Generac Welding System 005411 0 User Manual

Models:  
005411-0, 005413-0, 005415-0, 005751-0,  
005752-0, 005753-0, 005855-0, 005856-0,  
005857-0  
Owner's Manual  
Air-cooled Recreational  
Vehicle Generators  
RV 45, 55 and 65  
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Introduction  
The operator (driver) is responsible for proper and safe use of the  
vehicle and its equipment, and the safety of all vehicle occupants.  
We strongly recommend that the operator read this manual and  
thoroughly understand all instructions before using this equipment.  
We also strongly recommend instructing other occupants in the  
vehicle to properly start and operate the generator. This prepares  
them if they need to operate the equipment in an emergency.  
INTRODUCTION  
READ THIS MANUAL THOROUGHLY  
If any portion of this manual is not understood, contact the near-  
est Authorized Service Dealer for starting, operating and servicing  
procedures.  
Throughout this publication, and on tags and decals affixed to the  
generator, DANGER, WARNING, CAUTION and NOTE blocks are  
used to alert personnel to special instructions about a particular  
operation that may be hazardous if performed incorrectly or care-  
lessly. Observe them carefully. Their definitions are as follows:  
CONTENTS  
This manual contains pertinent owner’s information, including  
warranty, electrical diagrams, exploded views and lists of repair  
parts. In addition, the latter portion of this manual contains infor-  
mation necessary for the proper installation of these generators.  
After this heading, read instructions that, if not  
strictly complied with, will result in personal  
injury, including death, and property damage.  
OPERATION AND MAINTENANCE  
It is the operator's responsibility to perform all safety checks, to  
make sure that all maintenance for safe operation is performed  
promptly, and to have the equipment checked periodically by  
an Authorized Service Dealer. Normal maintenance service and  
replacement of parts are the responsibility of the owner/operator  
and, as such, are not considered defects in materials or workman-  
ship within the terms of the warranty. Individual operating habits  
and usage contribute to the need for maintenance service.  
After this heading, read instructions that, if not  
strictly complied with, may result in personal  
injury or property damage.  
After this heading, read instructions that, if not  
strictly complied with, could result in damage  
to equipment and/or property.  
Proper maintenance and care of the generator ensures a minimum  
number of problems and keep operating expenses at a minimum.  
See an Authorized Service Dealer for service aids and acces-  
sories.  
NOTE:  
After this heading, read explanatory statements that require  
special emphasis.  
HOW TO OBTAIN SERVICE  
When the generator requires servicing or repairs, simply contact  
an Authorized Service Dealer for assistance. Service technicians  
are factory-trained and are capable of handling all service needs.  
These safety warnings cannot eliminate the hazards that they  
indicate. Common sense and strict compliance with the special  
instructions while performing the service are essential to prevent-  
ing accidents.  
When contacting an Authorized Service Dealer about parts and  
service, always supply the complete model number and serial  
number of the unit as given on its data decal, which is located on  
the generator.  
Four commonly used safety symbols accompany the Danger,  
Warning and Caution blocks. The type of information each indi-  
cates follows:  
nThis symbol points out important safety  
information that, if not followed, could  
endanger personal safety and/or property of  
others.  
Model No. _________________ Serial No.______________  
This symbol points out potential explosion  
hazard.  
  
Authorized SERVICE  
DEALER LOCATION  
To locate the nearest AUTHORIZED SERVICE  
DEALER, please call this number:  
This symbol points out potential fire hazard.  
This symbol points out potential electrical  
shock hazard.  
1-800-333-1322  
ONLY DEALER LOCATION INFORMATION  
CAN BE OBTAINED AT THIS NUMBER.  
1
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Safety Rules  
nSAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be  
copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to  
all operators and potential operators of this equipment.  
Study these SAFETY RULES carefully before installing, operating  
or servicing this equipment. Become familiar with this manual and  
with the unit. The generator can operate safely, efficiently and reli-  
ably only if it is properly installed, operated and maintained. Many  
accidents are caused by failing to follow simple and fundamental  
rules or precautions.  
GENERAL HAZARDS  
• For safety reasons, the manufacturer recommends that the  
installation, initial start-up and maintenance of this equipment  
is carried out by an Authorized Service Dealer.  
• The generator engine releases DEADLY carbon monoxide gas  
through its exhaust system. This dangerous gas, if breathed  
in sufficient concentrations, can cause unconsciousness or  
even death. Never operate the generator set with the vehicle  
inside any garage or other enclosed area. Shut down the  
generator and do not operate it until it has been inspected  
and repaired.  
