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 www.generac.
Table of Contents Part I — Operating Instructions Part II — Installation Instructions Introduction .............................................................. 1 Safety Rules ........................................................... 18 Read This Manual Thoroughly........................................... 1 Notice to Installer ............................................................. 18 Contents .............................................................................
Introduction INTRODUCTION READ THIS MANUAL THOROUGHLY If any portion of this manual is not understood, contact the nearest 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 carelessly. Observe them carefully.
Safety Rules THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe operation be nSAVE 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.
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 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.
General Information 1.1 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. Hertz __________________________ 18 8 2 15 13 10, 17 3 4 5 1 12 11 14 16 6 7 9, 17 10 REFERENCE NUMBER IDENTIFICATION 1. 2. 3. 4. 5. 6. 7. 8. 9.
General Information 1.2 GENERATOR APPLICABILITY These generators have been designed and manufactured 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, write or call the factory. Do not use the unit until advised by competent authority. properly installed in compliance with ANSI For fire safety, the generator must have been 119.
General Information 2. 120/240 VAC loads — one load with a maximum total wattage requirement equal to the generator’s rated power output, and 240V across the generator output terminals; or two separate 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.
General Information 1.6.3 GENERATOR SPECIFICATIONS SERIES Rotor RPM RV45G RV55G RV65G 3600 3600 3600 Rotor Poles 2 2 2 Engine RPM 2571 2571 2571 Rated Max. Continuous AC Output Watts* 4500 5500 6500 Voltage* 120 120 120 37.5 (18.7) 45.8 (22.9) 54.1 (27) 1 1 1 Frequency 60 Hertz 60 Hertz 60 Hertz Weight 278 lbs. 285 lbs. 293 lbs. Length 33.7 in. 33.7 in. 33.7 in. Width 21.5 in. 21.5 in. 21.5 in. Height 16.8 in. 16.8 in. 16.8 in. Rated Max.
Operation 1.8 EVAPORATIVE EMISSIONS INFORMATION Figure 2.1 – Typical Control Panel 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.
Operation 2.1.4 DIAGNOSTICS 2.3.2 If the generator shuts down due to a fault, the indicator will flash a code to identify the problem. • 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.
Operation 2.4.5 ENGINE EXHAUST GAS NOTE: 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. If starting from the generator control panel, turn OFF loads by setting the generator’s main circuit breaker to the OFF (or open) position.
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. • 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.
Maintenance 2.8.5 OPERATION IN HIGH GRASS OR BRUSH is parked over high grass, weeds, brush, 3.2 CHANGING THE ENGINE OIL AND/OR OIL FILTER Never operate the generator while the vehicle 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. 3.1 CHECKING THE ENGINE OIL LEVEL oil may cause burns.
Maintenance 10. Remove the dipstick, valve cover plug and add new oil (see “Engine Oil Requirements”) to engine. DO NOT FILL ABOVE THE “FULL” MARK. 11. Install and tighten plug and dipstick before starting the engine. 12. Start engine and check for leaks. NOTE: 3.4 Check the oil level and fill to the “FULL” mark after checking for leaks. The filter will retain some oil. 2. 3.3 MAINTAINING THE ENGINE AIR CLEANER 1. 2. 3. 4. 5. 6. 7. 8. Reset the spark plug gap or replace the spark plugs as necessary.
Maintenance 3.6 CLEAN SPARK ARRESTOR The engine exhaust muffler has a spark arrestor screen. Inspect and clean the screen every 200 hours of operation or once each year, whichever comes first. NOTE: If using the generator on any forest-covered, brush-covered or grass-covered unimproved land, it must equipped with a spark arrestor. The spark arrestor must be maintained in good condition by the owner/operator. Clean and inspect the spark arrestor as follows: • Remove the screen by removing the screw.
Maintenance and high short circuit current.
Maintenance 3.10 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. 3.13.2 RETURN TO SERVICE To return the unit to service after storage, proceed as follows: 1. 3.11 DRIVE BELT The engine drives the generator rotor by means of a pulley and drive belt arrangement. Drive belt tension was properly adjusted before the unit was shipped from the factory.
