Generac Power Systems Portable Generator 004700 00 User Manual

Owner’s Manual and  
Installation Instructions  
Air-cooled Recreational  
Vehicle Generators  
• Model: 004700-0  
QUIETPACT 40G  
This manual should remain with the unit.  
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Table of Contents  
Recreational Vehicle Generator  
Part I – Owner’s Manual  
Part II – Installation Instructions  
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 .................................................................... 18  
Section 1 – General Information...............................20  
1.1 Purpose and Scope of the Manual..................... 20  
1.2 Safety................................................................. 20  
1.3 Standards Booklets........................................... 20  
1.4 Equipment Description ..................................... 20  
1.5 Generator Engine Operating Speed................... 20  
1.6 Generator AC Connection System ..................... 20  
Safety Rules ...................................................................... 2  
Section 1 – General Information................................. 4  
1.1 Generator Identification ...................................... 4  
1.2 Generator Applicability ....................................... 5  
1.3 Safety................................................................... 5  
1.4 Generator AC Connection System ....................... 5  
1.5 Specifications...................................................... 5  
Section 2 – Operation .................................................... 7  
2.1 Generator Control Panel....................................... 7  
2.2 Optional Remote Start/Stop Panel........................ 7  
2.3 Automatic Choke.................................................. 7  
2.4 Before Starting the Engine ................................... 7  
2.5 Starting the Generator ......................................... 8  
2.6 Stopping the Generator........................................ 9  
2.7 Applying Loads to Generator................................ 9  
2.8 Do Not Overload the Generator............................ 9  
2.9 Protection Systems............................................... 9  
2.10 Additional Information....................................... 10  
Section 3 – Maintenance.............................................. 11  
3.1 Checking the Engine Oil Level............................ 11  
3.2 Changing the Engine Oil and/or Oil Filter .......... 11  
3.3 Maintaining the Engine Air Cleaner.................... 12  
3.4 Clean Air Intake ................................................. 13  
3.5 Checking the Engine Spark Plug........................ 13  
3.6 Fuel Filter........................................................... 13  
3.7 Spark Arrestor Service....................................... 13  
3.8 Cleaning the Generator ...................................... 14  
3.9 Battery Maintenance........................................... 14  
3.10 Major Service Manual......................................... 15  
3.11 Exercising the Generator.................................... 15  
3.12 Out of Service Procedure.................................... 15  
3.13 Adjusting Valve Clearance................................... 15  
3.14 RV Generator Service Interval............................ 16  
Section 2 – Installation................................................22  
2.1 Location and Support ....................................... 22  
2.2 Generator Compartments ................................. 23  
2.3 Cooling and Ventilating Air................................ 26  
2.4 Gasoline Fuel System........................................ 26  
2.5 Exhaust System................................................. 27  
2.6 Electrical Connections....................................... 28  
2.7 Battery Installation............................................ 31  
2.8 Optional Accessories......................................... 31  
Section 3 – Post-installation Start-up  
Adjustments..............................................32  
3.1 Post Installation Tests ....................................... 32  
3.2 Before Initial Start-up........................................ 32  
3.3 Initial Start........................................................ 32  
3.4 Testing Under Load........................................... 32  
3.5 Installation Checklist......................................... 33  
Appendix 1 – Notes ......................................................34  
Appendix 2 – Troubleshooting...................................35  
Appendix 3 – Electrical Data......................................36  
Appendix 4 – Exploded Views and Parts Lists.......38  
Appendix 5 – Warranty ................................................48  
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.  
• The generator engine releases DEADLY carbon  
monoxide gas through its exhaust system. This  
dangerous gas, if breathed in sufficient concentra-  
tions, can cause unconsciousness or even death.  
Never operate the generator set with the vehicle  
inside any garage or other enclosed area. DO NOT  
OPERATE THE GENERATOR IF THE EXHAUST  
SYSTEM IS LEAKING OR HAS BEEN DAMAGED.  
SYMPTOMS OF CARBON MONOXIDE POISONING  
ARE (a) inability to think coherently, (b) nausea,  
(c) vomiting, (d) twitching muscles, (e) throbbing  
temples, (f) dizziness, (g) headaches, (h) weak-  
ness, and (i) sleepiness. IF EXPERIENCING ANY  
OF THESE SYMPTOMS, MOVE INTO FRESH AIR  
IMMEDIATELY. IF SYMPTOMS PERSIST, GET  
MEDICAL HELP. Shut down the generator and  
do not operate it until it has been inspected and  
repaired.  
