Guardian QUIETPACT 85D Operating instructions

Owner’s Manual and
Installation Instructions
Liquid-cooled Recreational Vehicle Generator
• Model: 005432-0
QUIETPACT™ 85D
This manual should remain with the unit.

INTRODUCTION
Thank you for purchasing this model by Generac
Power Systems, Inc. This model is designed and man-
ufactured to supply electrical power for recreational
vehicles.
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 per-
sonnel to special instructions about a particular
operation that may be hazardous if performed
incorrectly or carelessly. Observe them carefully.
Their definitions are as follows:
DANGER
After this heading, read instructions that, if not
strictly complied with, will result in serious person-
al injury, including death, or property damage.
After this heading, read instructions that, if not
strictly complied with, may result in personal inju-
ry or property damage.
After this heading, read instructions that, if not
strictly complied with, could result in damage to
equipment and/or property.
NOTE:
After this heading, read explanatory statements
that require special emphasis.
These safety warnings cannot eliminate the hazards
that they indicate. Common sense and strict compli-
ance with the special instructions while performing
the service are essential for preventing accidents.
Four commonly used safety symbols accompany the
Danger, Warning, and Caution blocks. Here are the
types of information indicated by each symbol:
This symbol points out important safety infor-
mation that, if not followed, could endanger
personal safety and/or property to self and
others.
This symbol points out potential explosion
hazard.
This symbol points out potential fire hazard.
This symbol points out potential electrical shock
hazard.
The operator (i.e., the driver) is responsible for the
proper and safe use of the vehicle and its equipment,
and for the safety of all vehicle occupants. Before
using this equipment, we strongly recommend that
the operator read this manual and thoroughly under-
stand all instructions. We also strongly recommend
instructing other occupants in the vehicle to properly
start and operate the generator. This prepares them
to operate the equipment in case of an emergency.
CONTENTS
This manual contains pertinent owner’s information,
including warranty, electrical diagrams, exploded
views, and lists of repair parts for generator model
number 005432-0. In addition, the latter portion of
this manual contains information necessary for the
proper installation of these generators.
OPERATION AND MAINTENANCE
It is the operator's responsibility to perform all
safety checks, to make sure that all maintenance
for safe operation is performed promptly, and to
have the equipment checked periodically by an
Authorized Service Dealer. Normal maintenance
service and replacement of parts are the responsi-
bilities of the owner/operator and, as such, are not
considered defects in materials or workmanship
within the terms of the warranty. Individual oper-
ating habits and usage contribute to the need for
maintenance service.
Proper maintenance and care of the generator
minimizes problems and operating expenses. See
the Authorized Service Dealer for service aids and
accessories.
HOW TO OBTAIN SERVICE
When the generator requires servicing or repairs,
simply contact an Authorized Service Dealer for
assistance. Service technicians are factory-trained
and are capable of handling all service needs.
When contacting an Authorized Service Dealer or the
factory about parts and service, always supply the
complete model number and serial number of the
unit, as given on its data label, which is located on
the generator.
Model No. ____________ Serial No.______________
AUTHORIZED SERVICE
DEALER LOCATION
To locate the nearest AUTHORIZED
SERVICE DEALER, please call this number:
1-800-333-1322
or locate us on the web at
www.generac.com

Table of Contents
Recreational Vehicle Generator
1
Part I – Owner’s Manual
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
1.1 Generator Identification ...................................... 4
1.2 Generator Applicability ....................................... 5
1.3 Safety .................................................................. 5
1.4 Generator AC Connection System ....................... 5
1.5 Specifications ...................................................... 5
Section 2 – Operation .................................................... 7
2.1 Generator Control Panel...................................... 7
2.2 Optional Remote Start/Stop ............................... 8
2.3 Before Starting the Engine .................................. 8
2.4 Starting the Generator ........................................ 9
2.5 Stopping the Generator....................................... 9
2.6 Applying Loads to Generator............................... 9
2.7 Protection Systems............................................ 10
2.8 Additional Information ...................................... 10
Section 3 – Maintenance............................................. 11
3.1 Checking the Engine Oil Level........................... 11
3.2 Changing the Engine Oil and/or Oil Filter ......... 11
3.3 Servicing the Engine Air Filter .......................... 12
3.4 Spark Arrestor Muffler...................................... 12
3.5 Cleaning the Generator ..................................... 13
3.6 Battery Maintenance.......................................... 13
3.7 Cooling System.................................................. 14
3.8 Engine Coolant.................................................. 14
3.9 Major Service Manual........................................ 14
3.10 Drive Belt ......................................................... 14
3.11 Exercising the Generator................................... 14
3.12 Out-of-Service Procedure................................... 15
3.13 Service Schedule ............................................... 16
Part II – Installation Instructions
Safety Rules .................................................................... 18
Section 1 – General Information............................... 20
1.1 Purpose and Scope of the Manual..................... 20
1.2 Safety ................................................................ 20
1.3 Standards Booklets........................................... 20
1.4 Equipment Description ..................................... 20
1.5 Generator Engine Operating Speed ................... 20
1.6 Generator AC Connection System ..................... 20
Major Features and Dimensions........................ 21
Section 2 – Installation................................................ 22
2.1 Location and Support ....................................... 22
2.2 Generator Compartments ................................. 23
2.3 Cooling and Ventilating Air................................ 26
2.4 Diesel Fuel System ............................................ 27
2.5 Exhaust System................................................. 29
2.6 Electrical Connections....................................... 30
2.7 Battery Installation............................................ 33
2.8 Optional Accessories ......................................... 34
Section 3 – Post-installation Startup Checks......... 35
3.1 Post Installation Tests ....................................... 35
3.2 Before Initial Startup......................................... 35
3.3 Initial Start........................................................ 35
3.4 Testing Under Load........................................... 35
3.5 Installation Checklist......................................... 36
Section 4 – Troubleshooting....................................... 37
4.1 Troubleshooting Guide...................................... 37
Section 5 - Electrical Data........................................... 38
Section 6 – Exploded Views and Parts Lists...........44
Section 7 – Warranty .................................................... 68

