Generac Power Systems 005411-0, Owner'S Manual

Page 1: ...www generac com or 1 888 GENERAC Air cooled Recreational Vehicle Generators RV 45 55 and 65 Owner s Manual Models 005411 0 005413 0 005415 0 005751 0 005752 0 005753 0 005855 0 005856 0 005857 0 ...

Page 2: ...4 3 7 Cleaning the Generator 14 3 8 Battery Maintenance 14 3 9 Adjusting Valve Clearance 15 3 10 Major Service Manual 16 3 11 Drive Belt 16 3 12 Exercising the Generator 16 3 13 Out of Service Procedure 16 3 14 RV Generator Service Interval 16 Part II Installation Instructions Safety Rules 18 Notice to Installer 18 Section 1 General Information 20 1 1 Purpose and Scope of the Installation Instruct...

Page 3: ...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 CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded view...

Page 4: ...s 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...

Page 5: ...moving components causing injury 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 generat...

Page 6: ...___ 1 2 3 4 5 8 15 13 16 14 6 7 9 17 10 12 11 10 17 18 1 1 GENERATOR IDENTIFICATION REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake 2 Data Plate 3 Engine Start Stop Switch 4 7 5 amp Fuse 5 Circuit Breaker 6 Optional Remote Panel Receptacle 7 Generator AC Output Leads 8 Starter Contactor 9 Fuel Inlet 10 Fuel Pump 11 Oil Filter 12 Oil Drain Plug 13 Oil Dipstick and Filler Tube 14 Air Filter B...

Page 7: ...ppliance 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 1 3 INSTALLATION This...

Page 8: ...h 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 Using unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits nThe manufacturer does not r...

Page 9: ...ystem 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 Emiss...

Page 10: ...ted on the generator control panel Figure 2 1 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 ...

Page 11: ... starts the choke stops cycling Gasoline only 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 m...

Page 12: ...F 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 2 To crank and start the engine push up on the Start Stop switch momentarily and release There i...

Page 13: ...H 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 Figure 2 2 Low Oil Pressure and High Temperature Switches 2 8 3 FIELD BOOST The Controller Circuit Board houses a field boost diode and resistor that are not part of the automatic choke c...

Page 14: ...l Fill 3 2 CHANGING THE ENGINE OIL AND OR OIL FILTER nHot 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 Oil Change Intervals see Section RV Generator Service Interval To change the oil and oil filter proceed as follows 1 Run the engine until it is thoroughly warmed up at least five minute...

Page 15: ... and turn turn clockwise to secure Figure 3 3 Engine Air Cleaner Air Cleaner Base Air Cleaner Air Cleaner Cover Knob 3 4 CHECKING THE ENGINE SPARK PLUG Reset the spark plug gap or replace the spark plugs as necessary See the Service Schedule section for maintenance requirements 1 Clean the area around the base of the spark plugs to keep dirt and debris out of the engine 2 Remove the spark plugs an...

Page 16: ...ich is detrimental to the generator nDo NOT use a forceful spray of water to clean the generator Water will enter the gen erator interior and cause problems and may also contaminate the generator fuel system 3 8 BATTERY MAINTENANCE NOTE This generator is not equipped with an internal battery charger It is intended for use in systems where an external battery char ger is installed by the RV O E M o...

Page 17: ... step to insure longest life for the engine To check valve clearance The engine should be cool before checking If valve clearance is 0 002 0 004 0 05 0 1mm adjustment is not needed Remove spark plug wires and position wires away from plugs Remove spark plugs Make sure the piston is at Top Dead Center TDC of its com pression stroke both valves closed To get the piston at TDC remove the intake scree...

Page 18: ...l 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 Clean and wipe the entire generator 3 13 2 RETURN TO SERVICE To return the unit to service after storage proceed as follows 1 Check the tag on the engine for oil viscosity and classification Ve...

Page 19: ...Part II Installation Instructions ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION Part II Installation Instructions ...

Page 20: ...us 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 DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISONING ARE a inability...

Page 21: ...tricity resulting in electric shock or may get caught in moving components causing injury 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 Adminis...

Page 22: ...ilable same as Item 1 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 RVIA EGS 1 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...

Page 23: ...21 Figure 1 2 Major Features and Dimensions Drawing No 0G5519 D Installation ...

