.25
CAPSCR. HEX HD.-M8-1.25 X 60MM
SPRING, BELT TENSION
WASHER, SPRING CNTR.
SLIDE (NYLON)
SUPPORT, NYLON SLIDE
MANIFOLD, EXHAUST
GASKET, EXHAUST MANIFOLD
SOCKET HD. CAPSCR.,-M8-1.25 X 20
LG.
PAN, SLIDE
SPECIAL LOCK WASHER, ¼”
CAPSCR., HEX HD.-3/8"-16 X 3/4"
SPECIAL LOCK WASHER, M5
SCREW, TAPTITE-M6-1.0 X 10 LG.
FLAT WASHER-M10
19
20
21
22
23
24
25
0A6858
0A8614
075224B
073106B
075216
049451
042633
1
1
1
1
1
1
1
GASKET, COLLECTOR PAN
SKID, RUBBER MOUNT
PULLEY, ENGINE
CLAMP, HOSE
PULLEY, ALT.
NUT, FLANGE-5/16"-18 (SPECIAL)
SCREW, TAPTITE M5-0.8 X 16 LG.
STARTER CONTACTOR
GASKET, BLOWER HSNG
HHS #10-32 X 9/16” LG, TAP-R
STARTER CABLE
HEX NUT-5/16”-24
BOOT, STARTER CONTACTOR
LOCK WASHER-M4
BELT (POLY V 4L)-40"
WASHER, PULLEY RETAINER
CAPSCR., SOCKET HD. 3/8"-24 X 1"
(GRADE 5)
CAPSCR., HEX HD.-M8-1.25 X 20
CAPSCR., HEX HD.-3/8"-24 X 2"
CRIMPTITE-#10-24 X 1/2"
BRACKET-FUEL PUMP
HOUSING, BLOWER
CRIMTITE-#8-18 X 1/4”
SCREEN, SLIDE PAN
GASKET, BLOWER / PAN
SPRING, GENERATOR SET MT
26
27
28
29
30
31
32
33
34
039253
0A8250
056893
0A8615
0C1320
063036
0A8694
0A8726
075242
3
1
5
1
1
3
1
1
4
HEX NUT-#10-32
PLATE, BLOWER SIDE
GASKET, BLOWER SIDE
FLAT WASHER ¼”
1
2
SCREW, SWAGE 1/4–28 X 1/2”
41
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Base and Pulleys (Model 04164-3) – Drawing No. 0F1124-D
42
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Base and Pulleys (Model 04164-3) – Drawing No. 0F1124-D
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
7
0F1126
048031M
0F7065
022145
022129
045771
066849
1
2
16”
8
12
3
2
ASSEMBLY REGULATOR
#8 HOSE CLAMP
HOSE, 1/2” I.D. PETROLEOM
WASHER FLAT 5/16”- M8
WASHER LOCK M8 - 5/16”
NUT HEX M8-1.25
SCREW, TAPTITE M5-0.8 X 16MM
LONG
WASHER FLAT 1/4” - M6
GROUNDING LUG
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
056893
0A8407
0A8531
039253
0C1320
0A8010
0A8010A
0A8726
0A8250
022131
075224B
023897
0A6858
042633
075216
049451
073106B
0A8694
063036
0A8594
0D1227
022152
022158
0D1741
0742600131
024114
075763A
023152
053407
0A4456
0E9193
0A2110
0C2824
5
1
1
3
1
1
1
1
1
1
1
3
1
1
1
1
1
1
3
1
1
2
2
2
1
2
1
2
1
2
1
2
7
SCREW CRIMPTITE #10-24 X 1/2”
GASKET, BLOWER SIDE
PLATE, BLOWER SIDE
SCREW HHC M8-1.25 X 20MM
HOUSING, BLOWER
GASKET, BLOWER HOUSING
GASKET, BLOWER HOUSING
GASKET, BLOWER / PAN
CAPSCR., HEX HD. 3/8"-24 X 2"
WASHER FLAT 3/8”- M10
PULLEY, ENGINE
8
9
10
11
022473
062684
0A8475
077603
1
1
2
2
LOCK WASHER SPECIAL #10
SAFETY BOLT SCREW HHC 5/16”-18 X
3.5”
WASHER FLAT #10
GASKET, COLLECTOR PAN
SCREW HHC 3/8”-24 X 1”
BELT (POLY V 4L)-40"
WASHER, PULLEY RETAINER
PULLEY, ALT.