• Never sleep in the vehicle while the genset is run-  
ning unless the vehicle has a working carbon  
monoxide detector. The exhaust system must be  
installed in accordance with the genset installation  
manual. Make sure there is ample fresh air when  
operating the genset in a confined area.  
• The engine exhaust fumes contain carbon monox-  
ide, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. This exhaust  
system must be installed properly, in strict com-  
pliance with applicable codes and standards.  
Following installation, do nothing that might ren-  
der the system unsafe or in noncompliance with  
such codes and standards. The generator com-  
partment must be completely vapor sealed from  
the vehicle interior. There must be no possibility of  
exhaust fumes entering the vehicle interior. Never  
operate this equipment with a leaking or defective  
exhaust system.  
WARNING:  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
The engine exhaust from this product  
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
Study these SAFETY RULES carefully before install-  
ing, operating or servicing this equipment. Become  
familiar with this manual and with the unit. The gen-  
erator can operate safely, efficiently and reliably only  
if it is properly installed, operated and maintained.  
Many accidents are caused by failing to follow simple  
and fundamental rules or precautions.  
The manufacturer cannot anticipate every possible  
circumstance that might involve a hazard. The warn-  
ings in this manual, and on tags and decals affixed  
to the unit, are, therefore, not all-inclusive. If using  
a procedure, work method or operating technique  
the manufacturer does not specifically recommend,  
ensure that it is safe for others. Also make sure the  
procedure, work method or operating technique uti-  
lized does not render the generator unsafe.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting  
its maintenance or being careless can cause  
possible injury or death. Permit only responsible  
and capable persons to operate or maintain this  
equipment.  
• Keep hands, feet, clothing, etc., away from drive  
belts, fans, and other moving or hot parts. Never  
remove any drive belt or fan guard while the unit  
is operating.  
• Adequate, unobstructed flow of cooling and ven-  
tilating air is critical to correct generator opera-  
tion and is required to expel toxic fumes and fuel  
vapors from the generator compartment. Without  
sufficient cooling airflow, the engine/generator  
quickly overheats, which causes serious damage  
to the generator. Do not alter the installation or  
permit even partial blockage of ventilation provi-  
sions, as this can seriously affect safe operation of  
the generator.  
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.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
GENERAL HAZARDS  
For safety reasons, the manufacturer recommends  
that the installation, initial start-up and main-  
tenance of this equipment is carried out by an  
Authorized Service Dealer.  
2
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Safety Rules  
Recreational Vehicle Generator  
• 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.  
• Before performing any maintenance on the gen-  
erator, disconnect its battery cables to prevent  
accidental start up. Disconnect the cable from the  
battery post indicated by a NEGATIVE, NEG or (–)  
first. Reconnect that cable last.  
• Never use the generator or any of its parts as a  
step. Stepping on the unit can stress and break  
parts, and may result in dangerous operating con-  
ditions from leaking exhaust gases, fuel leakage,  
oil leakage, etc.  
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 installa-  
tion, do nothing that might alter a safe installation  
and render the unit in noncompliance with the  
aforementioned codes, standards, laws and regula-  
tions.  
• Keep a fire extinguisher in the vehicle at all times.  
Extinguishers rated ABC” by the National Fire  
Protection Association are appropriate for use on  
the recreational vehicle generator electrical sys-  
tem. Keep the extinguisher properly charged and  
be familiar with its use. If there are any questions  
pertaining to fire extinguishers, consult the local fire  
department.  
ELECTRICAL HAZARDS  
• The generator covered by this manual produces  
dangerous electrical voltages and can cause fatal  
electrical shock. Avoid contact with bare wires, ter-  
minals, connections, etc., while the unit is running.  
Ensure all appropriate covers, guards and barriers  
are in place before operating the generator. If work  
must be done around an operating unit, stand on  
an insulated, dry surface to reduce shock hazard.  
• Do not handle any kind of electrical device while  
standing in water, while barefoot, or while hands or  
feet are wet. DANGEROUS ELECTRICAL SHOCK  
MAY RESULT.  
• During installation onto the vehicle, have the  
generator properly grounded (bonded) either by  
solid mounting to the vehicle frame or chassis,  
or by means of an approved bonding conductor.  