Page 24: ...on is to be used on the compartment walls and ceiling the minimum recommended applies to the space between the generator and such insulation The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense If mounting the generator in an enclosed compartment the base of the generator must rest flat on the floor without any gaps When usin...

Page 25: ...ENERATOR 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 top s...

Page 26: ...ble sound insulating material See Sound Insulating Materials Figure 2 6 Types of Lock Seams Do not install any flammable material directly above or around the compartment Heat transferred through the compartment struc ture may be sufficient to ignite char or dis color seat cushions fiberboard and other flammable materials Use approved nonflam mable insulating materials in high tempera ture areas 2...

Page 27: ... openings in the generator compartment for the following items Figure 2 9 Engine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts See Generator Restraint nFuel lines and exhaust piping must not pen etrate into the vehicle living area 2 3 COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling vent...

Page 28: ...26 Figure 2 9 Compartment Floor Cutout Drawing 0G4432 A Installation ...

Page 29: ...e 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 Gasoline generators are equipped with an Evaporative Emissions Port that may be used in conjunction with a cer...

Page 30: ...ered unimproved land a spark arrestor must be provided 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 When installing replacing the tailpipe or spark arrestor compo nents verify that the ta...

Page 31: ... 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 compar...

Page 32: ...ed with an internal battery charger It is intended for use in systems where an external battery char ger is installed by the RV O E M or an aftermarket installer 2 7 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 capab...

Page 33: ...31 Figure 2 14 Typical Transfer Switch Isolation Method Figure 2 15 Typical Installation With Isolation Receptacle Installation ...

Page 34: ...IONAL ACCESSORIES A plug in receptacle Figure 2 17 is provided on the generator set Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit starting and stopping the generator engine from any convenient location inside the vehicle 2 8 1 REMOTE PANEL MODELS The remote panels mount a rocker type start stop switch a Generato...

Page 35: ...es to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load see Testing Under Load Run the unit at least 30 min utes with loads applied 6 Turn off all electrical loads by sett...

Page 36: ...nal Electrical Codes 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 Generator is always isolated from other power sources BATTERY INSTALLATION Recommended battery is installed Recommended cables are installed Cables are clean and tight Cables are connected properly Proper...

Page 37: ...ap or replace as needed 7 Bad ignition magneto on engine 7 Replace if defective 8 Bad carburetor 8 Adjust repair or replace 9 Dirty air cleaner 9 Clean or replace as needed Engine starts hard runs rough 1 Dirty engine air cleaner 1 Clean or replace as needed 2 Automatic choke is sticking 2 Free choke linkage as needed 3 Defective spark plugs 3 Clean regap or replace 4 Defective ignition magneto 4 ...

Page 38: ...36 Electrical Data Wiring Diagram Drawing No 0G4221 C ...

Page 39: ...37 Wiring Diagram Drawing No 0G4221 C Electrical Data ...

Page 40: ...38 Electrical Data Wiring Diagram Drawing No 0H3633 A ...

Page 41: ...39 Wiring Diagram Drawing No 0H3633 A Electrical Data ...

Page 42: ...40 Exploded Views Parts Lists Enclosure Drawing No 0G3881 F ...

Page 43: ...PPER BLOWER HOUSING GASKET 30 0G3398 1 EXHAUST DIVIDER PANEL 31 0G3912 1 MUFFLER HOLD DOWN BRACKET 32 0G3400 1 ENCLOSURE EXHAUST SIDE PANEL 33 0G5240 1 FBR GLASS ENCLOSURE MFLR BACK 34 0G5242 1 FOAM EXHAUST END ENCL FRONT 35 0G5241 2 FBR GLASS ENCLOSURE MFLR SIDE 36 045756 9 SCREW HHTT M6 1 0X10 ZYC 37 0G5755 1 BUMPER 38 0G5761 1 STAND OFF 39 022473 1 WASHER FLAT 1 4 40 022097 1 WASHER LOCK 1 4 41...

Page 44: ...42 Exploded Views Parts Lists Control Panel Drawing No 0H3635 C ...

