Generac 005415-0 manual

www .generac.com or 1-888- GENERAC Air -cooled R ecreational V ehicle 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[...]

P art I — Operating Instructions Introduction .............................................................. 1 Read This Manual Thoroughly ........................................... 1 Contents ............................................................................. 1 Operation and Maintenance .............................................. 1[...]

INTRODUCTION READ THIS MANUAL THOROUGHL Y If any por tion of this manual is not understood, contact the near - est Authorized Ser vice Dealer for star ting, operating and ser vicing procedures. Throughout this publication, and on tags and decals affixed to the generator , DANGER, WARNING, CA UTION and NOTE blocks are used to aler t personnel to spe[...]

2 Study these SAFETY RULES carefully before installing, operating or ser vicing 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 r ules or p[...]

3 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 r unning. Ensure all appropriate covers, guards and bar - riers are in place before operating the generator . If work must be done a[...]

4 Please record the following information from the generator DA TA DECAL or information decal. 1. Model Number ____________________ 2. Serial Number _________________ 3. kW Rating _________________________ 4. Rated V oltage _________________ 5. Phase _____________________________ 6. Hertz __________________________ 1 2 34 5 81 5 13 16 14 6 7 9, 17 [...]

5 1.2 GENERA TOR 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 per taining to its applica- tion, write or call the factor y . Do not use the unit u[...]

6 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 [...]

7 1.6.4 ENGINE SPECIFICA TIONS T ype of Engine ........................................................................GT -530 Cooling Method ................................................................ Air -cooled Rated Horsepower ................................................... 18 at 3600 rpm Displacement ..................................[...]

8 1.8 EV APORA TIVE EMIS SIONS INFORMA TION This generator is subject to evaporative emission standards which have been implemented by the California Air Resource Board (CARB) and the Environmental Protection Agency (EP A). If this generator is offered for sale in the state of California, it must be covered by a CARB evaporative Executive Order . I[...]

9 2.1.4 DIAGNOSTIC S If the generator shuts down due to a fault, the indicator will flash a code to identify the problem. 2 Flashes = Low Batter y (V oltage 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. 3 Flashes = Overcrank (Unit do[...]

10 2.4.5 ENGINE EXHAUST GAS Before star ting 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. n The generator engine releases DEADL Y carbon monoxide gas [...]

11 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 VOL TS times AMPS to obtain WA TTS. Induction type motors (such as those that r un the vehicle?[...]

12 2.8.5 OPERA TION IN HIGH GRASS OR BRUSH  Never operate the generator while the vehicle is parked over high grass, weeds, brush, 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 dur- ing operation and remains hot for a long time[...]

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 star ting the engine. 12. Star t engine and check for leaks. NOTE: Check the oil level and fill to the “FULL ” mark after checking for leaks. The filter[...]

14 3.6 CLEAN SP ARK ARRESTOR The engine exhaust muffler has a spark arrestor screen. Inspect and clean the screen ever y 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 mus[...]

15  A battery presents a risk of electrical shock and high short circuit current. The following precautions are to be observed when work - ing on batteries: • Remove watches, rings or other metal objects; • Use tools with insulated handles; • W ear rubber gloves and boots; • Do not lay tools or metal parts on top of the battery; • Disc[...]

16 3.10 MAJOR SERVICE MANU AL T o obtain a ser vice manual for the generator , contact the near - est Authorized Ser vice Dealer . Make sure to identify the MODEL NUMBER and SERIES. 3.11 DRIVE BEL T 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 shi[...]

P ar t II – Installation Instructions ONL Y QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD A T TEMPT INST ALLA TION! P art II - Installation Instructions[...]

18 NOTICE TO INST ALLER These Installation Instructions have been published by the manu- facturer to aid in the installation of the products described in this manual. The manufacturer assumes that installation personnel are familiar with the procedures for installing such products, or similar products manufactured. The manufacturer also assumes tha[...]

19 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 r unning. Ensure all appropriate covers, guards and bar - riers are in place before operating the generator . If work must be done [...]

20 1.1 PURPOSE AND SCOPE OF THE INST ALLA TION 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 seri- ous consideration to all information and instr uctions in the manual, both for safe[...]

21 Figure 1.2 - Major F eatures and Dimensions (Drawing No. 0G5519-D) Installation[...]

22 Figure 1.3 - Connection for 120/240 Volts T1 RED T2 WHITE T3 BLACK GROUNDED NEUTRAL ST A TOR POWER WINDINGS CB1 CB2 The AC connection system on air -cooled generators uses a • GROUNDED neutral. A separate green ground wire is connected to the recreational • vehicle’s junction box. T otal load connected across T1 (Red) to T2 (White), and T3[...]