2
Study these SAFETY RULES carefully before install-
ing, operating, or servicing this equipment. Become
familiar with this manual and with the unit. The gen-
erator can operate safely, efficiently, and reliably only
if it is properly installed, operated, and maintained.
Many accidents are caused by failing to follow simple
and fundamental rules or precautions.
The manufacturer cannot anticipate every possible
circumstance that might involve a hazard. The warn-
ings in this manual, and on tags and decals affixed
to the unit, are, therefore, not all-inclusive. If using a
procedure, work method, or operating technique that
the manufacturer does not specifically recommend,
ensure that it is safe for others. Also make sure the
procedure, work method, or operating technique uti-
lized does not render the generator unsafe.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglect-
ing its maintenance, or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate and maintain
this equipment.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
GENERAL HAZARDS 
• For safety reasons, the manufacturer recommends
that the installation, initial startup, and main-
tenance of this equipment be performed by an
Authorized Service Dealer.
• The generator engine releases DEADLY carbon
monoxide gas through its exhaust system. This
dangerous gas, if breathed in sufficient concentra-
tions, can cause unconsciousness or even death.
Never operate the generator set with the vehicle
inside any garage or other enclosed area. DO NOT
OPERATE THE GENERATOR IF THE EXHAUST
SYSTEM IS LEAKING OR HAS BEEN DAMAGED.
SYMPTOMS OF CARBON MONOXIDE POISONING
ARE (a) inability to think coherently, (b) nausea,
(c) vomiting, (d) twitching muscles, (e) throbbing
temples, (f) dizziness, (g) headaches, (h) weak-
ness, and (i) sleepiness. IF EXPERIENCING ANY
OF THESE SYMPTOMS, MOVE INTO FRESH AIR
IMMEDIATELY. IF SYMPTOMS PERSIST, GET
MEDICAL HELP. Shut down the generator and
do not operate it until it has been inspected and
repaired.
• Never sleep in the vehicle while the genset is run-
ning 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 area.
• The engine exhaust fumes contain carbon mon-
oxide, which can be DEADLY. This dangerous
gas, if breathed in sufficient concentrations, can
cause unconsciousness or even death. Thus, the
exhaust system must be installed properly, in strict
compliance with applicable codes and standards.
Following installation, do nothing that might ren-
der the system unsafe or in noncompliance with
such codes and standards. The generator com-
partment must be completely vapor-sealed from
the vehicle interior. There must be no possibility of
exhaust fumes entering the vehicle interior. Never
operate this equipment with a leaking or defective
exhaust system.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and ven-
tilating air is critical to correct generator opera-
tion and is required to expel toxic fumes and fuel
vapors from the generator compartment. Without
sufficient cooling airflow, the engine/generator
quickly overheats, which seriously damages the
generator. Do not alter the installation or permit
even partial blockage of ventilation provisions, as
this can also seriously affect the safe operation of
the generator.
Safety Rules
Recreational Vehicle Generator
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.

The engine exhaust from this product
contains chemicals known to the state
of California to cause cancer, birth
defects, or other reproductive harm.
WARNING:

This product contains or emits chemicals
known to the state of California to cause
cancer, birth defects or other reproductive harm.
WARNING:


3
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Inspect the generator regularly, and contact the
nearest Authorized Service Dealer immediately for
parts needing repair or replacement.
• Before performing any maintenance on the genera-
tor, disconnect its battery cables to prevent acci-
dental startup. First, disconnect the cable from the
battery post, indicated by a NEGATIVE, NEG, or
(–). Reconnect this cable last.
• Never use the generator, or any of its parts, as a
step. Stepping on the unit can stress and break
parts, resulting in dangerous operating conditions
due to leaking exhaust gases, fuel leakage, oil leak-
age, etc.
• Never insert any tool or other object through open-
ings in the generator interior, even if the unit is not
running. Serious injury or damage to the equip-
ment could be done.
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 run-
ning. Before operating the generator, ensure all
appropriate covers, guards, and barriers are in
place . If work must be done around an operating
unit, stand on an insulated, dry surface to reduce
shock hazard.
• Do not handle any kind of electrical device while
standing in water, while barefoot, or while hands or
feet are wet. DANGEROUS ELECTRICAL SHOCK
MAY RESULT.
• During installation onto the vehicle, have the
generator properly grounded (bonded), either by
solid mounting to the vehicle frame or chassis,
or by means of an approved bonding conductor.
DO NOT disconnect the bonding conductor, if so
equipped. DO NOT reconnect the bonding conduc-
tor to any generator part that might be removed or
disassembled during routine maintenance. If the
grounding conductor must be replaced, use only a
flexible conductor that is of No. 8 American Wire
Gauge (AWG) copper wire minimum.
• In case of an accident caused by electric shock,
immediately shut down the source of electrical
power. If this is not possible, attempt to free the
victim from the live conductor. AVOID DIRECT
CONTACT WITH THE VICTIM. Use a nonconduct-
ing implement, such as, a dry rope or board, to
free the victim from the live conductor. If the victim
is unconscious, apply first aid and get immediate
medical help.
• Never wear jewelry when working on this equip-
ment. Jewelry can conduct electricity, resulting in
electric shock, or may get caught in moving com-
ponents, causing, injury.
FIRE HAZARDS 
• For fire safety, the generator must be installed
and maintained properly. Installation must always
comply with NFPA 70 (latest edition), “National
Electrical Code”, Article 551, and NFPA 1192 (lat-
est edition), “Standard for Recreational Vehicles”,
along with all applicable codes, standards, laws,
and regulations. Adhere strictly to local, state, and
federal electrical and building codes. Comply with
regulations the Occupational Safety and Health
Administration (OSHA) has established. Also,
ensure that the generator is installed in accordance
with the manufacturer’s instructions and recom-
mendations. After proper installation, do nothing
that might alter the installation and render the unit
in noncompliance with the aforementioned codes,
standards, laws, and regulations.
• Keep a fire extinguisher in the vehicle at all times.
Extinguishers rated “ABC” by the National Fire
Protection Association are appropriate for use on
the recreational vehicle generator electrical sys-
tem. Keep the extinguisher properly charged and
be familiar with its use. If there are any questions
pertaining to fire extinguishers, consult the local
fire department.
EXPLOSION HAZARDS 
• Do not smoke around the generator. Wipe off
any fuel or oil spills immediately. Ensure that no
combustible material is left in the generator com-
partment, or on or near the generator, as FIRE or
EXPLOSION may result. Keep the area surround-
ing the generator clean and free of debris.
• All fuel types are potentially FLAMMABLE and/or
EXPLOSIVE and should be handled with care.
Comply with all laws regulating the storage and
handling of fuels. Inspect the unit’s fuel system fre-
quently and correct any leaks immediately. Before
placing this equipment into service, the fuel supply
lines must be properly installed, purged, and leak-
tested according to applicable fuel-gas codes.
Safety Rules
Recreational Vehicle Generator

