Generac Power Systems RV 45 SERIES Owner's Manual
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Generac Power Systems RV 45 SERIES Owner's Manual

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Owner's Manual
Air-cooled Recreational Vehicle Generators
RV 45, 55, and 65
Models: 005410-1, 005412-1
005414-1, 005751-0
005752-0, 005753-0
This manual should remain with the unit.

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  • Page 1 Owner’s Manual Air-cooled Recreational Vehicle Generators RV 45, 55, and 65 Models: 005410-1, 005412-1 005414-1, 005751-0 005752-0, 005753-0 This manual should remain with the unit.

  • Page 2: Introduction

    INTRODUCTION CONTENTS This manual contains pertinent owner’s information, including READ THIS MANUAL THOROUGHLY warranty, electrical diagrams, exploded views and lists of repair parts. In addition, the latter portion of this manual contains infor- If any portion of this manual is not understood, contact the near- mation necessary for the proper installation of these generators.

  • Page 3: Table Of Contents

    Table of Contents Recreational Vehicle Generators Part I — Operating Instructions Part II — Installation Instructions Introduction .........Inside Front Cover Safety Rules ............18 Read This Manual Thoroughly ........IFC Contents ................. IFC Section 1 — General Information ......20 Operation and Maintenance ..........

  • Page 4: Safety Rules

    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.
  • Page 5 Safety Rules Recreational Vehicle Generators     ELECTRICAL HAZARDS FIRE HAZARDS • The generator covered by this manual produces dangerous • For fire safety, the generator must be installed and maintained electrical voltages and can cause fatal electrical shock. Avoid properly.

  • Page 6: Section 1 - General Information

    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 _____________________ 2. Serial Number __________________ 3. kW Rating _________________________ 4. Rated Voltage __________________ 5. Phase _____________________________ 6.

  • Page 7: Generator Applicability

    Section 1 – General Information Recreational Vehicle Generators GENERATOR APPLICABILITY INSTALLATION These generators have been designed and manufactured for sup- This Owner’s Manual has been prepared under the assumption plying electrical power for recreational vehicles. DO NOT modify that a competent, qualified technician installed the generator into the generator or use it for any application other than for what it a recreational vehicle.

  • Page 8: Specifications

    Section 1 – General Information Recreational Vehicle Generators 120/240 VAC loads — one load with a maximum total watt- NOTE age requirement equal to the generator’s rated power output, Some installations using a “shared” fuel tank may and 240V across the generator output terminals; or two sepa- have a generator fuel pickup tube that is shorter than rate loads, each with a maximum total wattage requirement the vehicle engine’s pickup tube.

  • Page 9: Section 2 - Operation

    Section 2 – Operation Recreational Vehicle Generators 1.6.3 GENERATOR SPECIFICATIONS SERIES RV45G RV55G RV65G Rotor RPM 3600 3600 3600 Rotor Poles Engine RPM 2571 2571 2571 Rated Max. Continuous AC Output Watts* 4500 5500 6500 Voltage* Rated Max. Continuous Current Amps (240V) 37.5 (18.7) 45.8 (22.9) 54.1 (27)

  • Page 10: Optional Remote Start/Stop Panel

    Section 2 – Operation Recreational Vehicle Generators 2.1.2 7.5 AMP FUSE NOTE: As the unit cools down it will attempt to restart auto- The fuse protects the engine’s DC control circuit against electrical matically when the temperature switch opens again. overload.

  • Page 11: Starting The Generator

    Section 2 – Operation Recreational Vehicle Generators 2.4.2 ENGINE LUBRICATION DANGER Have the engine crankcase properly serviced with the recommend-  ed oil before starting. Refer to sections "Engine Specifications", Never sleep in the vehicle while the genset is "Checking the Engine Oil Level" and "Changing the Engine Oil and/ running unless the vehicle has a working carbon or Oil Filter"...