SCREEN, SLIDE PAN
SCREW CRIMPTITE #8-18 X 1/4”
PAN, SLIDE
STARTER CONTACTOR
WASHER LOCK #10
NUT HEX #10-32
BOOT, STARTER CONTACTOR
STARTER CABLE
NUT HEX 5/16”-24
BOOT, BATTERY CABLE
SCREW HHC 3/8”-16 X 3/4”
GROUND CABLE
WASHER LOCK SPECIAL 3/8”
BRACKET, LP REGULATOR
SCREW, SWAGE 1/4-28 X 1/2”
SCREW HHTR #10-32 X 9/16
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
0C2368
051730
029459
075215
052858
073146
075209
075242
075237
0A6479
046911
025017
022237
022259
081105
0A8614
090239
040976
0A8341
077643
090859
079246
1
2
2
2
6
4
2
4
4
1
4
6
6
2
2
1
1
2
1
1
1
2
BASE, MOUNTING
SCREW HHC M8-1.25 X 60MM
SPRING, BELT TENSION
WASHER, SPRING CENTER
NUT TOP LOCK FL M8-1.25
SLIDE (NYLON)
SUPPORT, NYLON SLIDE
SPRING, GENERATOR MOUNT
WASHER, SPRING RETAINER
SKID, RUBBER MOUNT
MOUNT, (RUBBER)
SCREW HHC 3/8”-16 X 1/2”
WASHER LOCK 3/8”
NUT HEX 5/16”-18
NUT FLANGE 5/16"-18
SKID, RUBBER MOUNT
GASKET, EXHAUST MANIFOLD
SCREW SHC M8-1.25 X 20MM
MANIFOLD, EXHAUST
EXHAUST PIPE GASKET
EXHAUST COVER PLATE
SCREW HHC M6-1.0 X 16MM W/ LOCK
WASHER
43
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Alternator and Panel (Model 04164-3) – Drawing No. 0D1776-J
44
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Alternator and Panel (Model 04164-3) – Drawing No. 0D1776-J
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
0C9675
0A5649H
0A5646H
073159
031971
0C9674
0A6529
052858
066386
066849
0A8475
0C3818
075234
022473
022097
055816
090141
0A1658
074906
0922340SRV
0H3224
1
1
1
1
1
1
4
4
1
3
3
1
1
2
5
1
2
2
4
1
1
LOWER BEARING CARRIER
ROTOR ASSEM.
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
075235
082737
049813
055440
043182
045771
053623
023484S
0F9719
022152
051716
090144
090145
025105
086315
090734
2
4
4
2
2
4
1
1
1
5
3
1
1
4
1
4
M5-0.8 X 30 LG. CAPSCREW
VIBRATION MOUNT
3
STATOR ASSEM.
M6-1.0 HEX NUT
4
BALL BEARING
BALL BEARING
UPPER BEARING CARRIER
STUD-STATOR
M8-1.25 FLANGE LOCK NUT
BRUSH HOLDER
M5-0.8 X 16 LG. TAPTITE
SPECIAL LOCK WASHER, M5
GENERATOR TOP HOUSING
RESISTOR1R 5% 25 WLVG
¼”/ M6-FLAT WASHER
¼”/ M6-LOCK WASHER
M6-1.0 X 70 LG. CAPSCREW
GROUND CABLE
SPECIAL LOCK WASHER, M6
M6-1.0 X 20 LG. TAPTITE
CONTROLLER P.C.B.