23 2.1.3 SUSPENDED MOUNTING If planning to suspend the generator below the horizontal sup- por t tubing, the suspension method to use with the vehicle frame members must (a) be able to suppor t the weight of the generator AND (b) provide sufficient restraint for the generator . One typical suspended mounting system is shown in Figure 2.2. The locat[...]

24 Figure 2.5 – T ypical Compartment Construction NOTE: Caulking must be done so that the caulking material will stay in place permanently . Pressing such materials as putty tape onto joints and seams is not acceptable. A high quality silicone rub- ber base sealant is recommended. Holes and openings made in the compar tment walls to allow for •[...]

25 2.2.4 ACOUSTIC S For additional noise abatement, the installer may wish to consider the following: Using special sound insulating materials. • Constr uction of a special noise abatement compar tment. • NOTE: Any method used to reduce noise must not adversely affect the flow of cooling and ventilating air into or out of the compart- ment. In [...]

26 Figure 2.9 — Compartment Floor Cutout (Drawing 0G4432-A) Installation[...]

27 6.3.2 TESTING THE INST ALL A TION The manufacturer recommends testing the installation to be sure adequate cooling air flow is available to the unit before placing the unit into ser vice. If the unit shows signs of over heating, enlarge the air openings. Never place a unit into ser vice until absolutely cer tain that cooling and ventilation is a[...]

28 2.5 EXHA UST SYSTEM The generator exhaust system must be safely and properly installed. Only approved mufflers and other exhaust system par ts must be used. A properly installed exhaust system must be vapor tight, quiet and completely safe. n The generator engine gives off DEADL Y carbon monoxide gas through its exhaust system. This dangerous ga[...]

29 Do not terminate the exhaust system under any opening, win- • dow 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 ca[...]

30  Do NOT connect electrical loads in excess of any circuit breaker rating or problems will develop with circuit breaker tripping, which causes a loss of AC output. Also, do NOT exceed the generator's rated wattage capac- ity . Add the watts or amperes of all lighting, appliance, tool and motor loads the generator will operate at one time.[...]

31 Figure 2.14 — T ypical T ransfer Switch Isolation Method Figure 2.15 — T ypical Installation With Isolation Receptacle Installation[...]

32 Figure 2.16 – Connecting Battery Cables — + Battery Negative Cable Positive Cab le Chasis Ground 2.7.4 BA TTERY COMP ARTMENT Install the generator batter y in its own, vented compar tment. Place the batter y compar tment away from any source of heat, sparks or flame. Provide ventilation openings in the battery compar tment. The minimum size [...]

33 3.1 POST INST ALLA TION TESTS The air -cooled generator set was factor y tested and adjusted. It should not be necessar y to adjust the unit any fur ther except under special circumstances. n Do not make any unnecessary adjustments. Factory settings are correct for most applica- tions. When making adjustments, however , be careful to avoid overs[...]

34 3.5 INST ALLA TION CHECKLIST L OCA TION AND SUPPORT ❑ Generator is properly located. ❑ Generator is properly supported. ❑ Generator is properly restrained. GENERA TOR COMP ARTMENT ❑ Compartment construction is proper . ❑ Holes/Openings are vapor -sealed. ❑ Compartment size is correct. ❑ Compartment is vapor -sealed. ❑ Sound insul[...]

35 4.1 TROUBLESHOOTING GUIDE Problem Cause Correction Engine won’t crank. 1. 7.5 amp fuse blown. 1. Replace blown fuse. 2. Loose, or corroded or defective 2. Tighten, clean or replace, batter y cable(s). as necessar y . 3. Batter y is discharged or defective. 3. Recharge or replace battery . 4. Defective Star t/Stop switch. 4. Replace switch. 5. [...]

36 Electrical Data Wiring Diagram Drawing No. 0G4221-C[...]

37 Wiring Diagram Drawing No. 0G4221-C Electrical Data[...]

38 Electrical Data Wiring Diagram Drawing No. 0H3633-A[...]

39 Wiring Diagram Drawing No. 0H3633-A Electrical Data[...]

40 Exploded Views & P arts Lists Enclosure Drawing No. 0G3881-F[...]

41 ITEM P ART NO . QTY . DESCRIPTION 1 0G3396 1 ENCL OSURE DOOR 2 0C5644 2 SLIDE LA TCH, FLUSH 3 0G5236 1 FOAM ENCL OSURE DOOR 4 0D3700 23 NUT FLANGE M6-1.0 NYL OK 5 0G3401 1 DUCT , AIR IN DOOR 6 0G4077 1 GROMMET , OIL FIL TER 7 0G4433 1 U CHANNEL 1/8” 8 0G3377 1 TRA Y , 530 RV 9 0G3431 1 GASKET AIR IN BOTTOM DUCT 10 0F9199 1 PL UG PLASTIC 1.093-[...]