The manufacturer cannot anticipate every possible circumstance  
that might involve a hazard. The warnings in this manual, and on  
tags and decals affixed to the unit, are, therefore, not all-inclusive.  
If using a procedure, work method or operating technique the  
manufacturer does not specifically recommend, ensure that it is  
safe for others. Also make sure the procedure, work method or  
operating technique that chosen does not render the generator  
unsafe.  
• DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM  
IS LEAKING OR HAS BEEN DAMAGED.  
• SYMPTOMS OF CARBON MONOXIDE POISONING ARE (a)  
inability to think coherently, (b) nausea, (c) vomiting,  
(d) twitching muscles, (e) throbbing temples, (f) dizzi-  
ness, (g) headaches, (h) weakness, and (i) sleepiness. IF  
EXPERIENCING ANY OF THESE SYMPTOMS, MOVE INTO  
FRESH AIR IMMEDIATELY. IF SYMPTOMS PERSIST, GET  
MEDICAL HELP.  
• Never sleep in the vehicle while the genset is running unless  
the vehicle has a working carbon monoxide detector. The  
exhaust system must be installed in accordance with the  
genset installation manual. Make sure there is ample fresh  
air when operating the genset in a confined area.  
• Keep hands, feet, clothing, etc., away from drive belts, fans,  
and other moving or hot parts. Never remove any drive belt or  
fan guard while the unit is operating.  
• Adequate, unobstructed flow of cooling and ventilating air is  
critical to correct generator operation and is required to expel  
toxic fumes and fuel vapors from the generator compartment.  
Without sufficient cooling airflow, the engine/generator quickly  
overheats, which causes serious damage to the generator. Do  
not alter the installation or permit even partial blockage of ven-  
tilation provisions, as this can seriously affect safe operation of  
the generator.  
nDespite the safe design of this generator,  
operating this equipment imprudently,  
neglecting its maintenance or being careless  
can cause  
possible injury or death. Permit only respon-  
sible and capable persons to operate or  
maintain this equipment.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
nParts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
• When working on this equipment, remain alert at all times.  
Never work on the equipment when physically or mentally  
fatigued.  
• Inspect the generator regularly, and contact the nearest  
Authorized Service Dealer immediately for parts needing repair  
or replacement.  
CALIFORNIA PROPOSITION 65 WARNING  
Engine exhaust and some of its constituents are known  
to the State of California to cause cancer, birth defects  
and other reproductive harm.  
• Before performing any maintenance on the generator, discon-  
nect its battery cables to prevent accidental start up. Disconnect  
the cable from the battery post indicated by a NEGATIVE, NEG  
or (–) first. Reconnect that cable last.  
• Never use the generator or any of its parts as a step. Stepping  
on the unit can stress and break parts, and may result in dan-  
gerous operating conditions from leaking exhaust gases, fuel  
leakage, oil leakage, etc.  
CALIFORNIA PROPOSITION 65 WARNING  
This product contains or emits chemicals known to the  
State of California to cause cancer, birth defects and  
other reproductive harm.  
2
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Safety Rules  
ELECTRICAL HAZARDS  
FIRE HAZARDS  
• The generator covered by this manual produces dangerous  
electrical voltages and can cause fatal electrical shock. Avoid  
contact with bare wires, terminals, connections, etc., while the  
unit is running. Ensure all appropriate covers, guards and bar-  
riers are in place before operating the generator. If work must  
be done around an operating unit, stand on an insulated, dry  
surface to reduce shock hazard.  
• Do not handle any kind of electrical device while stand-  
ing in water, while barefoot, or while hands or feet are wet.  
DANGEROUS ELECTRICAL SHOCK MAY RESULT.  
• During installation onto the vehicle, have the generator prop-  
erly grounded (bonded) either by solid mounting to the vehicle  
frame or chassis, or by means of an approved bonding conduc-  
tor. DO NOT disconnect the bonding conductor, if so equipped.  
DO NOT reconnect the bonding conductor to any generator part  
that might be removed or disassembled during routine mainte-  
nance. If the grounding conductor must be replaced, use only a  
flexible conductor that is of No. 8 American Wire Gauge (AWG)  
copper wire minimum.  
• For fire safety, the generator must be installed and maintained  
properly. Installation always must comply with applicable  
codes, standards, laws and regulations. Adhere strictly to local,  
state and national electrical and building codes. Comply with  
regulations the Occupational Safety and Health Administration  
(OSHA) has established. Also, ensure that the generator is  
installed in accordance with the manufacturer’s instructions  
and recommendations. Following proper installation, do noth-  
ing that might alter a safe installation and render the unit in  
noncompliance with the aforementioned codes, standards,  
laws and regulations.  