DECAL, MAINTENANCE SCHEDULE
RV
5/16” –M8 LOCK WASHER
NYLON WASHER
PANEL SHEET METAL
4-PIN CONNECTOR
CONDUIT ASSEMBLY
ASSEMBLY, REMOTE CABLE
M5-.08 X 110 LG. PPHMS
SPACER-PLASTIC
M4-0.7 X 16 LG. CAPSCREW
#8/ M4-LOCK WASHER
BATTERY CHARGE RECTIFIER
M3-0.5 X 12 LG. PPHMS
PANEL SUPPORT BRACKET
M5-08 X 25 LG. HEX HD. CAPSCR.
M3-LOCK WASHER
HEX NUT, M8
C/BREAKER 2.5A.-ON
BUSHING
REGULATOR VOLTAGE
LOCKWASHER, #10
M5-0.8 HEX NUT
C/BREAKER 20A.
C/BREAKER 30A.
#6-32 SCREW W/LOCK WASHER
PANEL COVER
M4-0.7 X 12 LG. CAPSCR.W/LOCK-
WASHER & FLAT WASHER
#6-FLAT WASHER
FUSE HOLDER
FUSE AGC-15A.
SWITCH S.P.D.T. (START-STOP)
SWITCH S.P.D.T.-(FUEL PUMP)
TERMINAL BLOCK
SPECIAL LOCK WASHER, M4
M4-0.7 HEX NUT
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
022985
032300
022676
087798
092113
075210A
0A8475A
051715
090157
090156
074908
031791
023897
0D2724
031879
049815
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
1
22
23
24
25
26
27
28
29
30
31
32
33
34
022129
027756
086316
053650
0C4258
075244
094071
094070
075476
022264
065795
090987
086317A
4
4
1
1
1
1
1
1
3
4
1
2
1
DECAL, CB RATING 30A.
DECAL, CB RATING 20A.
M5-0.8 X 10 LONG TAPTITE
CLAMP, HOSE
#10/ M5-FLAT WASHER
BOOT, ROCKER SWITCH
WASHER FLAT #4
HHCS M5-0.8 X 16
45
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Engine Sheet Metal – Drawing No. 0D1760-J
46
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Engine Sheet Metal – Drawing No. 0D1760-J
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
7
8
9
0A4323
045756
029289
091222DSRV
067198N
067890
0A4456
056893
0A6358
091646
0G3279
0G3111
022717A
073132
061669
089685
022129
049813
057821
059637
0D9004A
059985
025034
0A8875
0A7299
0A9539
0A7838
038593
022473
0A6357
0A6360
0A6489
0A6359
0742600131
090892
091159
091160
091161
049821
086999
0A8584
075281
0C1085
043182
070185B
0E9649
082774
0C2308
0A1658
090388
075474A
0D1624
0C4373
1
8
SCROLL, FLYWHEEL
SCREW, TAPTITE M6-1.0 X 10MM
FOAM TAPE
2.5 FT.
1
1
1
1
21
1
1
1
2
1
1
1
2
6
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
2
1
1
1
1
1
1
1
1
FLYWHEEL
WASHER, BELLVILLE M20 X 2.2
NUT, M20 X 1.5, FLYWHEEL
3/8" SPECIAL LOCK WASHER
SCREW, CRIMPTITE #10-24 X 0.5”
COVER,TOP FLYWHEEL
DEFLECTOR, EXHAUST PORT
ASSEMBLY, IGNITION COIL NO ADV. V410 RV
SCREW, TAPTITE M6-1.0 X 25MM
GROMMET, RUBBER
BOOT, SPARK PLUG
PLUG, BUTTON ¾”
GROMMET, RUBBER
LOCK WASHER-M8
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
NUT, HEX M6-1.0
CAPSCR, HEX HD M8-1.25 X 40MM
SCREW, TAPTITE 3/8"-16 X 0.75”
ASSY, STARTER MOTOR
SOCKET HD. CAPSCR., M8-1.25 X 45MM
PLUG, BUTTON 1-1/16”
ASSEMBLY, DIPSTICK & CAP
OIL DRAIN/DIPSTICK TUBE
OIL DRAIN HOSE ASSEMBLY
PIPE NIPPLE, 3/8" X 8" LG.