  • Page 12: Applying Loads To Generator

    Section 2 – Operation Recreational Vehicle Generators APPLYING LOADS TO 2.8.2 HIGH TEMPERATURE SWITCH GENERATOR This switch (Figure 2.2), which has normally open (N.O.) contacts, is mounted near the oil filter. The contacts close if the temperature When applying electrical loads to the generator, observe these should exceed approximately 270º...

  • Page 13: Section 3 - Maintenance

    Section 3 – Maintenance Recreational Vehicle Generators 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 Never operate the engine with the oil level the rotor. By regulating the rotor’s excitation current, the strength below the “Add”...

  • Page 14: Maintaining The Engine Air Cleaner

    Section 3 – Maintenance Recreational Vehicle Generators Figure 3.2 — Engine Oil Filter Figure 3.3 – Engine Air Cleaner Air Cleaner Base Air Cleaner Knob Engine Oil Filter Air Cleaner Cover CHECKING THE ENGINE SPARK PLUG Twist Counter-clockwise to Loosen Reset the spark plug gap or replace the spark plugs as necessary.

  • Page 15: Fuel Filter (Gasoline Only)

    Section 3 – Maintenance Recreational Vehicle Generators FUEL FILTER CLEANING THE GENERATOR (GASOLINE ONLY) Remove and replace the fuel filter (Figure 3.5) every 400 hours of Keep the generator set as clean and dry as possible. Protect the operation. unit against excessive dust, dirt, corrosive vapors, road splash, etc.

  • Page 16: Adjusting Valve Clearance

    Section 3 – Maintenance Recreational Vehicle Generators ADJUSTING VALVE CLEARANCE DANGER After the first 50 hours of operation, check the valve  Do not dispose of the battery in a fire. The clearance in the engine, adjust if necessary. battery is capable of exploding. Storage batter- Important: If feeling uncomfortable about doing this procedure or ies give off explosive hydrogen gas.

  • Page 17: 3.10 Major Service Manual

    Section 3 – Maintenance Recreational Vehicle Generators 3.13.2 RETURN TO SERVICE When valve clearance is correct, hold the pivot ball stud in place with the allen wrench and tighten the rocker arm jam nut. Tighten To return the unit to service after storage, proceed as follows: the jam nut to 174 in/lbs.

  • Page 18: Section 4 - Notes

    Section 4 – Notes Recreational Vehicle Generators...

  • Page 19: Part Ii - Installation Instructions

    PART II – INSTALLATION INSTRUCTIONS DANGER ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!

  • Page 20: Safety Rules

    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”).
  • Page 21 Safety Rules Recreational Vehicle Generators • 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-   FIRE HAZARDS gerous operating conditions from leaking exhaust gases, fuel leakage, oil leakage, etc.

  • Page 22: Section 1 - General Information

    Section 1 – General Information Recreational Vehicle Generators PURPOSE AND SCOPE OF THE CSA Electrical Bulletin 946, available from the Canadian Standards Association, Housing and Constructions Materials INSTALLATION INSTRUCTIONS Section, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, These Installation Instructions have been prepared especially for M9W 1R3.

  • Page 23: Major Features And Dimensions

    Section 1 – General Information Recreational Vehicle Generators Figure 1.2 - Major Features and Dimensions (Drawing No. 0G5519-C)

  • Page 24: Section 2 - Installation

    Section 2 – Installation Recreational Vehicle Generators Figure 1.3 - Connection for 120/240 Volts • The location must provide sufficient room to allow minimum clearances as outlined in "Generator Compartments". If sound insulation is to be used on the compartment walls and ceiling, the minimum recommended applies to the space between the generator and such insulation.