4
Section 1 – General Information
Recreational Vehicle Generator
Please record the following information from the generator DATA LABEL or information label,
located below the user control panel.
1. Model Number _____________________ 2. Serial Number __________________
3. kW Rating _________________________ 4. Rated Voltage __________________
5. Phase______________________________ 6. Hertz __________________________
1.1 GENERATOR IDENTIFICATION
Model: 005432-0
1. 2-Pole, 40-amp Circuit
Breaker
2. Hourmeter
3. Oil Fill Opening and Plug
4. Oil Dipstick
5. Engine Start/Stop Switch
6. 15-amp Fuse
7. Engine Preheat Switch
8. Fuel Filter
9. Air Filter
10. Oil Filter
11. Starter Motor
12. Preheat Contactor
13. Starter Contactor
14. Radiator
15. Coolant Recovery Tank
16. Muffler
17. Battery Connections
18. Fuel Connections
19. Alternator
20. Fuel Pump
21. Centrifugal Cooling Fan
and Housing
22. Alternator Drive Belt
23. Alternator Drive Belt
Tensioner
24. Cooling Fan Drive Belt
25. Cooling Fan Drive Belt
Tensioner
26. Engine

5
Section 1 – General Information
Recreational Vehicle Generator
1.2 GENERATOR APPLICABILITY
These generators have been designed and manufac-
tured for supplying electrical power to recreational
vehicles. DO NOT modify the generator nor 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. Do not use the unit until
advised by a competent authority.
DANGER
For fire safety, the generator must have been
properly installed in compliance with NFPA
70 (latest edition), “National Electrical Code”,
Article 551, and NFPA 1192 (latest edition),
“Standard for Recreational Vehicles”. The gener-
ator also must have been installed in strict com-
pliance with the manufacturer’s detailed instal-
lation instructions. After installation, do nothing
that might render the unit in noncompliance
with such codes, standards, and instructions.
Use this generator to supply electrical power for
operating 120/240-volt, single-phase, 60-Hertz, AC
electrical loads. These loads can require up to 8,500
watts (8.5 kW) of power, but cannot exceed 70.8 AC
amps of current at 120 volts, or 35.4 AC amps at
240 volts.
Do not overload the generator. Some installa-
tions may require that electrical loads be alter-
nated to avoid overloading. Applying excessive-
ly high electrical loads may damage the genera-
tor and shorten its life. Add up the rated watts
of all electrical lighting, appliance, tool, and
motor loads the generator will power at one
time. This total should not be greater than the
wattage 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 electric motors require
more watts of power (or amps of current) for
starting than for continuous operation.
1.3 SAFETY
Before attempting to use the generator set, care-
fully read the “Safety Rules” section of this manual.
Comply strictly with these rules to prevent accidents
and damage to equipment and/or property. We sug-
gest copying and posting the “Safety Rules” in poten-
tial hazard areas of the vehicle. Stress safety to all
operators and potential operators of this equipment.
1.4 GENERATOR AC CONNECTION
SYSTEM
This generator is equipped with dual-stator AC power
windings. These two-stator windings supply electri-
cal power to customer electrical loads by means of
a dual, two-wire connection system. Note, however,
that the neutral is grounded.
The generator may have been installed so that it
powers 120-volt AC electrical loads only (Figure 1.1).
It can be rewired to connect 120/240-volt AC elec-
trical loads. This procedure should be done by an
Authorized Service Dealer or other qualified installer.
Refer to the installation portion of this manual for
more information.
Figure 1.1 – Connections for 120 Volts Only —
Dual Circuits
1.5 SPECIFICATIONS
1.5.1 FUEL REQUIREMENTS
The generator is equipped with a diesel fuel system.
Use clean, fresh No. 1D or No. 2D diesel fuel with
minimum Cetane number of 40. The diesel fuel must
also conform to American Society of Testing and
Materials (ASTM) specifications. Never use any dirty
or contaminated fuel. When adding fuel, DO NOT
overfill the tank. Allow room at the top of the tank
for fuel expansion. Depending on the installation,
the generator may have either a separate fuel tank or
“share” the vehicle’s engine fuel tank.

6
Section 1 – General Information
Recreational Vehicle Generator
NOTE:
Some installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter
than the vehicle’s engine pickup tube. Such an
arrangement causes the generator engine to “run
out of fuel”, while adequate fuel for the vehicle
engine remains in the tank.
Also, appropriate care should be taken in applica-
tions where extremely low ambient temperatures
are possible, to ensure the temperature of the die-
sel fuel is not allowed to fall below levels where
“gelling” could occur.
1.5.2 FUEL CONSUMPTION (GAL/HR)
Model No Load Half Load Full Load
005432-0 0.28 0.49 0.78
1.5.3 ENGINE OIL REQUIREMENTS
Use a high-quality detergent oil with American
Petroleum Institute (API) classification “For Service
CC.” Detergent oils keep the engine cleaner and
reduce carbon deposits. Use oil having the following
SAE viscosity rating, based on the ambient tempera-
ture range anticipated before the next oil change:
Temperature Oil Grade (Recommended)
Above 100° F (38° C) SAE 15W-40* or SAE 40
40° to 100° F (4.4° to 38° C) SAE 10W-30 or SAE 30
Below 40° F (4.4° C) SAE 5W-20 or 5W-30
* - in units from the factory
Crankcase and oil filter capacity is approximately
4.35L or 4.6 U.S. quarts. Do NOT use special
additives. See "Checking the Engine Oil Level" and
"Changing the Engine Oil and/or Filter" sections for
oil level checking and changing procedures.
1.5.4 COOLANT
Use a 50:50 mixture that is half low silicate, ethylene
glycol base antifreeze and half soft water. Use only
soft water and only low silicate antifreeze. If desired,
a high-quality rust inhibitor to the recommended
coolant mixture may be added. When adding coolant,
always add the recommended 50-50 mixture.
DANGER
Do not remove the radiator pressure cap while
the engine is hot; otherwise, serious burns from
boiling liquid or steam could result.
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
radiator, recovery bottle, or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze, even though it is poisonous to them.
Do not use any chromate base rust inhibitor
with ethylene glycol base antifreeze; or else,
chromium hydroxide (“green slime”) will form
and cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding eth-
ylene glycol base antifreeze. Using any high-
silicate antifreeze boosters or additives will also
cause overheating. DO NOT use any soluble oil
inhibitor for this equipment.
1.5.5 ENGINE
Type of Engine.........................................................ISM Diesel
Cylinder Arrangement................................................3, in-line
Displacement........................................... 69.02 in3. (1131 cc)
Bore.............................................................. 3.03 in. (77 mm)
Stroke........................................................... 3.18 in. (81 mm)
Compression Ratio ................................................. 23.56-to-1
Combustion Chamber Type...........................Pre-Combustion
Rated Horsepower ........................................15 @ 1,950 rpm
Cylinder Block .......................................................... Cast Iron
Number of Main Bearings...................................................... 4
Number of Teeth on Flywheel ............................................104
Type of Governor .............................Mechanical, Fixed Speed
Fuel Filter .......................... Full Flow Spin-On (Part # 69858)
Oil Filter ...................................... Full Flow with Bypass Valve
(Part # 126-70939)
Oil Pressure...............................................................29-71 psi
Type of Cooling System............ Pressurized, Closed Recovery
Cooling Method ..................................................Liquid-cooled
Type of Cooling Fan......................................Centrifugal Puller
Cooling System Capacity..........................1.4 U.S. gals (5.3 L)
Air Cleaner ..........................Disposable Filter (Part # C4880)
Starter ....................................................... 12-volt DC Electric
Recommended Battery...................70 Ah, 360 Cold-cranking
Amps (Minimum ratings)
Maximum Cranking Current .................................. 220 Amps
Ground Polarity...........................................................Negative