DO NOT disconnect the bonding conductor, if so  
equipped. DO NOT reconnect the bonding conduc-  
tor to any generator part that might be removed or  
disassembled during routine maintenance. If the  
grounding conductor must be replaced, use only a  
flexible conductor that is of No. 8 American Wire  
Gauge (AWG) copper wire minimum.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any  
fuel or oil spills immediately. Ensure that no com-  
bustible materials are left in the generator com-  
partment, or on or near the generator, as FIRE or  
EXPLOSION may result. Keep the area surround-  
ing the generator clean and free from debris.  
• Gasoline is extremely FLAMMABLE and its vapors  
are EXPLOSIVE. Do not permit smoking, open  
flame, sparks or any source of heat in the vicinity  
while handling gasoline. Comply with all laws gov-  
erning the storage and handling of gasoline.  
• In case of accident caused by electric shock, imme-  
diately shut down the source of electrical power.  
If this is not possible, attempt to free the victim  
from the live conductor. AVOID DIRECT CONTACT  
WITH THE VICTIM. Use a nonconducting imple-  
ment, such as a rope or board, to free the victim  
from the live conductor. If the victim is uncon-  
scious, apply first aid and get immediate medical  
help.  
• Never wear jewelry when working on this equip-  
ment. Jewelry can conduct electricity resulting in  
electric shock, or may get caught in moving com-  
ponents causing injury.  
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: 004700-0  
1. Generator Air Intake  
2. Engine Start/Stop Switch  
3. Fuse  
4. Optional Remote Panel Receptacle (Side View)  
5. Generator AC Output Leads (Side View)  
6. Fuel Primer Switch  
11. Fuel Filter (Side View)  
12. Oil Filter  
13. Oil Drain Cap  
14. Oil Dipstick  
15. Air Filter (Behind Access Panel)  
16. Oil Fill  
7. Circuit Breaker  
17. Spark Plug  
8. Starter Contactor  
9. Fuel Inlet  
10. Fuel Pump (Behind Access Panel)  
17  
8
2 6  
14,16  
CONTROL CENTER  
7
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AIR FILTER LOCATED BEHIND PANEL.  
MAINTENANCE SCHEDULE  
OIL LEVEL:  
AIR FILTER:  
CHECK DAILY  
CLEAN PREFILTER  
EVERY 100 HOURS.  
REPLACE ELEMENT  
EVERY 250 HOURS.  
*
*
10/15  
OIL  
&
OIL FILTER:  
CHANGE EVERY 100  
HOURS. (OR ANNUALLY)  
*
PERFORM MORE OFTEN IN DUSTY CONDITIONS  
*
SPARK PLUGS:  
FUEL FILTER:  
INSPECT  
&
CLEAN  
PLUGS EVERY 100  
HOURS. REPLACE PLUGS  
EVERY 500 HOURS.  
(IF NECESSARY)  
AC  
CHANGE EVERY 400  
HOURS. (OR ANNUALLY)  
D
REPLACEMENT INFORMATION  
PREFILTER P/N:  
AIR FILTER P/N:  
OIL FILTER P/N:  
SPARK PLUG P/N:  
FUEL FILTER P/N:  
0D4511  
0D3262  
070185  
072347  
0D7515  
OIL CAPACITY WITH FILTER:  
0.8L/0.84QT  
TEMPERATURE  
SAE VISCOSITY  
32˚F AND HIGHER  
10˚F TO 100˚F  
0˚F TO 80˚F  
30  
15W-40  
10W-30  
5W-30  
RAC OHVI INDU
-20˚F TO 50˚F  
WHEN SERVICE OR PARTS ARE NEEDED IN  
THE USA OR CANADA, CONTACT THE GENERAC  
SERVICE LOCATOR AT 1-800-333-1322.  
PACT
RV SERVICE LOCATOR:  
9/11  
13  
1
12  
4
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Section 1 – General Information  
Recreational Vehicle Generator  
1.2 GENERATOR APPLICABILITY  
1.4 GENERATOR AC  
These generators have been designed and manufac-  
tured for supplying electrical power for recreational  
vehicles. Do not modify the generator or use it for  
any application other than for what it was designed. If  
there are any questions pertaining to its application,  
contact an Authorized Service Dealer. Do not use the  
unit until advised by a competent authority.  
CONNECTION SYSTEM  
This generator set is equipped with dual stator AC  
power windings. These two-stator windings sup-  
ply electrical power to customer electrical loads by  
means of a two-wire connection system. Note, how-  
ever, that the neutral is bonded to the frame of the  
engine-generator.  