BRASS STREET ELBOW, 3/8"
FLAT WASHER, 1/4"-M6
WRAPPER, ENGINE SPARK PLUG
WRAPPER, STARTER SIDE
WRAPPER, REAR GEAR CASE
WRAPPER, CARB. SIDE
ASSEMBLY, WIRE-STARTER (#16)
SUPPORT, OIL FILTER
BUSHING, RUBBER
WASHER, RUBBER
BOLT, SHOULDER-M6-1.0 X 15MM
BOLT, SOCKET HD. CAPSCR.-M8-1.25 X 30MM
GASKET, OIL FILTER SUPPORT
SWITCH, OIL PRESSURE-10 PSI
SWITCH, OIL TEMPERATURE
SCREW, PHILIPS PAN HD. MACH.-M3-0.5 X 8MM
LOCK WASHER-M3
FILTER, OIL
ENGINE, LONG BLOCK-GN410VSRV
KEY, WOODRUFF 4 X 19 DIA.
COVER, CARB.
SPECIAL LOCK WASHER, M6
TAPTITE, M6-1.00 X 12MM
BOOT, TEMPERATURE SWITCH
BOOT, OIL PRESSURE SWITCH
SPACER, ENDFRAME
1
47
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
GN-410 Engine – Drawing No. 0E9615-B
48
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
GN-410 Engine – Drawing No. 0E9615-B
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
3
4
5
6
0G2565
0E3221
0E1466
071983
021713B
0A1442
1
1
1
2
1
8
RING SET, PISTON DIA 90
CONNECTING ROD
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
0E3812
076361
0A5776
0A7811
078645
078691
074908
0A7975
0A5771
0B2104
0E9667
078658
078659
0A7628
089288C
0E3341
086025
0D9853B
0E9666
090747
0C3150
092362
068527
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
4
CRANKSHAFT SEAL
THRUST WASHER
PISTON PIN
PRESSURE RELIEF BALL
GOVERNOR SPOOL
PISTON PIN RETAINER
CYLINDER HEAD GASKET
FLANGED HEX HD. CAPSCREW
M8-1.25 X 42
M10 1.5 X 105MM HHFL
PISTON, FLAT TOP DIA 90 COATED
CRANKCASE GASKET
M6-1.0 X 10 TAPTITE (THD.
FORMING)
BREATHER GASKET
BREATHER COVER
OIL BREATHER SEPARATOR
PIPE PLUG-3/8"
GOVERNOR RETAINER (C-RING)
COVER, OIL PRESSURE RELIEF
M5-0.8 X 10MM TAPTITE
GOVERNOR GEAR ASSEMBLY
OIL PRESSURE SPRING
SPRING WASHER
OIL SUMP ASSEMBLY
GOVERNOR ARM "R" PIN
THRUST WASHER
GOVERNOR ARM RC45
CRANKCASE SUB ASSEMBLY
BALANCER
SET GEROTOR
PUSH ROD
CRANKSHAFT ASSEMBLY
BREATHER VALVE ASSEMBLY
ROCKER COVER GASKET
ROCKER COVER W/FILL
M6-1.0 X 20MM HEX HEAD.