7
Section 2 – Operation
Recreational Vehicle Generator
1.5.6 GENERATOR
Rated Maximum Continuous AC Output at ...
85º F (29º C) Ambient........................8,500 Watts (8.5 kW)
100º F (38º C) Ambient......................7,500 Watts (7.5 kW)
120º F (49º C) Ambient......................6,000 Watts (6.0 kW)
Rated Voltage.............................................. 120/240 Volts AC*
Rated Maximum Continuous AC Current at ...
8,500 Watts
120 Volts ..................................................... 70.8 Amps
240 Volts ..................................................... 35.4 Amps
7,500 Watts
120 Volts ..................................................... 62.5 Amps
240 Volts ................................................... 31.25 Amps
6,000 Watts
120 Volts ..................................................... 50.0 Amps
240 Volts ..................................................... 25.0 Amps
Phase .............................................................................. Single
Rotor Speed at No Load .........................................3,780 rpm
Number of Rotor Poles........................................................... 2
Engine RPM.....................................................................1,950
Rated AC Frequency....................................................... 60 Hz
Battery Charge Voltage ..........................................14 Volts DC
Battery Charge Current..................................... 2 Amps (max)
Weight ....................................................................504 Pounds
Length...................................................36.6 inches (929 mm)
Width ....................................................23.8 inches (604 mm)
Height ...................................................23.8 inches (604 mm)
*All units are reconnectable to 240-volt only AC output.
2.1 GENERATOR CONTROL PANEL
The following features are mounted on the generator
control panel (Figure 2.1):
Figure 2.1 – Generator Control Panel
15 AMP
SYSTEM
CONTROL
STOPSTART
PREHEAT
30 SEC. MAX
LINE BREAKER
ONON
2.1.1 HOURMETER
This indicates the length of time the engine/generator
has operated, in hours and tenths of hours. Use the
hourmeter to ensure that the periodic maintenance
tasks for the generator are completed on a timely
basis.
2.1.2 START/STOP SWITCH
To crank and start the engine, hold this switch in the
START position. Release the switch when the engine
starts. To stop an operating engine, press and hold
the switch in the STOP position until the engine shuts
off. The switch’s center position is the RUN position.
2.1.3 FUSE
The 15-amp fuse protects the engine’s DC control
circuit against electrical overload. If the fuse element
has melted open due to overloading, the engine can-
not be cranked. If the fuse must be replaced, use only
an identical replacement (i.e., AGC-15).
If a fuse element melts, find the cause of the
overload before replacing the fuse.
2.1.4 LINE BREAKER
The line (i.e., main) breaker protects the generator’s
AC output circuit against overload and provides a
method of turning OFF the generator’s 120/240-volt
AC output to the vehicle circuits. The generator has
two 40-amp breakers.
NOTE:
Refer to section “Generator AC Connection
System,”. Individual installations will differ. If an
overload occurs, the dual breakers will open the
ungrounded (i.e., hot) stator leads (11 and 33 in
Figure 1.1). When the generator has been con-
nected for 120/240 dual voltage (Figure 2.16), the
line breakers will operate on the ungrounded (i.e.,
hot) stator leads (11 and 44 in Figure 2.16).
2.1.5 PREHEAT SWITCH
The diesel engine is equipped with glow plugs, one
for each cylinder. When the preheat switch is pressed,
the glow plugs heat the engine combustion chamber,
allowing for quicker starts when the engine is cold.
Pressing the preheat switch also operates the fuel
pump.

8
Section 2 – Operation
Recreational Vehicle Generator
2.2 OPTIONAL REMOTE START/STOP
This generator is equipped with a plug-in connec-
tor that can be interfaced with an optional remote
panel provided inside the vehicle. This option allows
for starting and stopping the generator conveniently
from within the vehicle. Refer to Part II - "Installation
Instructions", for details on the remote start/stop
option.
2.3 BEFORE STARTING THE ENGINE
NOTE:
Instructions and information in this manual
assume the generator has been properly installed,
connected, serviced, tested and adjusted by a
qualified installation technician or installation
contractor.
2.3.1 INSTALLATION
Generator installation must have been properly com-
pleted so that it complies with all applicable codes,
standards, and regulations and with the manufac-
turer's recommendations.
NOTE:
Be sure the installation complies with all stan-
dards and codes listed in the "Standards Booklets"
section of this manual.
2.3.2 ENGINE LUBRICATION
Before starting the engine, have the engine crankcase
properly serviced with the recommended oil. Refer to
the "Engine Oil Requirements", "Checking the Engine
Oil Level" and Changing the Engine Oil and/or Filter"
sections for oil servicing procedures and recommen-
dations.
Any attempt to crank or start the engine before
it has been properly serviced it with the recom-
mended oil may result in an engine failure.
2.3.3 FUEL SUPPLY
The engine must have an adequate supply of proper
fuel to operate. Before starting it, check that suffi-
cient fuel is available.
NOTE:
Depending on the installation, the generator may
have either a separate fuel tank or “share” the
vehicle’s engine fuel tank.
Some installations using a “shared” fuel tank may
have a generator fuel pickup tube that is shorter
than the vehicle’s engine pickup tube. Such an
arrangement causes the generator engine to “run
out of fuel”, while adequate fuel for the vehicle
engine remains in the tank.
2.3.4 COOLANT LEVEL
Check the engine coolant level prior to initial use and
at recommended intervals. Refer to the “Coolant” and
“Engine Coolant” sections for procedures and recom-
mendations.
2.3.5 COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator com-
partment must be open and unobstructed for con-
tinued proper operation. Without sufficient cooling
and ventilating airflow, the engine/generator may
overheat, causing engine shutdown and damage to
the generator.
2.3.6 ENGINE EXHAUST GAS
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.
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. DO NOT OPERATE THE GENERATOR IF THE
EXHAUST SYSTEM IS LEAKING OR HAS BEEN
DAMAGED. SYMPTOMS OF CARBON MONOXIDE
POISONING ARE (a) inability to think coher-
ently, (b) nausea, (c) vomiting, (d) twitching
muscles, (e) throbbing temples, (f) dizziness,
(g) headaches, (h) weakness, and (i) sleepiness.
IF EXPERIENCING ANY OF THESE SYMPTOMS,
MOVE INTO FRESH AIR IMMEDIATELY. IF
SYMPTOMS PERSIST, GET MEDICAL HELP. Shut
down the generator and do not operate it until
it has been inspected and repaired.