DANGER  
The generator may have been installed so that it pow-  
ers 120-volt AC loads (Figure 1.1). It can be wired to  
connect 120-volt AC electrical loads. This procedure  
should be done by an Authorized Service Dealer or  
other qualified installer.  
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-volt, single-phase, 60 Hertz, AC electri-  
cal loads. These loads can require up to 3,600 watts  
(3.6 kW) of power, but cannot exceed 30 AC amperes  
of current at 120 volts.  
Do not overload the generator. Some installa-  
tions may require that electrical loads be alter-  
nated 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 electri-  
cal device nameplate gives only volts and amps,  
multiply volts times amps to obtain watts (volts  
x amps = watts). Some electric motors require  
more watts of power (or amps of current) for  
starting than for continuous operation.  
1.5 SPECIFICATIONS  
1.5.1 FUEL REQUIREMENTS  
This generator is equipped with a gasoline fuel sys-  
tem. Depending on the installation, the generator may  
have either a separate fuel tank, or it may “share” the  
vehicle engine’s fuel tank.  
NOTE:  
Some installations using a “shared” fuel tank may  
have a generator fuel pickup tube that is shorter  
than the vehicle engine’s pickup tube. Such an  
arrangement causes the generator engine to “run  
out of gas” while adequate fuel for the vehicle  
remains in the tank.  
1.3 SAFETY  
Before attempting to use the generator set, care-  
fully read the “Safety Rules” section of this manual.  
Comply strictly with these rules to prevent accidents  
and damage to equipment and/or property. We sug-  
gest copying and posting the “Safety Rules” in poten-  
tial hazard areas of the vehicle. Stress safety to all  
operators and potential operators of this equipment.  
To reduce lead and carbon deposits use high qual-  
ity UNLEADED gasoline with the generator. Leaded  
REGULAR grade gasoline is an acceptable substitute.  
NOTE:  
Using unleaded gasoline contributes to longer  
engine valve life by reducing lead and carbon  
deposits.  
5
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Section 1 – General Information  
Recreational Vehicle Generator  
1.5.5 GENERATOR  
Rated Maximum Continuous  
AC Output (Gasoline)...........................3,600 Watts (3.6 kW)  
Rated Voltage.......................................................120 Volts AC  
Rated Maximum Continuous  
AC Current (Gasoline) ....................................... 30 Amperes  
The manufacturer does not recommend using  
any gasoline containing alcohol (such as “gaso-  
hol”). If using any gasoline containing alcohol, it  
must not contain more than 10 percent ethanol,  
and it must be removed from the generator dur-  
ing storage. Do NOT use any gasoline  
containing methanol. If using gasoline with alco-  
hol, inspect more frequently for fuel leaks and  
other abnormalities.  
Phase.............................................................................. Single  
Rotor RPM.......................................................................3,600  
Number of Rotor Poles...........................................................2  
Engine RPM.....................................................................3,600  
Rated AC Frequency....................................................... 60 Hz  
Battery Charge Voltage..........................................14 Volts DC  
Battery Charge Current................................2 Amperes (max)  
Gasoline weight.....................................................170 Pounds  
Length....................................................749.8 mm (29.52 in.)  
Width.....................................................483.1 mm (19.02 in.)  
Height....................................................342.2 mm (13.47 in.)  
1.5.2 FUEL CONSUMPTION  
Model  
004700-0  
No Load  
1/2 Load  
Full Load  
0.24  
0.35  
0.55  
Fuel consumption is in gal/hr.  
1.5.6 EMISSIONS COMPLIANCE PERIOD  
1.5.3 ENGINE OIL REQUIREMENTS  
For non-handheld engines the Emissions Compliance  
Period referred to on the Emissions Compliance  
Label indicates the number of operating hours for  
which the engine has been shown to meet Federal  
emission requirements.  
Use only high quality detergent oil rated with American  
Petroleum Institute (API) Service Classification SF,  
SG or SH. The recommended oil weights include the  
following:  
• During summer months: SAE 30. An acceptable  
substitute is SAE 10W-30.  
For engines less than 225 cc displacement, Category  
C=125 hours, B=250 hours, and A=500 hours.  
For engines of 225 cc or more, Category C=250  
hours, B=500 hours, and A=1000 hours.  
• During winter months: SAE 5W-30. DO NOT USE  
SAE 10-W40.  
