INTRODUCTION READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood, con- tact the nearest Authorized Service Dealer for start- ing, 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 person- nel to special instructions about a particular opera- tion that may be hazardous if performed incorrectly...
Part I — Operating 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 ... 2 Section 1 – General Information ... 4 Generator Identification ...
Safety Rules Recreational Vehicle Generators 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. ...
• 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.
Section 1 – General Information Recreational Vehicle Generators GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal. 1. Model Number _____________________ 3. kW Rating _________________________ 5. Phase ______________________________ 1. Generator Air Intake Screen 2. Data Plate 3.
GENERATOR APPLICABILITY 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 applica- tion, write or call the factory.
Section 1 – General Information Recreational Vehicle Generators Figure 1.1 – Connection for 120 Volts Only Figure 1.2 - Connection for 120/240 Volts GROUNDED NEUTRAL STATOR WINDINGS SPECIFICATIONS 1.6.1 FUEL REQUIREMENTS (GASOLINE) This generator is equipped with a gasoline fuel system as standard equipment.
1.6.3 GENERATOR SPECIFICATIONS SERIES Rotor RPM Rotor Poles Engine RPM Rated Max. Continuous AC Output Watts* Voltage* Rated Max. Continuous Current Amps (240V) Phase Frequency Battery Charging Current (Max.) Weight Length Width Height * All units are reconnectable to 120 and/or 240 volts, dual voltage output. Units are not listed per RVIA/ANSI when reconnected for dual voltage output 1.6.5 EMISSIONS COMPLIANCE PERIOD For nonhandled engines the Emissions Compliance Period referred to on the Emissions Compliance...
Section 2 – Operation Recreational Vehicle Generators OPTIONAL REMOTE START/STOP PANEL A remote mounted Start/Stop Panel (Figure 2.2) is available that allows starting and stopping the gen- erator engine conveniently from inside the vehicle. The remote panel includes a Start/Stop switch, hour- meter, generator run lamp, a fuel prime switch, and a wire harness.
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.
Section 2 – Operation Recreational Vehicle Generators 2.7.2 DO NOT OVERLOAD THE GENERATOR Read the rated wattage/amperage capacity of the gen- erator on the generator data decal (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.
2.8.4 OVERVOLTAGE PROTECTION A solid-state voltage regulator (Figure 2.5) controls the generator’s AC output voltage. This regulator supplies an excitation current to the rotor. By regulat- ing 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.
Section 3 – Maintenance Recreational Vehicle Generators 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 2.8.5). Thereafter, change the oil every 100 operating hours.
Figure 3.3 – Engine Air Cleaner Offset S Wing CHECKING THE ENGINE SPARK PLUG Clean the spark plug and reset the spark plug gap every 100 hours of operation. 1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.
Section 3 – Maintenance Recreational Vehicle Generators CLEANING THE GENERATOR Keep the generator set as clean and dry as possible. Protect the unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and mois- ture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings.
MAJOR SERVICE MANUAL To obtain a service manual for the generator, contact the nearest Authorized Service Dealer. Make sure to identify the MODEL NUMBER and SERIES. Manuals can be obtained from the internet website or a service dealer. 3.10 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement.
Safety Rules Recreational Vehicle Generators DANGER: For fire safety, installation of a generator into a recreational vehicle must comply strictly with article 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “Standard for Recreational Vehicles” (Part 3, “Installation of Electrical Systems”). In addition, installation must comply with the manufacturer’s instructions and recommendations.
• 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. • Never insert any tool or other object through open- ings in the generator interior, even if the unit is not running.
Section 5 – General Information Recreational Vehicle Generators PURPOSE AND SCOPE OF THE INSTALLATION INSTRUCTIONS These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product's installation requirements. Give serious consideration to all information and instructions in the manual, both for safety and for continued reliable operation of the equipment.