SCREW. AND LOCKWASHER
BEARING TUBE SHAFT
OIL SCREEN PICKUP ASSEMBLY
OIL FILL PLUG
7
8
9
021742
0G2751
076701
045756
4
1
1
2
10
11
12
13
14
15
16
17
18
19
20
21
080308
080309
080338
0D4788
083897
072694
0D3998
078672
078694
083907
0G6791
2
1
1
1
2
2
2
1
1
2
1
TAPPET, SOLID
PIVOT BALL STUD
NUT HEX M8-1.0 G8
SEAL, VALVE STEM
PUSH ROD GUIDE PLATE
ROCKER ARM
CYLINDER HEAD W/VALVE SEATS
AND GUIDES
22
23
24
25
26
27
28
0D2274
086515
086516
086517
089673
0C4391
0A9877
2
4
1
1
2
2
1
VALVE SPRING RETAINER
VALVE SPRING KEEPER
EXHAUST VALVE
52
53
54
55
56
083921
077158
076329
0E0057
093064
1
1
1
1
1
INTAKE VALVE
"O" RING
OIL FILL CAP ASSEMBLY
WASHER, VALVE SPRING
VALVE SPRING
CAMSHAFT ASSEMBLY
49
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Engine Accessories – Drawing No. 0F1135-E
50
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Engine Accessories – Drawing No. 0F1135-E
ITEM
PART NO.
QTY.
DESCRIPTION
1
2
3
4
5
6
0A6532
091039
051753
0E7585
089228
0A7336B
0A6562
090970
0A7660
0A7660A
056893
0A6566
0A6780
096290
073111
1
1
1
1
1
1
1
1
1
1
3
1
1
2
1
MANIFOLD, INTAKE
GASKET, MANIFOLD/HEAD
HHCS-M6-1.0 X 40MM
SPARK PLUG, CHAMP
GASKET, CARB/MANIFOLD
CARBURETOR, GN 410 L/P
CARBURETOR, GN410 GAS
GASKET, CARB/AIR FILTER
ASSY, AIR CLEANER/VALVE
ASSY, AIR CLEANER/VALVE W/EVAP (02010-3 & 05754 ONLY)
CRIMPTITE #10-24 X 1/2”
DETENT
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
SPRING, A/L BELLCRANK-CARB.
STUD, CARB. MOUNT 90 LG.
FILTER, AIR
0A6563
0C3633
0A6581A
0C2332
092164
082025
0A7029
0A6913
091161
049813
092586
083512
0A6778
0A6785
0A6753
0A8222
086681
020753
022473
022097
0A6582
0A6503
0A6569
0A7660
0A6568
0A6567
091916
083532
072683A
028414A
0A6239
0A6584
036544
089473
0A7094
1
2
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
COVER, AIR FILTER
KNOB, AIR CLEANER
BREATHER, TUBE
DECAL, AIRBOX QP55
ASSEMBLY, GOV. SPRING ADI BRACKET
NUT HEX LOCK M5-0.8 NYLON
NYLON WASHER, .31” X .26” X .13”
ROD, LINKAGE GOV. LEVER-BELLCRANK
BOLT, SHOULDER, M6-1.0 X 15MM
NUT, M6-1.0
WASHER, FELT
TAPTITE-M8-1.25 X 16MM
SPRING, A/L GOV. LEVER-BELLCRANK
ROD, LINKAGE BELLCRANK-CARB.