Crankcase and oil filter capacity is approximately  
800 mL or .84 U.S. quarts. Do NOT use special addi-  
tives. See Sections 3.1 and 3.2 for oil level check and  
fill procedures.  
1.5.4 ENGINE  
Type of Engine................................... GN-220, Single-cylinder  
Cooling Method........................................................Air-cooled  
Rated Horsepower .......................................7.8 @ 4,200 rpm  
Displacement.................................................................. 220cc  
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  
Champion ................................................................ RC14YC  
AC..................................................................................R45S  
Fram Autolite .....................................................................65  
Spark Plug Gap....................................... 0.030 inch (76 mm)  
Recommended Minimum Battery..............400 Cold-cranking  
Amperes  
6
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Section 2 – Operation  
Recreational Vehicle Generator  
2.1 GENERATOR CONTROL PANEL  
The following features are mounted on the generator  
control panel (Figure 2.1):  
2.2 OPTIONAL REMOTE  
START/STOP PANEL  
A remote mounted Start/Stop Panel is available that  
allows starting and stopping the generator engine  
conveniently from inside the vehicle.  
Figure 2.1 – Generator Control Panel  
Order part number 0F0429 or 0F0430, a remote  
panel that includes a Start/Stop switch, a generator  
run lamp, a fuel prime switch, and an hourmeter.  
The hourmeter provides a continuous indication of  
engine/generator operating time. Use the hourmeter  
for checking off periodic maintenance requirements  
on the unit.  
CONTROL CENTER  
C
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A
2.3 AUTOMATIC CHOKE  
The engine is equipped with an automatic choke that  
consists of two main components: a choke solenoid  
and prechoke.  
2.1.1 FUEL PRIMER  
2.3.1 CHOKE SOLENOID  
Before starting a cold engine (if it has not been  
started in more than two weeks), press this switch  
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.  
During engine cranking (Start/Stop switch at START),  
a solid-state choke module signals the choke sole-  
noid to activate and cycle (choke on/choke off) until  
the engine starts. The choke solenoid thus opens  
and closes the carburetor choke valve only when the  
engine is cranking. When the engine starts, the choke  
stops cycling.  
2.1.2 START/STOP SWITCH  
2.3.2 PRECHOKE  
To crank and start the engine, hold this switch in the  
START position. Release the switch when the engine  
starts. To stop an operating engine, press and hold  
the switch in the STOP position until the engine shuts  
off. The switch center position is the RUN position.  
The choke system also has a temperature-sensitive  
metal strip that adjusts choke valve angle according  
to ambient temperatures (i.e., in cold ambient tem-  
peratures, choke valve closes more). Once the engine  
starts, an element heats the temperature-sensitive  
strip to a normal operating condition, opening the  
choke valve. This may take about three minutes in  
cooler weather.  
2.1.3 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 replaced, use only an  
identical replacement.  
2.4 BEFORE STARTING THE ENGINE  
NOTE:  
Instructions and information in this manual  
assume the generator has been properly installed,  
connected, serviced, tested and adjusted by a  
qualified installation technician or installation  
contractor.  
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-volt AC output to the  
vehicle circuits. This generator has 30-amp breaker.  
2.4.1 INSTALLATION  
Generator installation must have been properly com-  
pleted so it complies with all applicable codes, stan-  
dards and regulations and with the manufacturer's  
recommendations.  
7
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Section 2 – Operation  
Recreational Vehicle Generator  
2.4.2 ENGINE LUBRICATION  
DANGER  
Have the engine crankcase properly serviced with the  
recommended oil before starting. Refer to Section  
1.5.4, and Sections 3.1 and 3.2 for oil servicing proce-  
dures and recommendations.  
Never sleep in the vehicle while the genset is  
running unless the vehicle has a working carbon  
monoxide detector. The exhaust system must be  
installed in accordance with the genset installa-  
tion manual. Make sure there is ample fresh air  
when operating the genset in a confined area.  
Any attempt to crank or start the engine before  
it has been properly serviced with the recom-  
mended oil may result in an engine failure.  
2.5 STARTING THE GENERATOR  
NOTE:  
Read the vehicle manufacturer’s instructions.  
The owner/operator should become familiar with  
the vehicle in which this generator is installed.  
Differences exist between vehicles. For example,  
some vehicles may use a transfer switch to isolate  
dockside power from the generator, while other  
vehicles may use an isolating receptacle. Some  
vehicles may be equipped with a DC converter,  
which allows the generator to power certain DC  
lighting and other DC loads.  