Part II - Installation Instructions Part II – Installation Instructions ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION!
Safety Rules For fire safety, installation of a generator into a recreational vehicle must comply strictly with nDANGER: 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.
Safety Rules ELECTRICAL 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 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.
General Information 1.1 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.
Installation Figure 1.2 - Major Features and Dimensions (Drawing No.
Installation Figure 1.3 - Connection for 120/240 Volts CB1 T1 RED T2 WHITE • 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. • The location must provide adequate cooling and ventilating airflow for the generator without a great deal of work and expense.
Installation 2.1.3 SUSPENDED MOUNTING If planning to suspend the generator below the horizontal 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 sufficient restraint for the generator. One typical suspended mounting system is shown in Figure 2.2.
Installation Figure 2.5 – Typical Compartment Construction Figure 2.6 – Types of Lock Seams above or around the compartment. Heat, Do not install any flammable material directly transferred through the compartment structure, may be sufficient to ignite, char or discolor seat cushions, fiberboard and other flammable materials. Use approved nonflammable insulating materials in high temperature areas. NOTE: 2.2.
Installation 2.2.4 ACOUSTICS 2.2.5 COMPARTMENT FLOOR CUTOUTS For additional noise abatement, the installer may wish to consider the following: Provide openings in the generator compartment for the following items (Figure 2.9): • Using special sound insulating materials. • Construction of a special noise abatement compartment. NOTE: • Engine exhaust and cooling air outlets • Generator cooling air inlet • Four holes for passage of generator mounting bolts. See "Generator Restraint".
Installation Figure 2.
Installation 6.3.2 TESTING THE INSTALLATION The manufacturer recommends testing the installation to be sure adequate cooling airflow is available to the unit before placing the unit into service. If the unit shows signs of overheating, enlarge the air openings. Never place a unit into service until absolutely certain that cooling and ventilation is adequate. NOTE: The installation must be tested, especially if bringing in air from below the generator set. 2.
Installation 2.5 EXHAUST SYSTEM Figure 2.11 - Spark Arrestor The generator exhaust system must be safely and properly installed. Only approved mufflers and other exhaust system parts must be used. A properly installed exhaust system must be vapor tight, quiet and completely safe. TAILPIPE P/N 0E0683 generator engine gives off DEADLY nThe carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness or even death.
Installation • Do not terminate the exhaust system under any opening, window or vent that can be opened or is not permanently sealed from the vehicle interior. • Exhaust piping must be large enough to prevent excessive back pressure on the generator engine. • 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 damage the other engine. • Plan exhaust system installation carefully.
Installation 2.7.1 RECOMMENDED BATTERY of any circuit breaker rating or problems will Install a battery that meets the following requirements: 2.6.4 If the battery is to be used to power other vehicle accessories, as well as start the generator, a battery with a larger capacity may be needed. Do NOT connect electrical loads in excess develop with circuit breaker tripping, which causes a loss of AC output. Also, do NOT exceed the generator's rated wattage capacity.
Installation Figure 2.14 — Typical Transfer Switch Isolation Method Figure 2.
Installation 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. Provide ventilation openings in the battery compartment. The minimum size of openings should be two (2) square inches at the top of the compartment.
Post Installation 3.1 POST INSTALLATION TESTS The air-cooled generator set was factory tested and adjusted. It should not be necessary to adjust the unit any further except under special circumstances. Do not make any unnecessary adjustments. Factory settings are correct for most applications. When making adjustments, however, be careful to avoid overspeeding the engine. n 3.2 BEFORE INITIAL START-UP Before starting, complete the following: 1. 2.
Post Installation 3.5 INSTALLATION CHECKLIST LOCATION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GENERATOR COMPARTMENT ❑ Compartment construction is proper. ❑ Holes/Openings are vapor-sealed. ❑ Compartment size is correct. ELECTRICAL CONNECTIONS ❑ Connections comply with local code requirements and all National Electrical Codes. ❑ Junction box is properly installed. ❑ Wiring meets all standards. ❑ All connections are correct.