Page 45: ... 1 C PNL FACE 32 092036 4 SCREW PPHM 6 32 X 1 4 SEMS 33 0A9611 1 FUSE 7 5AXBK AGC7 5NX 34 032300 1 HOLDER FUSE 35 0G4215 1 SWITCH RKRSPDT ON OFF ON ILLUM ITEM PART NO QTY DESCRIPTION 36 082025 4 NUT HEX LOCK M5 0 8 NYINS ZINC 37 0F9719 1 ASSY PCB VREG AIR COOLED 2006 38 0G3977 1 ASSY PCB RV CONTROLLER 39 0G3530 1 C PNL FRAME RV 40 075476 2 SCREW PPHM M4 0 7 X 16 41 090987 2 SCREW PPHM M3 0 5 X 12 ...

Page 46: ...44 Exploded Views Parts Lists Base Pulley Drawing No 0G7720 B ...

Page 47: ...USING WALL 23 0G3742 1 GASKET LOWER BLOWER HOUSING 24 0G7670 1 FRAME GT530 RV MOUNTING 25 0E0588 1 SPACER SAFETY BOLT 375 I D 26 0G4702 2 SCREW HHC 5 16 18 X 3 SPC 27 029451 1 5ft TAPE ELEC UL FOAM 1 8 X 1 2 28 0G3426 1 DUCT AIR OUT 29 0G5676 1 GASKET AIR OUT DUCT 0G5676A 1 GASKET AIR OUT DUCT OPPOSITE SIDE 30 0G4692 1 SCREEN BOTTOM AIR OUT 31 022473 3 WASHER FLAT 1 4 M6 ZINC 32 0A2110 3 SCREW SWA...

Page 48: ...46 Exploded Views Parts Lists Engine Accessories Drawing No 0G7718 K ...

Page 49: ...HOSE 3 8 I D 49 0G4426 1 ASSY OIL DRAIN FITTING ITEM PART NO QTY DESCRIPTION 50 0G3386 1 OIL FILTER SUPPORT 51 0A2311 2 SCREW SWAGE 1 4 20 X 1 52 070185B 1 OIL FILTER 53 0D9235 1 OIL PRESSURE SWITCH 5 PSI 54 0G4793 1 SWITCH THERMAL 270F 55 043182 2 WASHER LOCK M3 56 0C1085 2 SCREW PPHM M3 0 5 X 8 58 0G4576 1 BRACKET OIL CHECK TUBE 59 0A2110 1 SCREW SWAGE 1 4 20 X 1 2 60 0G3407 1 WRAPPER ENGINE VAL...

Page 50: ...48 Exploded Views Parts Lists 530 RV Engine Drawing No 0G7719 B ...

Page 51: ...R 25 0E9368 2 SPARK PLUG 26 077168 12 SCREW HHC M8 1 25 X 56 27 084186 4 WASHER VALVE SPRING 28 088156 2 SEAL VALVE STEM 29 0C4390 4 VALVE SPRING 30 0C3733 4 VALVE RETAINER 31 0C3592 8 KEEPER VALVE SPRING 32 077161 4 STUD ROCKER ARM 33 077160 4 ROCKER ARM 34 076307 4 JAM NUT ROCKER ARM 35 0E9353A 2 PUSH ROD GUIDE PLATE 36 0E9304 1 CYLINDER HEAD CYL 1 37 0C3591 2 INTAKE VALVE 38 0C3590 2 EXHAUST VA...

Page 52: ...50 Exploded Views Parts Lists Rotor Stator Drawing No 0G3953 B ...

Page 53: ...EARING CARRIER 13 0G3877H 1 RTR 200 4 5AD1 RV 0G3878H 1 RTR 200 5 5AD1 RV 0G3879H 1 RTR 200 6 5AD1 RV 14 0G3893H 1 STR 200 4 5AD1 RV 0G3894H 1 STR 200 5 5AD1 RV 0G3895H 1 STR 200 6 5AD1 RV 15 0G3381 1 UPPER BEARING CARRIER 16 022129 4 WASHER LOCK M8 5 16 17 045771 4 NUT HEX M8 1 25 G8 CLEAR ZINC 18 066386 1 ASSEMBLY BRUSH HOLDER 19 066849 2 SCREW HHTT M5 0 8 X 16 20 0G3542 1 FAN UPPER ALTERNATOR 2...

Page 54: ...oved by Generac You are responsible for contacting a Generac Authorized Warranty Dealer 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 Dealer To locate the Generac Authorized Warranty Service Dealer nearest you...

Page 55: ... 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 period prior to the first scheduled replacement point for that part 4 Repair or replacement of any warranted emissions related p...

Page 56: ...ide 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...