• Keep a fire extinguisher in the vehicle at all times. Extinguishers  
rated ABC” by the National Fire Protection Association are  
appropriate for use on the recreational vehicle generator elec-  
trical system. Keep the extinguisher properly charged and be  
familiar with its use. If there are any questions pertaining to fire  
extinguishers, consult the local fire department.  
• In case of accident caused by electric shock, immediately  
shut down the source of electrical power. If this is not pos-  
sible, attempt to free the victim from the live conductor. AVOID  
DIRECT CONTACT WITH THE VICTIM. Use a nonconducting  
implement, such as a rope or board, to free the victim from the  
live conductor. If the victim is unconscious, apply first aid and  
get immediate medical help.  
• Never wear jewelry when working on this equipment. Jewelry  
can conduct electricity resulting in electric shock, or may get  
caught in moving components causing injury.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any fuel or oil  
spills immediately. Ensure that no combustible materials are left  
in the generator compartment, or on or near the generator, as  
FIRE or EXPLOSION may result. Keep the area surrounding the  
generator clean and free from debris.  
• Gasoline is extremely FLAMMABLE and its vapors are  
EXPLOSIVE. Do not permit smoking, open flame, sparks or any  
source of heat in the vicinity while handling gasoline. Comply  
with all laws governing the storage and handling of gasoline.  
• This generator may use liquid propane (LP) gas as a fuel. LP  
gas is highly EXPLOSIVE. The gas is heavier than air and tends  
to settle in low areas where even the slightest spark can ignite  
the gas and cause an explosion.  
3
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General Information  
1.1 GENERATOR IDENTIFICATION  
Please record the following information from the generator DATA DECAL or information decal.  
1. Model Number ____________________  
3. kW Rating _________________________  
5. Phase _____________________________  
2. Serial Number _________________  
4. Rated Voltage _________________  
6. Hertz __________________________  
18  
8
2
15  
13  
10, 17 3 4 5  
1
12 11  
14  
16  
6
7
10  
9, 17  
REFERENCE NUMBER IDENTIFICATION  
1. Generator Air Intake  
2. Data Plate  
3. Engine Start/Stop Switch  
4. 7.5 amp Fuse  
10. Fuel Pump  
11. Oil Filter  
12. Oil Drain Plug  
13. Oil Dipstick and Filler Tube  
14. Air Filter (Behind access panel.)  
15. Spark Plugs  
16. Exhaust Outlet  
17. Fuel Filter  
18. Evaporative Port  
5. Circuit Breaker  
6. Optional Remote Panel Receptacle  
7. Generator AC Output Leads  
8. Starter Contactor  
9. Fuel Inlet  
4
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General Information  
1.2 GENERATOR APPLICABILITY  
These generators have been designed and manufactured for sup-  
plying electrical power for recreational vehicles. DO NOT modify  
the generator or use it for any application other than for what it  
was designed. If there are any questions pertaining to its applica-  
tion, write or call the factory. Do not use the unit until advised by  
competent authority.  
1.3 INSTALLATION  
This Owner’s Manual has been prepared under the assumption  
that a competent, qualified technician installed the generator into  
a recreational vehicle. We also assume the installer complied  
with all applicable codes, standards and regulations pertaining to  
installation.  
An INSTALLATION MANUAL was shipped with the generator. That  
Manual contains manufacturer’s instructions and recommenda-  
tions for installing the unit into an industrial vehicle. After installa-  
tion, installers should forward the Installation Manual to Owners/  
Operators for their information.  
For fire safety, the generator must have been  
properly installed in compliance with ANSI  
119.2-1975/NFPA 501C-1974, “Standard for  
Recreational Vehicles, Part III – Installation  
of Electrical Systems.” The generator also  
must have been installed in strict compliance  
with the manufacturer’s detailed installation  
instructions. After installation, do nothing  
that might render the unit in noncompliance  
with such codes, standards and instructions.  
Owners/Operators have the responsibility to make sure that noth-  
ing is done that might render the installation unsafe or in non-  
compliance with applicable codes, standards and instructions.  
1.4 SAFETY  
Before using the generator set, carefully read GENERAL SAFETY  
RULES inside the cover. Comply with these RULES to prevent  
accidents and damage to equipment and/or property. The manu-  
facturer suggests copying and posting the GENERAL SAFETY  
RULES to potential operators of this equipment.  
Use the generator set to supply electrical power for operating one  
of the following electrical loads:  
• RV 45 G: 120 and/or 240 volts, single phase, 60 Hz electrical  
loads. These loads can require up to 4500 watts (4.5 kW) of  
total power, but cannot exceed 37.5 AC amperes of current at  
120 volts (breaker is limited to 30 Amps).  