  • Page 25: Generator Compartments

    Section 2 – Installation Recreational Vehicle Generators GENERATOR COMPARTMENTS 2.1.3 SUSPENDED MOUNTING Whether the generator set is being installed inside a compartment If planning to suspend the generator below the horizontal sup- specifically manufactured to house a generator or inside a compart- port tubing, the suspension method to use with the vehicle frame ment that the installer constructs, the compartment MUST meet members must (a) be able to support the weight of the generator...
  • Page 26 Section 2 – Installation Recreational Vehicle Generators Figure 2.5 – Typical Compartment Construction Figure 2.6 – Types of Lock Seams • After the compartment has been metal lined and vapor sealed, line the compartment interior walls and ceiling with an approved, nonflammable sound insulating material.

  • Page 27: Cooling And Ventilating Air

    Section 2 – Installation Recreational Vehicle Generators 2.2.4 ACOUSTICS 2.2.5 COMPARTMENT FLOOR CUTOUTS For additional noise abatement, the installer may wish to consider Provide openings in the generator compartment for the following the following: items (Figure 2.9): • Using special sound insulating materials. •...
  • Page 28 Section 2 – Installation Recreational Vehicle Generators Figure 2.9 — Compartment Floor Cutout (Drawing 0G4432-A)

  • Page 29: Gasoline Fuel System

    Section 2 – Installation Recreational Vehicle Generators 6.3.2 TESTING THE INSTALLATION If the generator is to share the vehicle engine's tank, separate fuel pickup tubes are required for the engine and the generator. The manufacturer recommends testing the installation to be sure The manufacturer recommends that the fuel pickup tube be two adequate cooling airflow is available to the unit before placing the to three inches (51 to 76 mm) shorter than the vehicle engine's...
  • Page 30 Section 2 – Installation Recreational Vehicle Generators Figure 2.11 - Spark Arrestor DANGER  The generator engine gives off DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concen- trations, can cause unconsciousness or even TAILPIPE death.

  • Page 31: Electrical Connections

    Section 2 – Installation Recreational Vehicle Generators • Do not terminate the exhaust system under any opening, win- • From the junction box, route power supply wires through dow or vent that can be opened or is not permanently sealed approved conduit to either (a) double-pole, double-throw trans- from the vehicle interior.

  • Page 32: Battery Installation

    Section 2 – Installation Recreational Vehicle Generators 2.7.1 RECOMMENDED BATTERY Install a battery that meets the following requirements:  Do NOT connect electrical loads in excess of • The battery must be a 12-volt, automotive type storage bat- any circuit breaker rating or problems will devel- tery.
  • Page 33 Section 2 – Installation Recreational Vehicle Generators Figure 2.14 — Typical Transfer Switch Isolation Method Figure 2.15 — Typical Installation With Isolation Receptacle...

  • Page 34: Optional Accessories

    Section 3 – Post Installation Recreational Vehicle Generators Figure 2.16 – Connecting Battery Cables Figure 2.17 – Remote Panel Plug-in Receptacle Positive Cable — Battery Chasis Ground Negative Cable 2.7.4 BATTERY COMPARTMENT Install the generator battery in its own, vented compartment. Place the battery compartment away from any source of heat, sparks or flame.

  • Page 35: Section 3 - Post Installation

    Section 3 – Post Installation Recreational Vehicle Generators POST INSTALLATION TESTS Carefully inspect the engine/generator for fuel, oil and exhaust system leaks. Before proceeding to the next step, correct any The air-cooled generator set was factory tested and adjusted. It leakage immediately.

  • Page 36: Installation Checklist

    Section 3 – Post Installation Recreational Vehicle Generators INSTALLATION CHECKLIST EXHAUST SYSTEM ❑ Exhaust system complies with all applicable codes. LOCATION AND SUPPORT ❑ Exhaust system is properly and safely installed. ❑ Generator is properly located. ❑ Generator is properly supported. ELECTRICAL CONNECTIONS ❑...

  • Page 37: Section 4 - Troubleshooting

    Section 4 – Troubleshooting Recreational Vehicle Generators TROUBLESHOOTING GUIDE Problem Cause Correction Engine won’t crank. 1. 7.5 amp fuse blown. Replace blown fuse. 2. Loose, or corroded or defective Tighten, clean or replace, battery cable(s). as necessary. 3. Battery is discharged or defective. Recharge or replace battery.