9
Section 2 – Operation
Recreational Vehicle Generator
DANGER
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 installa-
tion manual. Make sure there is ample fresh air
when operating the genset in a confined area.
2.4 STARTING THE GENERATOR
NOTE:
Read the vehicle manufacturer’s instructions.
The owner/operator should become familiar with
the vehicle in which this generator is installed.
Differences exist between vehicles. For example,
some vehicles may use a transfer switch to isolate
dockside power from the generator, while other
vehicles may use an isolating receptacle. Some
vehicles may be equipped with a DC converter,
which allows the generator to power certain DC
lighting and other DC loads.
To start the generator from either the generator con-
trol panel or from the optional remote panel, proceed
as follows:
1. Turn OFF electrical loads using the means pro-
vided in the vehicle (such as, a main-line circuit
breaker or transfer switch).
NOTE:
If starting from the generator control panel, turn
OFF loads by setting the generator’s main-line
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 will be
turned ON, after the generator has started, stabi-
lized, and warmed up.
2. If the engine is cold, press the Preheat switch for
a maximum of 15 to 30 seconds.
3. While pressing the Preheat switch to crank the
engine, hold the engine Start/Stop switch in the
START position. When the engine starts, release
the switches.
If the engine does not start after it has been
cranking for 15 seconds, release the Start/Stop
switch, wait 15 seconds, and try again. Holding
the switch for longer than 15 seconds can dam-
age the starter motor.
4. Let the engine run at no-load for a few minutes to
stabilize and warm up.
5. Turn ON electrical loads, using the means pro-
vided in the vehicle (such as, a main-line circuit
breaker or transfer switch).
2.5 STOPPING THE GENERATOR
1. Turn OFF all electrical loads, using the means
provided in the vehicle (such as, a main-line cir-
cuit breaker or transfer switch).
2. Let the generator run at no-load for a few minutes,
to stabilize internal engine generator tempera-
tures.
Do not stop the engine/generator immediately
after running under load. This can overheat and
damage the engine and/or generator.
3. Press and hold the Start/Stop switch in the STOP
position, until the engine shuts off.
2.6 APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator,
observe these guidelines:
• Before applying electrical loads, let the generator
stabilize and warm up for a minute or two.
• DO NOT overload the generator.
2.6.1 LETTING THE ENGINE STABILIZE
The generator supplies correctly rated voltage only
at the proper governed speed. Some electrical appli-
ances may be extremely sensitive to voltage. Incorrect
voltages can damage such appliances.
Electrical loads applied on the engine at reduced
operating speeds, such loads imposed on the engine,
when sufficient power is not available, may shorten
engine life. Never turn ON electrical loads until after
the generator engine has started and stabilized at
no-load.
2.6.2 DO NOT OVERLOAD THE GENERATOR
Read the rated wattage/amperage capacity of the gen-
erator on the generator data label located below the
user control panel.
Applying electrical loads in excess of the unit’s rated
capacity may trip the line breaker or cause the
engine/generator to shut down.
To avoid overloading, add up the wattage of all con-
nected electrical lighting, appliance, tool, and motor
loads. This total should not be greater than the gen-
erator’s rated wattage capacity.
• 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.

10
Section 2 – Operation
Recreational Vehicle Generator
• Induction-type motors (such as, those that run the
vehicle’s furnace fan, refrigerator, air conditioner,
etc.) need about 2-1/2 time more watts of power
for starting than for running (for a few seconds
during motor starting). Be sure to allow for this
when connecting electrical loads to the generator.
First, calculate the watts needed to start electric
motors in the system. To that figure, add the run-
ning wattages of other items that will be operated
by the generator.
• For the first two or three hours of operation, do not
apply electrical loads over 75 percent of the unit’s
rating.
2.7 PROTECTION SYSTEMS
The engine has several safety switches that cause
it to automatically shut down, under the following
conditions: low oil pressure, high coolant tempera-
ture, and engine overspeed. See Figure 2.2 for the
location of these devices. If automatic shutdown does
occur, refer to “Troubleshooting Guide”.
2.7.1 LOW OIL PRESSURE SWITCH
This switch is normally closed (N.C.) but is held open
by engine oil pressure during engine running. Should
operating oil pressure drop below approximately 10
psi, the switch contacts close, and the engine shuts
down automatically.
2.7.2 HIGH COOLANT TEMPERATURE
SWITCH
This normally-open (N.O.) thermostatic switch has
a sensing tip that is immersed in captive coolant.
Should the coolant temperature exceed approximate-
ly 115° C (240° F), the switch contacts close, and the
engine shuts down automatically.
Figure 2.2 – Engine Protective Devices
2.7.3 OVERSPEED SHUTDOWN
A DC control circuit board senses engine speed from
the frequency of the alternator AC output. Should the
alternator output frequency exceed approximately 72
Hertz (4,320 alternator rpm), circuit board action
initiates an automatic engine shutdown.
2.7.4 OVERVOLTAGE PROTECTION
A solid-state voltage regulator (Figure 2.3) controls
the generator’s AC output voltage. This regulator sup-
plies an excitation current to the rotor. By regulating
the rotor’s excitation current, the strength of its mag-
netic field is regulated and, in turn, the voltage deliv-
ered to connected electrical loads is controlled. When
the AC frequency is 60 Hertz, voltage is regulated at
120 volts (voltage-to-frequency ratio is 2-to-1).
Figure 2.3 – Solid-state Voltage Regulator
The voltage regulator also incorporates a “volt-
age surge protection circuit.” This circuit prevents
troublesome surges in the generator AC output volt-
age. Voltage surge is a common cause of damage to
electronic equipment.
2.8 ADDITIONAL INFORMATION
2.8.1 ATTENTION REQUIRED
AFTER SUBMERSION
If the recreational vehicle generator has been sub-
merged in water, it MUST NOT be started and oper-
ated. Following any submersion in water, have an
Authorized Service Dealer thoroughly clean and dry
the generator.