2.4.3 FUEL SUPPLY  
The engine must have an adequate supply of proper  
fuel to operate. Before starting it, check that suffi-  
cient fuel is available.  
NOTE:  
Depending on the installation, the generator may  
have either a separate fuel tank, or it may “share”  
the vehicle engine’s fuel tank.  
To start the generator from either the generator con-  
trol panel or from the optional remote panel, proceed  
as follows:  
2.4.4 COOLING AND VENTILATING AIR  
Air inlet and outlet openings in the generator com-  
partment must be open and unobstructed for con-  
tinued proper operation. Without sufficient cooling  
and ventilating airflow, the engine/generator quickly  
overheats, which causes it to shut down and may  
damage the generator.  
1. Turn OFF electrical loads using the means pro-  
vided in the vehicle (such as a main line circuit  
breaker or transfer switch).  
NOTE:  
If starting from the generator control panel, turn  
OFF loads by setting the generator’s main circuit  
breaker to the OFF (or open) position. If starting  
from a remote panel, turn OFF loads using the  
means provided in the vehicle (such as a main  
circuit breaker). Electrical load circuits will be  
turned ON after the generator has started, stabi-  
lized and warmed up.  
2.4.5 ENGINE EXHAUST GAS  
Before starting the generator engine, be sure there is  
no way for exhaust gases to enter the vehicle interior  
and endanger people or animals. Close windows,  
doors and other openings in the vehicle that, if open,  
might permit exhaust gases to enter the vehicle.  
2. 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.  
DANGER  
The generator engine releases DEADLY carbon  
monoxide gas through its exhaust system. This  
dangerous gas, if breathed in sufficient con-  
centrations, can cause unconsciousness or even  
death. Never operate the generator set with  
the vehicle inside any garage or other enclosed  
area. DO NOT OPERATE THE GENERATOR IF THE  
EXHAUST SYSTEM IS LEAKING OR HAS BEEN  
DAMAGED. SYMPTOMS OF CARBON MONOXIDE  
POISONING ARE (a) inability to think coher-  
ently, (b) nausea, (c) vomiting, (d) twitching  
muscles, (e) throbbing temples, (f) dizziness,  
(g) headaches, (h) weakness, and (i) sleepiness.  
IF EXPERIENCING ANY OF THESE SYMPTOMS,  
MOVE INTO FRESH AIR IMMEDIATELY. IF  
If the engine does not start after it has been  
cranking for 15 seconds, release the Start/Stop  
switch, wait one minute and try again. Holding  
the switch for longer than 15 seconds can dam-  
age the starter motor.  
SYMPTOMS PERSIST, GET MEDICAL HELP. Shut  
down the generator and do not operate it until  
it has been inspected and repaired.  
4. Let the engine run at no-load for a few minutes to  
stabilize and warm up.  
5. Turn ON electrical loads using the means pro-  
vided (such as a main circuit breaker or transfer  
switch).  
8
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Section 2 – Operation  
Recreational Vehicle Generator  
• 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 con-  
necting electrical loads to the generator. First, fig-  
ure the watts needed to start electric motors in the  
system. To that figure, add the running wattages of  
other items that will be operated by the generator.  
• Do not apply heavy electrical loads for the first two  
or three hours of operation.  
2.6 STOPPING THE GENERATOR  
1. Turn OFF all electrical loads using the means  
provided (such as a main circuit breaker or  
transfer switch).  
2. Let generator run at no-load for a few minutes, to  
stabilize internal engine generator temperatures.  
3. Place the Start/Stop switch in its STOP position.  
2.7 APPLYING LOADS TO GENERATOR  
When applying electrical loads to the generator,  
observe these guidelines:  
• Before applying electrical loads, let the generator  
stabilize and warm up for a minute or two.  
• DO NOT overload the generator.  
2.9 PROTECTION SYSTEMS  
2.9.1 LOW OIL PRESSURE SWITCH  
This switch (Figure 2.2) has normally closed (N.C.)  
contacts that are held open by engine oil pressure dur-  
ing cranking and operating. Should oil pressure drop  
below a preset level, switch contacts close, and the  
engine automatically shuts down. The unit should not  
be restarted until oil is added.  