BELLCRANK, GOV. RODS
SPRING, GOVERNOR
NUT, GOVERNOR LEVER
HHCS-M6-1.0 X 60MM
M6 FLAT WASHER
M6 LOCK WASHER
TUBE, WINTER INLET
GROMMET 1/16”-1-1/2”
GROMMET, AIR IN/OUT
VALVE, WINTER/SUMMER
GROMMET, WINTER/SUMMER VALVE
SPRING, DETENT
LEVER, GOVERNOR ARM
BOLT, HEX HD. WASHER/LOCK WASHER-M6-1.0 X 30MM
PLUG, 1/8 NPTF (02010-3 ONLY)
BARBED STRAIGHT 1/8 NPT X 1/4 (05754-0 ONLY)
ASSEMBLY, CHOKE SOLENOID (02010-3 & 05754 ONLY)
LINKAGE, CHOKE (02010-3 & 05754 ONLY)
PIN, COTTER 3/32” X .5” (02010-3 & 05754 ONLY)
ASSEMBLY, CHOKE HEATER (02010-3 & 05754 ONLY)
PPHMS #4-40 X .25” (02010-3 & 05754 ONLY)
44
45
46
47
48
51
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Alternator & Panel – Drawing No. 0H3636-A
52
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Section 6 — Exploded Views and Parts Lists
Recreational Vehicle Generator
Alternator & Panel – Drawing No. 0H3636-A
ITEM PART NO. QTY. DESCRIPTION
ITEM PART NO. QTY. DESCRIPTION
1
2
0C9675
0A5649H
0A5646H
073159
031971
0C9674
0A6529
052858
066386
066849
0A8475
0C3818
075234
022473
022097
055816
090141
0A1658
074906
0922340SRV
0H3224
022129
027756
086316
053650
0C4258
075244
094071
094070
075476
022264
065795
090987
086317A
075235
082737
049813
055440
043182
1
1
1
1
1
1
4
4
1
3
3
1
1
2
5
1
2
2
4
1
1
4
4
1
1
1
1
1
1
3
4
1
2
1
2
4
4
2
2
LOWER BEARING CARRIER
ROTOR ASSEM.
40
41
42
43
44
45
46
47
48
49
045771
053623
023484S
0F9719
022152
051716
090144
090145
025105
086315
086315A
090734
4
1
1
1
5
3
1
1
4
1
1
4
HEX NUT, M8
C/BREAKER 2.5A.-ON
BUSHING
3
STATOR ASSEM.
4
BALL BEARING
BALL BEARING
UPPER BEARING CARRIER
STUD-STATOR
M8-1.25 FLANGE LOCK NUT
BRUSH HOLDER
M5-0.8 X 16 LG. TAPTITE
SPECIAL LOCK WASHER, M5
GENERATOR TOP HOUSING
RESISTOR1R 5% 25 WLVG
¼”/ M6-FLAT WASHER
¼”/ M6-LOCK WASHER
M6-1.0 X 70 LG. CAPSCREW
GROUND CABLE
SPECIAL LOCK WASHER, M6
M6-1.0 X 20 LG. TAPTITE
CONTROLLER P.C.B.
DECAL, UNIT
5/16” –M8 LOCK WASHER
NYLON WASHER
PANEL SHEET METAL
4-PIN CONNECTOR
CONDUIT ASSEMBLY
ASSEMBLY, REMOTE CABLE
M5-.08 X 110 LG. PPHMS
SPACER-PLASTIC
M4-0.7 X 16 LG. CAPSCREW
#8/ M4-LOCK WASHER
BATTERY CHARGE RECTIFIER
M3-0.5 X 12 LG. PPHMS
PANEL SUPPORT BRACKET
M5-0.8 X 30 LG. CAPSCREW
VIBRATION MOUNT
REGULATOR VOLTAGE
LOCKWASHER, #10
5
6
M5-0.8 HEX NUT
7
C/BREAKER 20A.
8
C/BREAKER 30A.
9
#6-32 SCREW W/LOCK WASHER
PANEL COVER
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
PANEL COVER EVAP. (05754 ONLY)
M4-0.7 X 12 LG. CAPSCR.W/LOCK-
WASHER & FLAT WASHER
#6-FLAT WASHER
FUSE HOLDER
FUSE AGC-15A.
SWITCH S.P.D.T. (START-STOP)
SWITCH S.P.D.T.-(FUEL PUMP)
TERMINAL BLOCK
SPECIAL LOCK WASHER, M4
M4-0.7 HEX NUT
DECAL, CB RATING 30A.
DECAL, CB RATING 20A.