• RV 55 G: 120 and/or 240 volts, single phase, 60 Hz electrical  
loads. These loads can require up to 5500 watts (5.5 kW) of  
total power, but cannot exceed 45.8 AC amperes of current at  
120 volts or exceed 22.9 AC amperes at 240 volts.  
• RV 65 G: 120 and/or 240 volts, single phase, 60 Hz electrical  
loads. These loads can require up to 6500 watts (6.5 kW) of  
total power, but cannot exceed 54.1 AC amperes of current at  
120 volts or exceed 27 AC amperes at 240 volts.  
1.5 GENERATOR AC CONNECTION  
SYSTEM  
These air-cooled generator sets are equipped with dual stator  
AC power windings. These two stator windings supply electrical  
power to customer electrical loads by means of a dual 2-wire  
connection system.  
Generators may be installed to provide the following outputs:  
1. 120 VAC loads only — two loads, each with a maximum  
total wattage requirement equal to half of the generator’s  
rated power output (in watts), and 120V across the generator  
output terminals. Figure 1.1 shows the generator lead wire  
connections for 120VAC ONLY.  
Do not overload the generator. Some instal-  
lations may require that electrical loads be  
nꢀ  
Figure 1.1 – Connection for 120 Volts Only  
alternated to avoid overloading. Applying  
excessively high electrical loads may dam-  
age the generator and may shorten its  
life. Add up the rated watts of all electrical  
lighting, appliance, tool and motor loads  
the generator will power at one time. This  
total should not be greater than the watt-  
age capacity of the generator. If an electri-  
cal device nameplate gives only volts and  
amps, multiply volts times amps to obtain  
watts (volts x amps = watts). Some elec-  
tric motors require more watts of power (or  
amps of current) for starting than for con-  
tinuous operation.  
5
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General Information  
2. 120/240 VAC loads — one load with a maximum total watt-  
age requirement equal to the generator’s rated power output,  
and 240V across the generator output terminals; or two sepa-  
rate loads, each with a maximum total wattage requirement  
equal to half of the generator’s rated power output (in watts),  
and 120V across the generator output terminals. Figure 1.2,  
shows the generator lead wire connections for 120/240 VAC  
loads. Also refer to the "Line Breakers" section for circuit  
breaker ratings.  
NOTE  
Some installations using a “shared” fuel tank may have a gen-  
erator fuel pickup tube that is shorter than the vehicle engine’s  
pickup tube. Such an arrangement causes the generator engine  
to “run out of gas” while adequate fuel for the vehicle remains  
in the tank.  
To reduce lead and carbon deposits use high quality UNLEADED  
gasoline with the generator. Leaded REGULAR grade gasoline is an  
acceptable substitute.  
This procedure should be done by an Authorized Service Dealer or  
other qualified installer.  
NOTE:  
Using unleaded gasoline contributes to longer engine valve life by  
reducing lead and carbon deposits.  
Figure 1.2 - Connection for 120/240 Volts  
T1  
RED  
CB1  
nThe manufacturer does not recommend  
using any gasoline containing alcohol (such  
as “gasohol”). If using any gasoline contain-  
ing alcohol, it must not contain more than  
10 percent ethanol (Do not use E85), and it  
must be removed from the generator during  
storage. Do NOT use any gasoline contain-  
ing methanol. If using gasoline with alcohol,  
inspect more frequently for fuel leaks and  
other abnormalities.  
T2  
WHITE  
1.6.2 ENGINE OIL REQUIREMENTS  
All oil should meet minimum American Petroleum Institute (API)  
Service Class SJ, SL or better. Use no special additives. Select the  
oil's viscosity grade according to the expected operating tempera-  
ture (also see chart).  
CB2  
T3  
BLACK  
GROUNDED NEUTRAL  
STATOR POWER  
WINDINGS  
• SAE 30 Î Above 32° F  
• 10W-30 Î Between 40° F and -10° F  
• Synthetic 5W-30 Î 10° F and below  
1.6 SPECIFICATIONS  
1.6.1 FUEL REQUIREMENTS (GASOLINE)  
SAE 30  
This generator is equipped with a gasoline fuel system as standard  
equipment. Specific installations may provide either a separate fuel  
tank for the generator, or the generator may “share” the vehicle  
engine’s fuel tank.  
10W-30  
Syntthetiic 5W-30  
1.6.1.1 Fuel Consumption (gph)  
Model  
RV45G  
RV55G  
RV65G  
10% Load  
50% Load  
100% Load  
.33  
.35  
.37  
.45  
.55  
.65  
.73  
.89  
.97  
Crankcase and oil filter capacity is approximately 1.4 L or 1.5 U.S.  
quarts. DO NOT use special additives. See sections "Checking the  
Engine Oil Level" and "Changing the Engine Oil and/or Oil Filter" for  
oil level check and filling procedures.  