11
Section 3 – Maintenance
Recreational Vehicle Generator
2.8.2 OPERATION IN HIGH GRASS
OR BRUSH
Never operate the generator while the vehicle is
parked over high grass, weeds, brush, leaves, or
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.
2.8.3 EFFECTS OF MOISTURE AND DIRT
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.
When moisture is allowed to remain in contact with
windings, some of the moisture will be retained in
voids and cracks in the insulation. This reduces insu-
lation resistance and will eventually cause problems.
Dirt will make the problem worse, since it tends to
hold moisture in contact with windings. Salt (as from
sea air) will also worsen the problem, since it tends
to absorb moisture from the air. Salt and moisture,
when combined, form a good electrical conductor.
3.1 CHECKING THE ENGINE OIL
LEVEL
Check the engine crankcase oil level every eight hours
of operation, or at least once daily, before using the
generator. For oil capacities and requirements, see
“Engine Oil Requirements”. To check the engine oil
level, proceed as follows (see Figure 3.1):
1. Be sure the generator is as leveled as possible.
2. Remove the dipstick, and wipe it dry with a clean,
lint-free cloth.
3. Install the dipstick, and fully seat the T-handle;
then, remove it again. The oil level should be at
the dipstick “Full” mark.
4. If necessary, remove the oil fill plug and slowly
add oil until it reaches the dipstick “FULL” mark.
DO NOT FILL ABOVE THE “FULL” MARK.
Never operate the engine with the oil level
below the “ADD” mark on the dipstick. Doing
this could damage the engine.
5. Install the oil-fill plug and the dipstick before
operating the engine.
Figure 3.1 – Oil Maintenance Features
OIL FILL
OPENING AND PLUG
OIL DIPSTICK
REMOVABLE FRONT
PANEL TRANSPARENT
FOR VIEWING PURPOSES.
OIL
FILTER
FRONT SERVICE
DOOR
LATCHES
OIL DRAIN
PLUG
3.2 CHANGING THE ENGINE OIL
AND/OR OIL FILTER
Never operate the engine with the oil level
below the “ADD” mark on the dipstick. Doing
this could damage the engine.
Change the engine oil and oil filter after the first 25
hours of operation. See the “Service Schedule” sec-
tion for subsequent oil and filter changes. Change the
oil more frequently, if operating consistently under
heavy load or at high ambient temperatures.
To change the oil and/or oil filter, proceed as follows
(see Figure 3.1):
1. Run the engine until it is thoroughly warmed up (for
at least five minutes) then shut OFF the engine.
2. Immediately after the engine shuts OFF, remove
the front service door, located beneath the unit,
by retracting the two latches and pivoting the
door downward. If space allows, remove the front
panel by removing the four retaining bolts. Be
careful not to let the panel fall.
3. Remove the air filter (see "Servicing the Engine
Air Filter").
4. Remove the oil-drain plug and drain the oil into a
suitable container. Removing the oil-fill plug will
allow the crankcase to drain faster.
5. After the oil has drained, replace the oil-drain
plug. Go to step 9 if changing oil only.
6. With the oil drained, remove the old oil filter by
turning it counterclockwise.
7. Apply a light coating of clean engine oil to the
gasket of the new filter.

12
Section 3 – Maintenance
Recreational Vehicle Generator
8. Screw the new filter on by hand, until its gasket
lightly contacts the oil filter adapter. Then, tighten
the filter an additional 3/4 to one turn.
9. Remove the dipstick, and wipe it dry with a clean,
lint-free cloth. This will be used later to check the
oil level.
10. Remove the oil-fill plug, and slowly add the
proper type and amount of recommended oil (see
"Engine Oil Requirements"). Periodically use the
dipstick to check the oil level and continue to fill
the crankcase until the oil reaches the dipstick
“FULL” mark. DO NOT FILL ABOVE THE “FULL”
MARK.
11. Install the oil-fill plug and the dipstick.
12. Reinstall the air filter.
13. Reattach the front service door or front panel;
make sure the latches are fully engaged and the
bolts are fully tightened.
14. Start the engine, and check for leaks.
NOTE:
Check the oil level and fill to the “FULL” mark,
after checking for leaks. The filter will retain some
oil.
3.3 SERVICING THE ENGINE
AIR FILTER
To access the engine air filter (Figure 3.2), remove
the front service door, located beneath the unit, by
retracting the two latches and pivoting the door
downward. Loosen the hose clamp at the base of
the air filter and remove the filter. Place the hose
clamp on the new filter and install it, making sure it
is positioned properly before reattaching the service
door. Make sure the service door latches are fully
engaged.
Figure 3.2 – Engine Air Filter
REMOVABLE FRONT
PANEL TRANSPARENT
FOR VIEWING PURPOSES.
See the “Service Schedule” for recommended air
cleaner maintenance.
3.4 SPARK ARRESTOR MUFFLER
The exhaust muffler supplied with the generator
is a spark arrestor type. The exhaust mufflers for
recreational vehicle generators do not have a spark
arrestor screen, but are of the more efficient “toroid”
or “swirl” type. To remove carbon and combustion
deposits from the muffler, proceed as follows (see
Figure 3.3):
1. Place the unit above a noncombustible surface,
and ensure that the generator exhaust piping is
cool.
2. Remove the two screws holding the spark arres-
tor access plate to the rear floor pan.
3. Remove the spark arrestor access plate and gas-
ket.
4. Remove the hex pipe cap from the end of the
spark arrestor cleanout pipe.
5. Thread on a 3/8” NPT pipe coupling and pipe
nipple to extend the cleanout pipe at least 10
inches (250 mm) below the rear floor pan; addi-
tional piping may be added to direct the muffler
exhaust away from the cooling air discharge flow
beneath the unit.
Figure 3.3 – Spark Arrestor Muffler Maintenance
3/8" NPT HEX
PIPE CAP
GASKET
ACCESS PLATE
6. Start and run the engine for approximately 15
minutes.
7. Shut down the engine, and allow the piping to
cool.
8. Remove the 3/8” NPT coupling and piping.
9. Apply a graphite-base, anti-seize compound to
the cleanout pipe threads.
10. Reinstall the hex pipe cap, spark arrestor access
plate, gasket, and two screws.
The exhaust system of this product gets
extremely hot and remains hot after shutdown.
High grass, weeds, brush, leaves, etc., must
remain clear of the exhaust. Such materials may
ignite and burn from the heat of the exhaust
system.