M5-0.8 X 10 LONG TAPTITE
CLAMP, HOSE
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
022985
032300
022676
087798
092113
075210A
0A8475A
051715
090157
090156
074908
031791
023897
0D2724
031879
049815
0G0247
0G7457
0G9319
069598
035579
1
1
1
1
1
1
1
1
1
1
2
1
2
2
2
1
1
1
1
1
1
#10/ M5-FLAT WASHER
BOOT, ROCKER SWITCH
WASHER FLAT #4
HHCS M5-0.8 X 16
SOLENOID, LP/NG DC12V
BARBED EL 90 1/4 NPT X 5/16
WIRE ASSY. (NOT SHOWN)
BULKHEAD ADAPTER
BUSHING REDUCER HEX 1/4 TO
1/8 NPT
72
73
035578
028740
1
1
NIPPLE PIPE 1/8 X 3/4
BARBED EL 90 1/8 NPT X 1/4
M6-1.0 HEX NUT
M5-08 X 25 LG. HEX HD. CAPSCR.
M3-LOCK WASHER
53
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Section 7 – Notes
54
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Section 7 – Notes
55
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Section 8 – Warranty
Recreational Vehicle Generator
CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power Systems, Inc.
(Generac), are pleased to explain the Emission Control System Warranty on your new engine.* New utility, and lawn and garden equipment engines must
be designed, built and equipped to meet stringent anti-smog standards for the state of California and the federal government. Generac will warrant the emis-
sion control system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modification or improper
maintenance of your engine.
Your emission control system may include parts such as the carburetor, ignition and exhaust systems. Generac will repair your engine at no cost to you
for diagnosis, replacement parts and labor, should a warrantable condition occur.
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted. If, during such warranty period, any
emission-related component or system on your engine is found to be defective in materials or workmanship, repairs or replacement will be performed by
a Generac Authorized Warranty Service Facility.
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory supplied Owner’s Manual. For
warranty purposes, Generac recommends that you retain all receipts covering maintenance on your engine. However, Generac cannot deny warranty solely
because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance.
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or responsibility if your engine,
or a part/component thereof, has failed due to abuse, neglect, improper maintenance or unapproved modifications, or the use of counterfeit and/or ‘grey
market’ parts not made, supplied or approved by Generac.
You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem
occurs. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility. To locate the Generac
Authorized Warranty Service Facility nearest you, call our toll-free number:
1-800-333-1322
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System Warranty (ECS Warranty), which is
provided to you by Generac pursuant to California and federal law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which
is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new
engine. If there is any conflict in terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where
the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe important rights and obligations
with respect to your new engine.
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty service, evidence must be presented
showing the date of the sale to the original purchaser/owner. The purchaser/owner shall be responsible for any expenses or other charges incurred for
service calls and/or transportation of the product to/from the inspection or repair facilities. The purchaser/owner also shall be responsible for any and/or
all damages or losses incurred while the engine is being transported/shipped for inspection or warranty repairs.
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the following
address:
ATTENTION WARRANTY DEPARTMENT
GENERAC POWER SYSTEMS, INC.
P.O. BOX 297
WHITEWATER, WI 53190
Part 1
56
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Section 8 – Warranty
Recreational Vehicle Generator
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines:
(a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or 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 subse-
quent purchaser/owner, that each of its engines is ...
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the EPA and CARB pursuant to their respective authority,
and
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a warranted emissions-related part
to fail to be identical in all material respects to the part as described in the engine manufacturer’s application for certification.
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for
the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac according to Subsection (4)
below. Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual shall be warranted for the ECS
Warranty Period. A statement in such written instructions to the effect of “repair or replace as necessary” shall not reduce the ECS Warranty Period.
Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s Manual shall be warranted for the
period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be
repaired or replaced by Generac according to Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall
be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge to the owner at a Generac
Authorized Warranty Service Facility.
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible for diagnostic costs if the
repair is deemed warrantable.
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty
of any emission-related part covered by the ECS Warranty.
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand
for such emission-related parts.
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS Warranty maintenance or repairs
and will be provided without charge to the purchaser/owner. Such use shall not reduce Generac’s ECS Warranty obligations.