2.7.1 LETTING THE ENGINE STABILIZE  
The generator supplies correct rated voltage only at  
the proper governed speed. Some electrical appli-  
ances may be extremely sensitive to voltage. Incorrect  
voltages can damage such appliances.  
If electrical loads are applied at reduced operating  
speeds, such loads imposed on the engine when suf-  
ficient power is not available may shorten engine life.  
Never turn ON electrical loads until after the generator  
engine has started and stabilized at no-load.  
2.9.2 HIGH TEMPERATURE SWITCH  
This switch (Figure 2.2), which has normally open  
(N.O.) contacts, is mounted near the oil filter. The  
contacts close if the temperature should exceed  
approximately 284º F (140º C), initiating an engine  
shutdown.  
2.8 DO NOT OVERLOAD THE  
GENERATOR  
Figure 2.2 – Low Oil Pressure and  
High Temperature Switches  
High Temperature Switch  
Read the rated wattage/amperage capacity of the gen-  
erator on the generator data label (see Section 1.1).  
Applying electrical loads in excess of the unit’s rated  
capacity will cause the engine/generator to automati-  
cally shut down.  
Low Oil Pressure  
Switch  
To avoid overloading, add up the wattage of all con-  
nected electrical lighting, appliance, tool and motor  
loads. This total should not be greater than the  
generator’s rated wattage capacity.  
• Most lighting, appliance, tool and motor loads  
indicate their required watts on their nameplate or  
data plate. For light bulbs, simply note the wattage  
rating of the bulb.  
• If a load does not show its rated wattage, multiply  
that load’s rated VOLTS times AMPS to obtain  
WATTS.  
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Section 2 – Operation  
Recreational Vehicle Generator  
The voltage regulator also incorporates a “voltage  
surge protection circuit.” This circuit prevents trou-  
blesome surges in the generator AC output voltage.  
Voltage surge is a common cause of damage to elec-  
tronic equipment.  
2.9.3 FIELD BOOST  
The Controller Circuit Board houses a field boost  
diode and resistor that are not part of the automatic  
choke circuit. These two components are part of  
a “field boost” circuit (Figure 2.3). During engine  
cranking only, a positive DC (battery) voltage is  
delivered through the diode, resistor, brushes and  
slip rings, to 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.  
2.10 ADDITIONAL INFORMATION  
2.10.1 25-HOUR BREAK-IN PERIOD  
The first 25 hours of operation is the break-in period  
for the generator. Properly breaking in the genera-  
tor is essential to minimize fuel consumption and  
provide maximum engine performance. During this  
25-hour break-in period, follow this procedure:  
Figure 2.3 – Field Boost Circuit  
• Run the unit at varying electrical loads to help seat  
the engine piston rings properly.  
• Check the engine oil level frequently. Add oil if  
needed. It is normal for the generator engine to  
consume more oil than is normal until the piston  
rings have properly seated.  
For the 75-hour operation following the break-in  
period, avoid light electrical loads. Load the gen-  
erator at 50 percent (or more) of its rated watt-  
age capacity. Repeated light loads during these 75  
hours can cause improper seating of engine piston  
rings, resulting in blowby and high oil consump-  
tion.  
• After operating the unit for 25 hours, complete the  
tasks recommended under Section 2.10.2.  
2.9.4 OVERVOLTAGE PROTECTION  
2.10.2 25-HOUR CHECK-UP  
A solid-state voltage regulator (Figure 2.4) controls  
the generator’s AC output voltage. This regulator sup-  
plies an excitation current to the rotor. By regulating  
the rotor’s excitation current, the strength of its mag-  
netic field is regulated and, in turn, the voltage deliv-  
ered to connected electrical loads is controlled. When  
the AC frequency is 60 Hertz, voltage is regulated at  
120 volts (voltage-to-frequency ratio is 2-to-1).  
After the 25-hour break-in period, contact an  
Authorized Service Dealer for the following main-  
tenance. The vehicle owner is responsible for any  
charges:  
• Change the engine crankcase oil and oil filter.  
• Check the oil level.  
• Inspect the cooling and ventilation openings.  
• Check the engine carburetor adjustments.  
• Check the engine ignition system.  
• Inspect the entire electrical system.  
• Inspect the engine exhaust system.  
Figure 2.4 – Solid State Voltage Regulator  
2.10.3 ATTENTION REQUIRED  
AFTER SUBMERSION  
If the recreational vehicle generator has been sub-  
merged in water, it MUST NOT be started and oper-  
ated. Following any submersion in water, have an  
Authorized Service Dealer thoroughly clean and dry  
the generator.  