6
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General Information  
1.6.3 GENERATOR SPECIFICATIONS  
SERIES  
RV45G  
3600  
RV55G  
3600  
RV65G  
3600  
Rotor RPM  
Rotor Poles  
2
2
2
Engine RPM  
2571  
2571  
2571  
Rated Max. Continuous AC Output Watts*  
4500  
5500  
6500  
Voltage*  
120  
120  
120  
Rated Max. Continuous Current Amps (240V)  
37.5 (18.7)  
1
45.8 (22.9)  
1
54.1 (27)  
1
Phase  
Frequency  
Weight  
Length  
Width  
60 Hertz  
278 lbs.  
33.7 in.  
21.5 in.  
16.8 in.  
60 Hertz  
285 lbs.  
33.7 in.  
21.5 in.  
16.8 in.  
60 Hertz  
293 lbs.  
33.7 in.  
21.5 in.  
16.8 in.  
Height  
*
All units are re-connectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output  
** Maximum wattage and current are subject to, and limited by, such factors as fuel Btu content, ambient temperature, altitude, engine condition, etc.. Maximum power  
decreases about 3.5% for each 1,000 feet above sea level; and will also decrease about 1% for each 6° C (10° F) above 16° C (60° F) ambient temperature.  
• Fuel Metering System  
~ Carburetor assembly  
~ Fuel pump and lines  
• Air Induction System  
~ Intake pipe / manifold  
~ Air cleaner  
• Ignition System  
~ Spark plug  
~ Ignition module  
• Catalytic Converter (if equipped)  
1.6.4 ENGINE SPECIFICATIONS  
Type of Engine........................................................................GT-530  
Cooling Method................................................................ Air-cooled  
Rated Horsepower ...................................................18 at 3600 rpm  
Displacement........................................................................... 530cc  
Compression Ratio................................................................8.5 to 1  
Cylinder Block.................................. Aluminum w/Cast Iron Sleeve  
Type of Governor.......................................Electronic, Fixed Speed  
Engine Governor Speed................................................... 2571 rpm  
Air Cleaner................................................................. Paper Element  
Starter .................................................................. 12-volt DC Electric  
Ignition System ............................ Solid-state w/Flywheel Magneto  
Recommended Spark Plug  
The Emissions Compliance Period referred to on the Emissions  
Compliance Label indicates the number of operating hours for  
which the engine has been shown to meet Federal and California  
emission requirements. See the table below to determine the com-  
pliance period for this generator. The displacement of the engine is  
listed on the Emissions Compliance Label.  
NGK....................................................................................BPR6HS  
Spark Plug Gap ............................................. 0.030 inch (0.76 mm)  
Recommended Min. Battery.................. 400 Cold Cranking Amps  
Class II Emission Certified  
Displacement  
Category  
Compliance Period  
500 Hours  
1.7 EXHAUST EMISSIONS  
A
B
C
A
B
C
INFORMATION (GASOLINE)  
> 66 cc - < 225 cc  
250 Hours  
The Environmental Protection Agency (EPA) and the California Air  
Resource Board (CARB) require that this generator comply with  
exhaust emission standards. The generator is certified to meet all  
applicable exhaust emission levels. This generator is certified for  
use as a mobile engine. It is important that you follow the mainte-  
nance specifications listed in this manual to ensure that the engine  
complies with emission standards for the duration of its life. This  
engine is certified to operate on gasoline. The emission control  
system on the generator consists of the following:  
125 HOurs  
1000 Hours  
500 Hours  
225 cc  
250 Hours  
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Operation  
Figure 2.1 – Typical Control Panel  
1.8 EVAPORATIVE EMISSIONS  
INFORMATION  
This generator is subject to evaporative emission standards which  
have been implemented by the California Air Resource Board  
(CARB) and the Environmental Protection Agency (EPA). If this  
generator is offered for sale in the state of California, it must be  
covered by a CARB evaporative Executive Order. If this generator  
is offered for sale to the final consumer in any other state, certified  
low-permeation fuel line must be used to supply fuel to the genera-  
tor as required by EPA.  