(9) Unapproved, add-on, modified, counterfeit and/or ‘grey market’ parts may not be used to modify or repair a Generac engine. Such use voids this ECS
Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac shall not be held liable hereunder for failures of any warranted
parts of a Generac engine caused by the use of such an unapproved, add-on, modified, counterfeit and/or ‘grey market’ part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
*Generac engine types covered by this warranty statement include the following:
1) Utility
2) Lawn and Garden Equipment
3) Recreational Vehicle (RV) Generator
4) Industrial Mobile (IM) Generator
Part 2
1) Fuel Metering System:
2) Air Induction System including:
a) Intake pipe/manifold
b) Air cleaner
3) Ignition System including:
a) Spark plug
b) Ignition module
1.1) Gasoline carburetor assembly and its
internal components (if so equipped).
a) Fuel filter (if so equipped)
b) Carburetor gaskets
c) Fuel pump (if so equipped)
1.2) LPG carburetion assembly and its
internal components (if so equipped).
a) Fuel controller (if so equipped)
4) Catalytic Muffler Assembly (if so equipped) including:
a) Muffler gasket
b) Exhaust manifold
b) Mixer and its gaskets (if so equipped)
c) Carburetor and its gaskets (if so equipped)
d) Primary gas regulator (if so equipped)
e) LP liquid vaporizer (if so equipped)
5) Crankcase Breather Assembly including:
a) Breather connection tube
57
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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 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 pur-
chaser/owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility.
All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the purchaser/owner. This
warranty applies only to Generac generators sold and rated for “Recreational Vehicle” (RV) applications, as Generac has defined
Recreational Vehicle generator applications. The factory recommends exercising the unit one half-hour every month.
WARRANTY SCHEDULE – COMMERCIAL APPLICATIONS
YEAR ONE – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:
• Engine – All components
• Alternator – All components
WARRANTY SCHEDULE – CONSUMER/PERSONAL APPLICATIONS
YEARS ONE AND TWO – 100% (one hundred percent) coverage on part(s), labor, removal and reinstallation listed:
• Engine – All components
• Alternator – All components
YEAR THREE – 100% (one hundred percent) only on selected part(s) and labor listed [Any labor and part(s) not listed, and removal
and reinstallation are the owner’s responsibility]:
• Rotor, Stator, Computer Control Board (part numbers 0A6060 and 0A3369) and inverter, (if applicable with regard to the generator)
Cylinder Block, Cylinder Head, Crankshaft, Piston(s), Valve, Valve Lifter(s), Intake and Exhaust Manifolds
Generac RV generators manufactured prior to December 31, 1997, DO NOT have a transferable warranty. Generac RV generators
manufactured after January 1, 1998, have a transferable warranty to the second owner ONLY for the remainder of the three-year
limited warranty. Proof-of-purchase is required and must be presented to a Generac Authorized Warranty Service Facility prior to
the performance of any warranty service.
All warranty expense allowances are subject to the conditions defined in Guardian’s Warranty Policies and Procedures Guide.
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:
• Generac Guardian generators that utilize non-Generac replacement parts.
• Costs of normal maintenance, adjustments, installation and start-up.
• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by
Generac Power Systems.
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all
mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not
cover repair when normal use has exhausted the life of a part(s) or engine.
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.
• Damage related to rodent and/or insect infestation.
• Products that are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or
replacement of the defective part(s).
• Failure due to misapplication.
• Telephone, cellular phone, facsimile, internet access or other communication expenses.
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit war-
ranty 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 limita-
tions on how long an implied warranty lasts, so the above limitation may not apply to you.
GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL
GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A DIRECT RESULT
OF GENERAC'S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation may not apply to you.
This warranty gives you specific legal rights. You also have other rights from state to state.
GENERAC® POWER SYSTEMS, INC.
P.O. BOX 297
•
WHITEWATER, WI 53190
Revision 02.05
Part No. 0H3468
Revision A (06/26/09)
Printed in U.S.A.
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