Troubleshooting 4.1 TROUBLESHOOTING GUIDE Problem Engine won’t crank. Cause 1. 2. Correction 1. 2. 3. 4. 5. 6. 7. 7.5 amp fuse blown. Loose, or corroded or defective battery cable(s). Battery is discharged or defective. Defective Start/Stop switch. Defective starter contactor. Defective starter motor. Defective Engine Control Board 3. 4. 5. 6. 7. Replace blown fuse. Tighten, clean or replace, as necessary. Recharge or replace battery. Replace switch. Replace starter contactor.
Electrical Data 36 Wiring Diagram Drawing No.
Wiring Diagram Drawing No.
Electrical Data 38 Wiring Diagram Drawing No.
Wiring Diagram Drawing No.
Exploded Views & Parts Lists 40 Enclosure Drawing No.
Exploded Views & Parts Lists Enclosure Drawing No. 0G3881-F ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 23 24 25 26 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 PART NO. 0G3396 0C5644 0G5236 0D3700 0G3401 0G4077 0G4433 0G3377 0G3431 0F9199 0G3430 0G3402 090388 0G3422 0G5237 0G3399 0D3472 0G4933 0G5238 0G3397 0G4391 0G5239 0G3392 0G3754 0G3398 0G3912 0G3400 0G5240 0G5242 0G5241 045756 0G5755 0G5761 022473 022097 022287 0G3429 QTY.
Exploded Views & Parts Lists 42 Control Panel Drawing No.
Exploded Views & Parts Lists Control Panel Drawing No. 0H3635-C ITEM PART NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 045757 0F5458 023484S 0G9081* 049813 022473 0A1658 0G3380 0F9176 0G3662A 028414 0D3700 0G5225 028916 087769 025965 022097 0G5318 0H3634 0G4602 0C7968 022237 0A4456 0C7423 022259 022129 022145 0E0593 0D8502 0G5233 0G3825 0G3689 092036 0A9611 032300 0G4215 QTY. DESCRIPTION 1 2 1 1 1 2 1 1 28.
Exploded Views & Parts Lists 44 Base & Pulley Drawing No.
Exploded Views & Parts Lists Base & Pulley Drawing No. 0G7720-B ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 PART NO. QTY.
Exploded Views & Parts Lists 46 Engine Accessories Drawing No.
Exploded Views & Parts Lists Engine Accessories Drawing No. 0G7718-K ITEM PART NO. QTY.
Exploded Views & Parts Lists 48 530 RV Engine Drawing No.
Exploded Views & Parts Lists 530 RV Engine Drawing No. 0G7719-B ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 PART NO.
Exploded Views & Parts Lists 50 Rotor & Stator Drawing No.
Exploded Views & Parts Lists Rotor & Stator Drawing No. 0G3953-B ITEM 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PART NO. 052858 075237 075242 0C1878 073146 052203 022145 0G3913 029459 075215 0G3382 0G3877H 0G3878H 0G3879H 0G3893H 0G3894H 0G3895H 0G3381 022129 045771 066386 066849 0G3542 022131 042633 022237 QTY. 6 4 4 2 4 2 6 4 2 2 1 1 1 1 1 1 1 1 4 4 1 2 1 1 1 1 DESCRIPTION NUT TOP LOCK FL M8-1.25 WASHER, SPRNG CENTER SPRING, GEN. MOUNT SUPPORT, SLIDE SLIDE, NYLON SCREW HHC M8-1.
Warranty 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 2008 and later generator.
Warranty EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS warranty) for equipment using small spark-ignited engines: (a) Applicability: This warranty shall apply to equipment that uses small off-road engines. The ECS Warranty period shall begin on the date the new equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue for 24 consecutive months thereafter.
Warranty GENERAC POWER SYSTEMS’ THREE-YEAR LIMITED WARRANTY FOR GENERAC 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.