Section 3 – Maintenance
Recreational Vehicle Generator
Failure to provide and maintain a spark arres-
tor may be in violation of the law. If this gen-
erator is used on any forest-covered, brush-
covered, or grass-covered unimproved land, the
vehicle owner or operator must maintain the
spark arrestor 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.
Be sure to reinstall the hex pipe cap tightly to
the spark arrestor cleanout pipe. Vibration could
cause a loose cap to fall out, resulting in hot
engine exhaust being drawn through the cen-
trifugal cooling fan and out beneath the unit.
This could result in damage to the generator or
in discharge of hot exhaust sparks beneath the
unit.
3.5 CLEANING THE GENERATOR
Keep the generator as clean and as dry as possible.
Dirt and moisture that accumulate on internal gen-
erator windings have adversely affect insulation
resistance.
Periodically, clean the generator’s exterior surfaces. A
soft brush may be used to loosen caked-on dirt. Use
a vacuum system or dry, low-pressure air to remove
any accumulations of dirt. The generator is housed
inside an all-weather enclosure; clean the enclosure
with a soft, damp cloth or with sponge and water.
Once each year, have the generator cleaned and
inspected by an Authorized Service Dealer. Service
technicians will use dry, low-pressure air to clean
internal windings. Parts inside the control console
should be cleaned and inspected at this time, as
well.
Finally, have the insulation resistance of stator and
rotor windings checked. If insulation resistances are
excessively low, the generator may require drying.
Do NOT use a forceful spray of water to clean
the generator. Water will enter the generator
interior and cause problems, and may also
contaminate the generator fuel system.
3.6 BATTERY MAINTENANCE
All lead-acid batteries will discharge when not in use.
The generator battery should be inspected per the
“Service Schedule”. The following procedure should
be used for inspection:
• Inspect the battery posts and cables for tightness
and corrosion. Tighten and clean as necessary.
• Check the battery fluid level of unsealed batteries
and, if necessary, fill with Distilled Water Only. Do
not use tap water in batteries.
• Have the state of charge and condition checked by
an Authorized Service Dealer.
NOTE:
Servicing of the battery is to be performed or
supervised by knowledgeable personnel, accord-
ing to the required precautions. Keep unauthor-
ized personnel away from batteries.
Damage will result if the battery connections are
made in reverse.
DANGER
Do not dispose of the battery in a fire. The
battery is capable of exploding. Storage batter-
ies release explosive hydrogen gas. This gas can
form an explosive mixture around the battery
for several hours after charging. The slightest
spark can ignite the gas and cause an explo-
sion. Such an explosion can shatter the battery
and cause blindness or other injury. Any area
that houses a storage battery must be properly
ventilated. Do not allow smoking, open flame,
sparks, or any spark-producing tool or equip-
ment near the battery. Discharge static electric-
ity from body before touching the battery by
first touching a grounded metal surface.
A battery presents a risk of electrical shock and
high short-circuit current. The following precau-
tions are to be observed when working on bat-
teries:
• Remove watches, rings, and other metal objects;
• Use tools with insulated handles;
• Wear rubber gloves and boots;
• Do not lay tools or metal parts on top of the
battery;
• Disconnect any charging source prior to connect-
ing, or disconnecting, battery terminals; and
• Do not use any jumper cables or booster battery
to crank and start the generator engine. If any bat-
tery has discharged, remove it for recharging.
13

14
Do not open or mutilate the battery. Released
electrolyte has been known to be harmful to the
skin and eyes, and to be toxic.
The electrolyte is a dilute sulfuric acid that is
harmful to the skin and eyes. It is electrically
conductive and corrosive. The following
procedures are to be observed:
• Wear full eye protection and protective clothing;
• Immediately wash with water all skin areas that
come into contact with the electrolyte.
• If the electrolyte contacts the eyes, immediately
flush eyes thoroughly with water, and seek medi-
cal attention.
• Spilled electrolyte is to be washed down with an
acid-neutralizing agent. A common practice is to
use a solution of 1 pound (500 grams) bicarbonate
of soda to 1 gallon (4 liters) of water. The bicar-
bonate of soda solution is to be added until the
evidence of reaction (foaming) has ceased. The
resulting liquid is to be flushed with water and the
area dried.
3.7 COOLING SYSTEM
Air intake and outlet openings in the generator com-
partment must be open and unobstructed for contin-
ued proper operation. Avoid obstructions, such as,
high grass, weeds, brush, leaves, and snow.
Without sufficient cooling and ventilating air flow, the
engine/generator quickly overheats, which causes it
to shut down.
3.8 ENGINE COOLANT
Check the coolant level in the coolant recovery tank
at least once daily or prior to use. Add the recom-
mended coolant mixture (see "Coolant"), as neces-
sary; the tank should be kept within the levels indi-
cated on the adjacent decal. If desired, a high-quality
rust inhibitor to the recommended 50-50 coolant
mixture may be added. If added consistently, the
recommended mixture will protect the unit against
freezing temperatures.
Periodically remove the radiator pressure cap, locat-
ed behind the access cover above the user control
panel, to make sure the coolant recovery system is
functioning properly. Coolant should be at the bot-
tom of the radiator filler neck. If the coolant level is
low, inspect the gasket in the radiator pressure cap.
Replace the cap, if necessary. To have the pressure
cap tested, contact an Authorized Service Dealer.
Inspect both the cooling system and coolant recovery
system for leaks.
DANGER
Do not remove the radiator pressure cap while
the engine is hot; otherwise, serious burns from
boiling liquid or steam could result.
Ethylene glycol base antifreeze is poisonous.
Do not use mouth to siphon coolant from the
radiator, recovery bottle, or any container. Wash
hands thoroughly after handling. Never store
used antifreeze in an open container because
animals are attracted to the smell and taste of
antifreeze, even though it is poisonous to them.
Do not use any chromate base rust inhibitor
with ethylene glycol base antifreeze; otherwise,
chromium hydroxide (“green slime”) will form
and cause overheating. Engines that have been
operated with a chromate base rust inhibitor
must be chemically cleaned before adding eth-
ylene glycol base antifreeze. Using any high-
silicate antifreeze boosters or additives will also
cause overheating. DO NOT use any soluble oil
inhibitor for this equipment.
3.9 MAJOR SERVICE MANUAL
To obtain a service manual for the generator, the
nearest Authorized Service Dealer. Make sure to iden-
tify the MODEL NUMBER and SERIES.
3.10 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. If suspect that drive belt tension is
incorrect, contact an Authorized Service Dealer.
3.11 EXERCISING THE GENERATOR
At least once every seven days, start and operate the
generator. Let the unit run for at least 30 minutes to
“exercise” the engine. If the generator cannot be exer-
cised every seven days, and it is to be out of service
longer than 30 days, see "Out-of-Service Procedure".
Section 3 – Maintenance
Recreational Vehicle Generator