10  
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Section 3 – Maintenance  
Recreational Vehicle Generator  
2.10.4 OPERATION IN HIGH GRASS  
OR BRUSH  
3.1 CHECKING THE ENGINE OIL  
LEVEL  
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.  
For oil capacities and requirements, see “Engine  
Oil Requirements,” Section 1.5.4. Check the engine  
crankcase oil level at least every eight hours of opera-  
tion, or before each use. To check the engine oil level,  
proceed as follows (see Figure 3.1):  
1. Be sure the generator is as level as possible.  
2. Remove the dipstick and wipe it dry with a clean,  
lint-free cloth.  
3. Install and tighten the dipstick cap; then, remove  
it again. The oil level should be at the dipstick  
Full” mark.  
4. If necessary, remove the oil fill cap on the rocker  
cover and slowly add oil until it reaches the dip-  
stick “Full” mark. DO NOT FILL ABOVE THE  
“FULLMARK.  
2.10.5 EFFECTS OF MOISTURE AND DIRT  
Keep the generator set as clean and dry as possible.  
Protect the unit against excessive dust, dirt, corrosive  
vapors, road splash, etc. Permitting dirt and mois-  
ture to accumulate on generator windings will have  
an adverse effect on the insulation resistance of those  
windings.  
When moisture is allowed to remain in contact with  
windings, some of the moisture will be retained in  
voids and cracks in the insulation. This causes a  
reduced insulation resistance and will eventually  
cause problems. Dirt will make the problem worse,  
since dirt tends to hold moisture in contact with  
windings. Salt (as from sea air) also will worsen the  
problem since it tends to absorb moisture from the  
air. Salt and moisture, when combined, form a good  
electrical conductor.  
Never operate the engine with the oil level  
this could damage the engine.  
5. Install and tighten the oil fill cap and the dipstick  
before operating the engine.  
below the “Add” mark on the dipstick. Doing  
3.2 CHANGING THE ENGINE OIL  
AND/OR OIL FILTER  
• Change the engine oil after the first 25 hours of  
operation (after the 25-hour break-in period, see  
Section 2.10.1). Thereafter, change the oil every  
100 operating hours. Change the oil more fre-  
quently if operating consistently under heavy load  
or at high ambient temperatures.  
Figure 3.1 – Oil Maintenance Features  
CONTROL CENTER  
C
3
.
0
B
A
.
S
T
A
R
T
F
U
E
L
S
T
O
P
P
R
I
M
E
F
U
S
A
E
7.5  
S
E
R
V
IC  
E
A
C
C
E
S
S
P
A
N
E
L
AIR FILTER LOCATED BEHIND PANEL.  
MAINTENANCE SCHEDULE  
OIL LEVEL:  
AIR FILTER:  
CHECK DAILY  
CLEAN PREFILTER  
EVERY 100 HOURS.  
REPLACE ELEMENT  
EVERY 250 HOURS.  
*
*
OIL  
&
OIL FILTER:  
CHANGE EVERY 100  
HOURS. (OR ANNUALLY)  
*
PERFORM MORE OFTEN IN DUSTY CONDITIONS  
*
SPARK PLUGS:  
FUEL FILTER:  
INSPECT  
&
CLEAN  
PLUGS EVERY 100  
HOURS. REPLACE PLUGS  
EVERY 500 HOURS.  
(IF NECESSARY)  
CHANGE EVERY 400  
HOURS. (OR ANNUALLY)  
REPLACEMENT INFORMATION  
PREFILTER P/N:  
AIR FILTER P/N:  
OIL FILTER P/N:  
SPARK PLUG P/N:  
FUEL FILTER P/N:  
0D4511  
0D3262  
070185  
072347  
0D7515  
OIL CAPACITY WITH FILTER:  
0.8L/0.84QT  
TEMPERATURE  
SAE VISCOSITY  
32˚F AND HIGHER  
10˚F TO 100˚F  
0˚F TO 80˚F  
30  
15W-40  
10W-30  
5W-30  
-20˚F TO 50˚F  
WHEN SERVICE OR PARTS ARE NEEDED IN  
THE USA OR CANADA, CONTACT THE GENERAC  
SERVICE LOCATOR AT 1-800-333-1322.  
Oil Drain  
Oil Filter  
Oil Dipstick/Oil Fill  
11  
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