Section 6 – Installation Recreational Vehicle Generators Figure 5.3 - Connection for 120/240 Volts GROUNDED NEUTRAL STATOR WINDINGS • The AC connection system on all air-cooled PRIMEPACT series generators uses a GROUNDED neutral. • A separate green ground wire is connected to the recreational vehicle’s junction box.
• If the generator cannot be bolted directly to the supporting frame or support tubing, consider using additional tubing, angle brackets or other supports to give the supporting frame sufficient strength. 6.1.3 SUSPENDED MOUNTING If planning to suspend the generator below the hori- zontal support tubing, the suspension method to use with the vehicle frame members must (a) be able to support the weight of the generator AND (b) provide...
Section 6 – Installation Recreational Vehicle Generators • If the compartment is lined with galvanized steel, it may be constructed of any material. The manu- facturer recommends that the compartment be constructed of 1/2-inch thick plywood (not strand- board), with the floor made of a double thickness of 1/2-inch plywood with the grain of the wood at cross section for added strength (Figure 6.5).
Using a combination of sound insulating materials can often reduce noise more effectively than a single material. For example, a sheet of lead or visco-elastic material, along with a layer of other acoustical mate- rial, is more effective than when a single material is used.
Figure 6.10 – Generator Fuel System Fuel Line Factory installed generator fuel system components include (a) fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and (d) interconnecting lines and fittings. Connect a fuel supply line to the fuel filter inlet.
Section 6 – Installation Recreational Vehicle Generators 6.5.2 PARTS NOT INCLUDED IN FUEL SYSTEM The propane fuel system does NOT include such items as (a) gas tank, (b) gas piping, (c) fittings, (d) valves, and (e) primary regulator, used to store the gaseous fuel and deliver it to the gaseous fuel sole- noid (Figure 6.11).
Figure 6.12 – LP Gas Carburetion Diagram The greater the airflow through the carburetor ven- turi, the lower the pressure at the venturi throat. The lower the pressure at the venturi throat, the greater the diaphragm movement, and the greater the move- ment of the regulator valve.
Section 6 – Installation Recreational Vehicle Generators Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping. This causes excessive back pressure on the generator engine. Also, water from one engine can dam- age the other engine. 6.6.1 MUFFLERS AND SPARK ARRESTORS This muffler meets code and standard requirements of the U.S.
6.7.1 ELECTRICAL JUNCTION BOX Install an approved, square electrical junction box with a blank cover on the interior or exterior wall of the area planned for installation of the generator (NOT on the generator). Route the generator's AC output leads into this junction box through approved flexible conduit.
Section 6 – Installation Recreational Vehicle Generators 6.7.6 POWER SUPPLY CORD The power supply cord must comply with all appli- cable codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected. 6.7.7 GROUND FAULT CIRCUIT INTERRUPTERS...
Section 7 – Post Installation Recreational Vehicle Generators OPTIONAL ACCESSORIES A plug-in receptacle (Figure 6.18) is provided on the generator set, above the muffler enclosure. Use this receptacle to connect an optional remote-mounted start/stop panel to the generator. Installation of such a panel will permit starting and stopping the gen- erator engine from any convenient location inside the vehicle.
TESTING UNDER LOAD Apply electrical loads equal to about 75 to 100 per- cent of the unit's rated wattage/amperage capacity. Let the unit run at least 30 minutes with load applied. During this part of the test, check that the unit is not running excessively hot and that adequate cooling airflow is available.
Section 12 – Warranty Recreational Vehicle Generators CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EPA), together with Generac Power Systems, Inc. (Generac), are pleased to explain the Emission Control System Warranty on your new engine.* New utility, and lawn and garden equipment engines must be designed, built and equipped to meet stringent anti-smog standards for the state of California and the federal government.
Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Section 12 – Warranty Recreational Vehicle Generators GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS NOTE: ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES. For a period of 3 (three) years of operation from the date of original sale, Generac Power Systems, Inc. (Generac) will, at its option, repair or replace any part which, upon examination, inspection and testing by Generac or a Generac Authorized Warranty Service Facility, is found to be defective under normal use and service, in accordance with the warranty schedule set forth below.