Anyone who installs or configures a fuel system to supply this  
generator with gasoline is required to comply with all applicable  
evaporative emission regulations. If this generator is configured  
such that it shares the primary fuel system of a vehicle in which it  
is installed, reduced certification requirements may apply. See the  
ca.gov/msprog/macs/mac0505/mac0505.pdf for further details. If  
this generator is installed such that it uses a dedicated fuel system,  
detailed evaporative emission requirements apply; contact a repu-  
table fuel system manufacturer to purchase a complete fuel sys-  
tem certified for use with this generator, or consult the California  
Code of Regulations if you wish to obtain certification on your  
own. See the installation instructions in this manual for connecting  
fuel system vapor lines to the engine.  
The switch center position is the RUN position.  
To stop a running engine, press momentarily the bottom half of the  
switch to kill the ignition.  
2.1.2 7.5 AMP FUSE  
The fuse protects the engine’s DC control circuit against electrical  
overload. If the fuse element has melted open due to overloading,  
the engine cannot be cranked. If the fuse must be replaced, use  
only an identical 7.5 amp replacement fuse.  
This generator is not legal for sale in the state of California unless  
all CARB evaporative emission requirements are adhered to, and  
is not legal for sale in any other state unless certified low-per-  
meation fuel line is used to supply the generator with gasoline.  
Contact the California Air Resource Board or the Environmental  
protection agency for further information. CARB regulations can  
be found in 13 CCR §§2750 – 2773; EPA regulations can be  
found in 40 CFR Part 90.  
2.1.3 LINE BREAKERS  
Protects generator’s AC output circuit against overload, i.e., pre-  
vents unit from exceeding wattage/amperage capacity. The circuit  
breaker ratings are as follows:  
2.1 GENERATOR CONTROL PANEL  
The following features are mounted on the generator control panel  
(Figure 2.1):  
Model  
RV45  
RV55  
RV65  
Cir. Breaker 1  
Cir. Breaker 2  
240 Volt  
N/A  
30A  
20A  
30A  
N/A  
30A  
30A  
25A 2P  
30A 2P  
2.1.1 START/STOP SWITCH  
This generator is started with a "One Touch" starting sequence.  
Push up on the top half of the momentary switch. Hold for one  
(1) second and release. Note flashing indicator light on the switch.  
Fuel pump engages automatically for a three (3) to five (5) second  
delay before starter motor cranks the engine for 16 seconds or  
until the engine starts. If the engine does not start, the starter  
will cool for seven (7) seconds and crank the engine again for 16  
seconds. If the engine does not start, the starter will cool for seven  
(7) seconds before cranking for seven (7) seconds to a maximum  
cycle total of 90 seconds. Once started, the light on the switch  
stays on continuously. If the generator does not start at the end  
of the start sequence, a fault code will flash on the switch (see  
Diagnostics).  
NOTE:  
If this generator has been reconnected for dual voltage AC out-  
put (120/240 volts), install line breakers having an amperage  
rating equal to that stated in the preceding chart. The replace-  
ment line breakers consist of two separate breakers with a  
connecting piece between the breaker handles (so that both  
breakers will operate at the same time). If the unit is recon-  
nected for dual voltage, it is no longer RVIA listed.  
The switch center position is the RUN position.  
To stop a running engine, press momentarily the bottom half of the  
switch to kill the ignition.  
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Operation  
2.1.4 DIAGNOSTICS  
2.3.2 PRECHOKE  
If the generator shuts down due to a fault, the indicator will flash a  
code to identify the problem.  
The choke system also has a temperature-sensitive metal strip that  
adjusts choke valve angle according to ambient temperatures (i.e.,  
in cold ambient temperatures, choke valve closes more). Once the  
engine starts, an element heats the temperature-sensitive strip to  
a normal operating condition, opening the choke valve. This may  
take about three minutes in cooler weather (Gasoline only.).  
• 2 Flashes = Low Battery (Voltage falls below 11.0 VDC for one  
minute)  
NOTE:  
Alarm will clear automatically if voltage rises over 11.0 VDC.  
Battery voltage is not monitored during crank cycle.  
2.4 BEFORE STARTING THE  
• 3 Flashes = Overcrank (Unit does not start through entire start  
ENGINE  
cycle)  
NOTE:  
• 4 Flashes = Overspeed (Alternator spins at 4200 rpm/72 Hz  
or greater)  
Instructions and information in this manual assume the genera-  
tor has been properly installed, connected, serviced, tested and  
adjusted by a qualified installation technician or installation  
contractor.  
• 5 Flashes = Low Oil Pressure (Drops below the 5 psi threshold  
of the switch)  
NOTE:  
There is a five second delay of the alarm when the engine is  
first started up.  
2.4.1 INSTALLATION  
Generator installation must have been properly completed so it  
complies with all applicable codes, standards and regulations  
and with the manufacturer's recommendations. (See Part II -  
Installation Instructions.)  