15
3.12 OUT-OF-SERVICE PROCEDURE
3.12.1 REMOVAL FROM SERVICE
Prepare the generator for storage as follows:
1. Start the engine and let it run until it is thoroughly
warmed up (at least five minutes), then shut off the
engine.
2. While the engine is still warm from running, drain
the oil completely (see "Changing the Engine Oil
and/or Filter"). Refill the crankcase with the recom-
mended oil (see "Engine Oil Requirements").
3. Attach a tag to the engine, indicating the viscosity
and classification of the oil in the crankcase.
4. 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.
5. Clean and wipe the entire generator.
3.12.2 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 clas-
sification. Verify that the correct recommended oil is
used in the engine (see "Engine Oil Requirements").
If necessary, drain and refill with the proper oil.
2. Check the state of the battery. Fill all cells of
unsealed batteries to the proper level with distilled
water. DO NOT USE TAP WATER IN THE BATTERY.
Recharge the battery to 100 percent state of charge,
or, if defective, replace the battery.
3. Clean and wipe the entire generator.
4. Reconnect the battery. Observe battery polarity.
Damage may occur if the battery is connected incor-
rectly.
5. Turn OFF all electrical loads. Add fuel, if necessary,
and then start the engine.
6. Allow the unit to warm up thoroughly.
7. Apply electrical loads to at least 50 percent of the
unit’s rated wattage capacity.
8. When the engine is thoroughly warmed up, shut it
down.
9. The generator is now ready for service.
Section 3 – Maintenance
Recreational Vehicle Generator

3.13 SERVICE SCHEDULE
ATTENTION: It is recommended that all service work
be performed by the nearest Authorized Service Dealer.
SYSTEM/COMPONENT PROCEDURE FREQUENCY
X = Action Inspect Change Clean D = Daily W = Weekly
R = Replace/Adjust as Needed M = Monthly Y = Yearly
* = To Be Completed by an H = Hours
Authorized Service Dealer.
FUEL
Fuel level X AFTER 25-H,
D / BEFORE USE
Fuel lines and connections* X AFTER 25-H,
EVERY 250 H / 6 M
Fuel Filter* X EVERY 250 H / 6 M
LUBRICATION
Oil level X EVERY 8 H / D
Oil X AFTER 25-H,
EVERY 250 H / 6 M
Oil Filter X AFTER 25-H,
EVERY 250 H / 6 M
Oil line leakage* X EVERY 100 H
COOLING
Engine cooling system* X AFTER 25-H,
EVERY 100 H / M
Coolant level X AFTER 25-H,
D / BEFORE USE
Coolant* X EVERY 500 H / Y
Enclosure louvers X X EVERY 250 H / 6 M
EXHAUST
Exhaust system X EVERY 100 H / M
Retorque Exhaust Manifold* X EVERY 750 H
Clean out Muffler/Spark Arrestor X EVERY 150 H/Y
BATTERY
Electrolyte fluid level X AFTER 25-H, W
Charge and condition X R X W, EVERY 250 H / 6 M
FAN/ALTERNATOR BELTS
Tension and condition* X R EVERY 750 H
ENGINE
Retorque cylinder head* X EVERY 750 H
Retorque intake manifold* X EVERY 750 H
Starter motor* X EVERY 750 H
Air filter X R EVERY 500 H
Compression* X EVERY 750 H
Valve clearance* X R EVERY 750 H
Governor* X R EVERY 750 H
Safety devices* X R EVERY 750 H
Injection system* X R EVERY 750 H
GENERAL
Overall condition X X AFTER 25-H, W
Exercise system W
COMPLETE TUNE-UP* X X X Y
16
Section 3 – Maintenance
Recreational Vehicle Generator

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

18
NOTICE TO INSTALLER
These Installation Instructions have been published
by The manufacturer 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 simi-
lar products manufactured. The manufacturer also
assumes that personnel have been trained in the rec-
ommended installation procedures for these products
and that such training includes (a) use of common
hand tools, (b) use of special tools, and (c) use of any
tools and/or equipment from other suppliers.
The manufacturer cannot possibly know of, nor
advise the recreational vehicle trade of, all conceiv-
able methods, procedures, or techniques by which
to perform an installation. Nor can the manufacturer
anticipate every possible hazard that might result
from each installation method, procedure, or tech-
nique. The manufacturer has not undertaken any
such wide evaluation. Therefore, people who use a
method, procedure, or technique that the manufac-
turer does not specifically recommend must first
completely satisfy themselves that their safety, the
safety of the vehicle's occupants, and the product's
safety are not endangered by the method, procedure,
or technique selected.
Information, illustrations, specifications, etc., con-
tained in these Installation Instructions are based on
the latest information available at the time of publica-
tion. Every effort has been expended to be sure that
such data are both accurate and current. However,
the manufacturer reserves the right to change, alter,
or otherwise improve this product at any time, with-
out prior notice.
DANGER
Despite the safe design of this generator,
operating this equipment imprudently, neglecting
its maintenance, or being careless can cause
possible injury or death. Permit only responsible
and capable persons to operate or maintain this
equipment.
Parts of the generator are rotating and/or hot
during operation. Exercise care near running
generators.
Potentially lethal voltages are generated by
these machines. Ensure all steps are taken to
render the machine safe before attempting to
work on the generator.
GENERAL HAZARDS 
• For safety reasons, the manufacturer recommends
that the installation, initial startup, and main-
tenance of this equipment is carried out by an
Authorized Service Dealer.
• The engine exhaust fumes contain carbon monox-
ide, which can be DEADLY. This dangerous gas, if
breathed in sufficient concentrations, can cause
unconsciousness or even death. This exhaust
system must be installed properly, in strict com-
pliance with applicable codes and standards.
Following installation, do nothing that might ren-
der the system unsafe or in noncompliance with
such codes and standards. The generator com-
partment must be completely vapor-sealed from
the vehicle interior. There must be no possibility of
exhaust fumes entering the vehicle interior. Never
operate this equipment with a leaking or defective
exhaust system.
• Keep hands, feet, clothing, etc., away from drive
belts, fans, and other moving or hot parts. Never
remove any drive belt or fan guard while the unit
is operating.
• Adequate, unobstructed flow of cooling and ven-
tilating air is critical to correct generator opera-
tion and is required to expel toxic fumes and
fuel vapors from the generator compartment.
Without sufficient cooling airflow, the engine/
generator quickly overheats, which causes seri-
ous damage to the generator. Do not alter the
installation or permit even partial blockage of
ventilation provisions, as this can seriously
affect safe operation of the generator.
• When working on this equipment, remain alert
at all times. Never work on the equipment when
physically or mentally fatigued.
• Before performing any maintenance on the genera-
tor, disconnect its battery cables to prevent acci-
dental startup. First, disconnect the cable from the
battery post, indicated by a NEGATIVE, NEG, or
(–). Reconnect that cable last.
• 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. Serious injury or damage to the equip-
ment could be done.
Safety Rules
Recreational Vehicle Generator
DANGER: For fire safety, installation of a generator into a recreational vehicle must comply
strictly with NFPA 70 (latest edition), “National Electrical Code”, Article 551, and NFPA 1192
(latest edition), “Standard for Recreational Vehicles”. In addition, installation must comply
with the manufacturer’s instructions and recommendations.