42 Exploded Views & P arts Lists Control P anel Drawing No. 0H3635-C[...]

43 ITEM P ART NO . QTY . DESCRIPTION 1 045757 1 SCREW HHC M6-1.0 X 25 G8.8 2 0F5458 2 SCREW PLASTITE HI-L OW #10X3/8 3 023484S 1 BUSHING SNAP SB -1093-937 4 0G9081* 1 WIRE HARNES S C/PNL FRAME 5 049813 1 NUT HEX M6 X 1.0 G8 YEL CHR 6 022473 2 WASHER FLA T 1/4-M6 ZINC 7 0A1658 1 WASHER L OCK SPECIAL 1/4" 8 0G3380 1 FUEL PUMP MOUNTING BRACKET 9 [...]

44 Exploded Views & P arts Lists Base & Pulley Drawing No. 0G7720-B[...]

45 ITEM P ART NO . QTY . DESCRIPTION 1 0G3377 1 TRA Y , 530 RV 2 081105 2 NUT FLANGE 5/16-18 L OCK 3 022259 8 NUT HEX 5/16-18 STEEL 4 022129 12 WASHER L OCK M8-5/16 5 022145 13 WASHER FLA T 5/16-M8 ZINC 6 0G5217 2 SCREW HHC 3/8-24 X 1-1/2 G8 7 0G3748 1 BEL T V -RIBBED 4L X 43.75" LG 8 046526 2 WASHER L OCK M10 9 022131 2 WASHER FLA T 3/8-M10 Z[...]

46 Exploded Views & P arts Lists Engine Accessories Drawing No. 0G7718-K[...]

47 ITEM P ART NO . QTY . DESCRIPTION 1 0G7670 1 FRAME 3 0G3404 1 ENGINE WRAPPER , ST AR TER SIDE 4 0E9507 8 SCREW HHFC M8-1.25 X 14 5 023484S 1 SNAP BUSHING 6 056893 14 SCREW CRIMPTITE 10-24 X 1/2 7 0G4129 1 SHIELD WRAPPER , CYLINDER #1 8 0C8563 12 SCREW HHFC M6-1.0 X 12 G8.8 9 0G3405 1 ENGINE WRAPPER , BACK 10 0G4985A 1 BACKPL A TE 11 0E9525A 1 AS[...]

48 Exploded Views & P arts Lists 530 RV Engine Drawing No. 0G7719-B[...]

49 ITEM P ART NO . QTY . DESCRIPTION 1 0E3812 2 SEAL D 35 X 48.2 2 0D4788 1 3/8” SQUARE HEAD PLUG 3 073144 9 SCREW HHFC M8 – 1.25 X 45 4 0G7260A 1 GEAR COVER 5 078699B 6 SLEEVE DOWEL PIN 6 0A5776 1 11/32 DIAMETER PRES SURE RELIEF BALL 7 0E9482 1 OIL PRES SURE SPRING 8 0C5315A 1 GEAROTOR, OUTER 9 0C5314A 1 GEAROTOR, INNER 10 0E9379 1 SCREEN, OIL[...]

50 Exploded Views & P arts Lists Rotor & Stator Drawing No. 0G3953-B[...]

51 ITEM P ART NO . QTY . DESCRIPTION 1 052858 6 NUT TOP L OCK FL M8-1.25 2 075237 4 WASHER , SPRNG CENTER 3 075242 4 SPRING, GEN. MOUNT 4 0C1878 2 SUPPOR T , SLIDE 5 073146 4 SLIDE, NYL ON 6 052203 2 SCREW HHC M8-1.25 X 70 G8.8 7 022145 6 WASHER FLA T 5/16-M8 ZINC 9 0G3913 4 STUD, 530 RV ST A TOR 10 029459 2 TENSION SPRING 11 075215 2 WASHER, SPRIN[...]

52 CALIFORNIA AND FEDERAL EMIS SION CONTROL WARRANTY ST A TEMENT YOUR W ARRANTY RIGHTS AND OBLIGA TIONS The California Air Resources Board (CARB) and the United States Environmental Protection Agency (EP A), together with Generac Po wer Systems, Inc. (Generac), are pleased to explain the Emission Control System warranty on your new 2008 and later g[...]

53 EMIS SION CONTROL SYSTEM WARRANTY Emission Control System Warranty (ECS war ranty) 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 equip- ment is purchased by/delivered to its original, end-use pur[...]

Part No. 0H3467 Revision B (04/15/10) Printed in U .S.A. GENERAC POWER SYSTEMS’ THREE- YEAR LIMITED WARRANTY FOR GENERAC RECREA TIONAL VEHICLE GENERATORS NOTE: ALL UNITS MUST BE INST ALLED B Y GENERAC POWER SYSTEMS AUTHORIZED SERVICE F ACILITIES. For a period of 3 (three) years of operation from the date of original sale, Generac Power Systems, I[...]