• 6 Flashes = High Oil Temperature (Unit shuts down when tem-  
perature switch limit is reached)  
NOTE:  
2.4.2 ENGINE LUBRICATION  
As the unit cools down it will attempt to restart automatically  
when the temperature switch opens again.  
Have the engine crankcase properly serviced with the recommend-  
ed oil before starting. Refer to sections "Engine Specifications",  
"Checking the Engine Oil Level" and "Changing the Engine Oil and/  
or Oil Filter" for oil servicing procedures and recommendations.  
• 7 Flashes = Underspeed (Alternator spins less than 3240  
rpm/54 Hz for three (3) seconds)  
NOTE:  
After a fault is indicated, press stop momentarily to clear the  
alarm once the problem is fixed.  
nAny attempt to crank or start the engine  
before it has been properly serviced it with  
the recommended oil may result in an engine  
failure.  
2.2 OPTIONAL REMOTE  
START/STOP PANEL  
A remote mounted Start/Stop Panel is available that allows start-  
ing and stopping the generator engine conveniently from inside the  
vehicle. The remote panel includes a Start/Stop switch, hourmeter,  
generator run lamp, and a wire harness.  
2.4.3 FUEL SUPPLY  
The engine must have an adequate supply of proper fuel to oper-  
ate. Before starting it, check that sufficient fuel is available.  
NOTE:  
Depending on the installation, the generator may have either a  
separate fuel tank, or it may “share” the vehicle engine’s fuel  
tank.  
2.3 AUTOMATIC CHOKE  
This engine is equipped with an automatic choke that consists of  
two main components: a choke solenoid and prechoke (Gasoline  
only.).  
2.4.4 COOLING AND VENTILATING AIR  
2.3.1 CHOKE SOLENOID  
Air inlet and outlet openings in the generator compartment must  
be open and unobstructed for continued proper operation. Without  
sufficient cooling and ventilating airflow, the engine/generator  
quickly overheats, which causes it to shut down and may damage  
the generator.  
During engine cranking (Start/Stop switch at START), a solid-state  
choke module signals the choke solenoid to activate and cycle  
(choke on/choke off) until the engine starts. The choke solenoid  
thus opens and closes the carburetor choke valve only when  
the engine is cranking. When the engine starts, the choke stops  
cycling (Gasoline only.).  
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Operation  
NOTE:  
2.4.5 ENGINE EXHAUST GAS  
If starting from the generator control panel, turn OFF loads  
by setting the generator’s main circuit breaker to the OFF (or  
open) position. If starting from a remote panel, turn OFF loads  
using the means provided in the vehicle (such as a main circuit  
breaker). Electrical load circuits should be turned ON after the  
generator has started, stabilized and warmed up.  
Before starting the generator engine, be sure there is no way for  
exhaust gases to enter the vehicle interior and endanger people or  
animals. Close windows, doors and other openings in the vehicle  
that, if open, might permit exhaust gases to enter the vehicle.  
2. To crank and start the engine, push up on the Start/Stop  
switch momentarily and release. There is a delay as the fuel  
pump primes and the generator automatically begins the start  
sequence (Note the flashing light on the switch.).  
3. Let the engine run at no-load for a few minutes to stabilize and  
warm up.  
The generator engine releases DEADLY  
n
carbon monoxide gas through its exhaust  
system. This dangerous gas, if breathed in  
sufficient concentrations, can cause uncon-  
sciousness or even death. Never operate  
the generator set with the vehicle inside  
any garage or other enclosed area. DO NOT  
OPERATE THE GENERATOR IF THE EXHAUST  
SYSTEM IS LEAKING OR HAS BEEN  
4. Turn ON electrical loads using the means provided (such as a  
main circuit breaker or transfer switch).  
DAMAGED. Shut down the generator and  
do not operate it until it has been inspected  
and repaired. SYMPTOMS OF CARBON  
MONOXIDE POISONING ARE (a) inability to  
think coherently, (b) nausea, (c) vomiting, (d)  
twitching muscles, (e) throbbing temples, (f)  
dizziness, (g) headaches, (h) weakness, and  
(i) sleepiness. IF EXPERIENCING ANY OF  
THESE SYMPTOMS, MOVE INTO FRESH AIR  
IMMEDIATELY. IF SYMPTOMS PERSIST, GET  
MEDICAL HELP.  
2.6 STOPPING THE GENERATOR  
1. Turn OFF all electrical loads using the means provided (such  
as a main circuit breaker or transfer switch).  
2. Let generator run at no-load for a few minutes, to stabilize  
internal engine generator temperatures.  
3. Place the Start/Stop switch in its STOP position. The engine  
will come to a complete stop.  