  • Page 38: Section 5 - Notes

    Section 5 – Notes...
  • Page 39 Section 5 – Notes...

  • Page 40: Section 6 - Electrical Data

    Section 6 — Electrical Data Recreational Vehicle Generators Wiring Diagram – Drawing No. 0G4221-C...
  • Page 41 Section 6 — Electrical Data Recreational Vehicle Generators Electrical Schematic – Drawing No. 0G4221-C...

  • Page 42: Section 7 - Exploded Views And Parts Lists

    Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Enclosure – Drawing No. 0G3881-E...
  • Page 43 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Enclosure – Drawing No. 0G3881-E ITEM PART NO. QTY. DESCRIPTION 0G3396 ENCLOSURE DOOR 0C5644 SLIDE LATCH, FLUSH 0G5236 FOAM ENCLOSURE DOOR 0D3700 NUT FLANGE M6-1.0 NYLOK 0G3401 BRACKET, ENCLOSURE ELECTRIC HTR 0G4077 GROMMET, OIL FILTER 0G4433...
  • Page 44 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Control Panel – Drawing No. 0G5489-G...
  • Page 45 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Control Panel – Drawing No. 0G5489-G ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 045757 SCREW HHC M6-1.0 X 25 G8.8 0F9719 ASSY PCB VREG AIR COOLED 2006 0F5458 SCREW PLASTITE HI-LOW #10X3/8 0G3977...
  • Page 46 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Base & Pulley – Drawing No. 0G7720-B...
  • Page 47 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Base & Pulley – Drawing No. 0G7720-B ITEM PART NO. QTY. DESCRIPTION 0G3377 TRAY, 530 RV 081105 NUT FLANGE 5/16-18 LOCK 022259 NUT HEX 5/16-18 STEEL 022129 WASHER LOCK M8-5/16 022145 WASHER FLAT 5/16-M8 ZINC 0G5217...
  • Page 48 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Engine Accessories – Drawing No. 0G7718-G...
  • Page 49 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Engine Accessories – Drawing No. 0G7718-G ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION 0G7670 FRAME 0G4426 ASSY, OIL DRAIN FITTING 0G3404 ENGINE WRAPPER, STARTER SIDE 0G3386 OIL FILTER SUPPORT 0E9507 SCREW HHFC M8-1.25 X 14...
  • Page 50 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators 530 RV Engine – Drawing No. 0G7719-B...
  • Page 51 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators 530 RV Engine – Drawing No. 0G7719-B ITEM PART NO. QTY. DESCRIPTION 0E3812 SEAL D 35 X 48.2 0D4788 3/8” SQUARE HEAD PLUG 073144 SCREW HHFC M8 – 1.25 X 45 0G7260A GEAR COVER 078699B...
  • Page 52 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Rotor & Stator – Drawing No. 0G3953-B...
  • Page 53 Section 7 — Exploded Views and Parts Lists Recreational Vehicle Generators Rotor & Stator – Drawing No. 0G3953-B ITEM PART NO. QTY. DESCRIPTION 052858 NUT TOP LOCK FL M8-1.25 075237 WASHER, SPRNG CENTER 075242 SPRING, GEN. MOUNT 0C1878 SUPPORT, SLIDE 073146 SLIDE, NYLON 052203...

  • Page 54: Section 8 - Warranty

    Warranty), which is provided to you by Generac pursuant to California and federal law. See also the “Generac Limited Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by Generac. The ECS Warranty applies only to the emission control system of your new engine.

  • Page 55: Emission Control System Warranty

    Section 8 – Warranty Recreational Vehicle Generators EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS Warranty) for 1997 and later model year engines: (a) Applicability: This warranty shall apply to 1997 and later model year engines. The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
  • Page 56 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 examina- tion, 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.

This manual is also suitable for:

Rv 65 seriesRv 55 series

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