2.7 APPLYING LOADS TO  
GENERATOR  
When applying electrical loads to the generator, observe these  
guidelines:  
nNever sleep in the vehicle while the genset  
is running unless the vehicle has a working  
• Before applying electrical loads, let the generator stabilize and  
warm up for a minute or two.  
• DO NOT overload the generator.  
carbon monoxide detector. The exhaust sys-  
tem must be installed in accordance with the  
genset installation manual. Make sure there  
is ample fresh air when operating the genset  
in a confined area.  
2.7.1 LETTING THE ENGINE STABILIZE  
The generator supplies correct rated voltage only at the proper  
governed speed. Some electrical appliances may be extremely  
sensitive to voltage. Incorrect voltages can damage such appli-  
ances.  
2.5 STARTING THE GENERATOR  
NOTE:  
If electrical loads are applied at reduced operating speeds, such  
loads imposed on the engine when sufficient power is not available  
may shorten engine life. Never turn ON electrical loads until after  
the generator engine has started and stabilized at no-load.  
Read the vehicle manufacturer’s instructions. The owner/  
operator should become familiar with the vehicle in which this  
generator is installed. Differences exist between vehicles. For  
example, some vehicles may use a transfer switch to isolate  
dockside power from the generator, while other vehicles may  
use an isolating receptacle. Some vehicles may be equipped  
with a DC converter which allows the generator to power certain  
DC lighting and other DC loads.  
2.7.2 DO NOT OVERLOAD THE GENERATOR  
Read the rated wattage/amperage capacity of the generator on the  
generator data label (See the "Generator Identification" section.).  
To crank and start the generator engine, proceed as follows:  
Applying electrical loads in excess of the unit’s rated capacity will  
cause the engine/generator to automatically shut down.  
1. Turn OFF electrical loads using the means provided in the  
vehicle (such as a main line circuit breaker or transfer  
switch).  
To avoid overloading, add up the wattage of all connected electrical  
lighting, appliance, tool and motor loads. This total should not be  
greater than the generator’s rated wattage capacity.  
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Operation  
• Most lighting, appliance, tool and motor loads indicate their  
required watts on their nameplate or data plate. For light bulbs,  
simply note the wattage rating of the bulb.  
2.8.3 FIELD BOOST  
The Controller Circuit Board houses a field boost diode and resistor  
that are not part of the automatic choke circuit. These two compo-  
nents are part of a “field boost” circuit (Figure 2.3). During engine  
cranking only, a positive DC (battery) voltage is delivered through  
a diode, resistor, brushes, slip rings, and the generator rotor.  
Application of this voltage to the rotor “flashes the field” whenever  
it is started. Flashing of the field each time the generator starts  
makes sure that a sufficiently strong magnetic field is available to  
produce “pickup” voltage in the stator windings.  
• If a load does not show its rated wattage, multiply that load’s  
rated VOLTS times AMPS to obtain WATTS.  
• Induction type motors (such as those that run the vehicle’s  
furnace fan, refrigerator, air conditioner, etc.) need about 2-1/2  
times more watts of power for starting than for running (for a  
few seconds during motor starting). Be sure to allow for this  
when connecting electrical loads to the generator. First, figure  
the watts needed to start electric motors in the system. To that  
figure, add the running wattages of other items that will be oper-  
ated by the generator.  
Figure 2.3 – Field Boost Circuit  
• Do not apply heavy electrical loads for the first two or three  
hours of operation.  
2.8 PROTECTION SYSTEMS  
2.8.1 LOW OIL PRESSURE SWITCH  
This switch (Figure 2.2) has normally closed (N.C.) contacts that  
are held open by engine oil pressure during cranking and operat-  
ing. Should oil pressure drop below a preset level, switch contacts  
close, and the engine automatically shuts down. The unit should  
not be restarted until oil is added.  
2.8.2 HIGH TEMPERATURE SWITCH  
This switch (Figure 2.2), which has normally open (N.O.) contacts,  
is mounted near the oil filter. The contacts close if the temperature  
should exceed approximately 270º F (132º C) for gasoline mod-  
els.  
2.8.4 OVERVOLTAGE PROTECTION  
A solid-state voltage regulator (Figure 2.4) controls the generator’s  
AC output voltage. This regulator supplies an excitation current to  
the rotor. By regulating the rotor’s excitation current, the strength  
of its magnetic field is regulated and, in turn, the voltage delivered  
to connected electrical loads is controlled. When the AC frequency  
is 60 Hertz, voltage is regulated at 125 to 120 volts.  
Figure 2.2 – Low Oil Pressure and  
High Temperature Switches  
Figure 2.4 – Solid State Voltage Regulator  
11  
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