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Generac Power Systems RV 45 SERIES, Owner'S Manual

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49

ITEM  

PART 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 PRESSURE RELIEF BALL

  7 

0E9482 

1 

OIL PRESSURE SPRING

 8 

0C5315A 

1 

GEAROTOR, 

OUTER

 9 

0C5314A 

1 

GEAROTOR, 

INNER

  10 

0E9379 

1 

SCREEN, OIL PICK-UP

 11 

0E9382 

1 

COVER, GEROTOR

  12 

0G0919 

3 

SCREW, HHFCS M6-1.0 x 12

 13 

0E3372A 

1 

BREATHER SEPARATOR

 14 

0E9345 

1 

GEAR, GEAROTOR

 15 

076390 

4 

RETAINER RING

  16 

0G4379 

2 

PISTON RING SET

 17 

0G4331 

2 

PISTON

 18 

076389 

2 

PISTON PIN

  19 

0G1054 

2 

CONNECTING ROD ASSEMBLY

 20 

0G1063G 

1 

CRANKSHAFT

  21 

093064 

1 

OIL FILL CAP

  22 

0E9334F 

1 

COVER ROCKER W/FILL

  23 

080318 

8 

SCREW HHFC M6-1.0 X 25

  24 

0E9352 

2 

GASKET, VALVE COVER

 25 

0E9368 

2 

SPARK PLUG

  26 

077168 

12 

SCREW HHC M8-1.25 X 56

  27 

084186 

4 

WASHER, VALVE SPRING

  28 

088156 

2 

SEAL, VALVE STEM

 29 

0C4390 

4 

VALVE SPRING

 30 

0C3733 

4 

VALVE RETAINER

  31 

0C3592 

8 

KEEPER, VALVE SPRING

  32 

077161 

4 

STUD, ROCKER ARM

 33 

077160 

4 

ROCKER ARM

  34 

076307 

4 

JAM NUT, ROCKER ARM

  35 

0E9353A 

2 

PUSH ROD GUIDE PLATE

  36 

0E9304 

1 

CYLINDER HEAD CYL. 1

 37 

0C3591 

2 

INTAKE VALVE

 38 

0C3590 

2 

EXHAUST VALVE

  39 

0E9351 

2 

GASKET CYLINDER HEAD

 40 

0G5728 

1 

SCREEN

 41 

0E9455E 

4 

PUSHROD

 42 

083235 

4 

TAPPET

  43 

0G7679 

1 

CAM SHAFT & GEAR

 44 

0E9350 

1 

GASKET, CRANKCASE

 45 

0E9334G 

1 

COVER ROCKER

  46 

0E9305 

1 

CYLINDER HEAD CYL 2

 47 

0E9429C 

1 

CRANKCASE

  48 

0E9366 

1 

GASKET, BREATHER ASSEMBLY

 49 

0G5670 

1 

BREATHER ASSY

  50 

0C8566 

1 

SCREW HHFC M6-1.0 X 20

  51 

0C5943 

1 

SEAL, OIL PASSAGE

 52 

0G0273 

1 

GASKET KIT

 53 

0G5896 

1 

BREATHER KIT

  54 

0G0275 

1 

KIT HEAD ASSY CYLINDER #1

  55 

0G0276 

1 

KIT HEAD ASSY CYLINDER #2

Section 7 — Exploded Views and Parts Lists

Recreational Vehicle Generators

530 RV Engine – Drawing No. 0G7719-B

Summary of Contents for RV 45 SERIES

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

Page 2: ...ad this manual and thoroughly understand all instructions before using this equipment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to operate the equipment in an emergency CONTENTS This manual contains pertinent owner s information including warranty electrical diagrams exploded views and lists of ...

Page 3: ... 7 Cleaning the Generator 13 3 8 Battery Maintenance 13 3 9 Adjusting Valve Clearance 14 3 10 Major Service Manual 15 3 11 Drive Belt 15 3 12 Exercising the Generator 15 3 13 Out of Service Procedure 15 3 14 RV Generator Service Interval 15 Section 4 Notes 16 Part II Installation Instructions Safety Rules 18 Section 1 General Information 20 1 1 Purpose and Scope of the Installation Instructions 20...

Page 4: ...MMEDIATELY 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 running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset instal lation manual Make sure there is ample fresh air when operat ing the genset in...

Page 5: ...s causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed ...

Page 6: ...__________ 6 Hertz __________________________ 1 2 3 4 5 8 15 13 16 14 6 7 9 17 10 12 11 10 17 18 1 1 GENERATOR IDENTIFICATION REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake 2 Data Plate 3 Engine Start Stop Switch 4 7 5 amp Fuse 5 Circuit Breaker 6 Optional Remote Panel Receptacle 7 Generator AC Output Leads 8 Starter Contactor 9 Fuel Inlet 10 Fuel Pump 11 Oil Filter 12 Oil Drain Plug 13 Oi...

Page 7: ...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 startin...

Page 8: ...than the vehicle engine s pickup tube Such an arrange ment causes the generator engine to run out of gas while adequate fuel for the vehicle remains in the tank To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator Leaded REGULAR grade gasoline is an acceptable substitute NOTE Using unleaded gasoline contributes to longer engine valve life by reducing lead and ca...

Page 9: ...quence a fault code will flash on the switch see Diagnostics The switch center position is the RUN position To stop a running engine press momentarily the bottom half of the switch to kill the ignition Figure 2 1 Typical Control Panel Indicator Light TO START GENERATOR Push up oncontrol switch Hold for 1 second and release Note flashing indicator Generator will start automatically TO STOP GENERATO...

Page 10: ...unit cools down it will attempt to restart auto matically when the temperature switch opens again 7 Flashes Underspeed Alternator spins less than 3240 rpm 54 Hz for three 3 seconds NOTE After a fault is indicated press stop momentarily to clear the alarm once the problem is fixed 2 2 OPTIONAL REMOTE START STOP PANEL A remote mounted Start Stop Panel is available that allows start ing and stopping ...

Page 11: ...MS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired 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 ar...

Page 12: ...hat run the vehicle s furnace fan refrigerator air conditioner etc need about 2 1 2 times 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 figure the watts needed to start electric motors in the system To that figure add the running wattages of other items that will be oper at...

Page 13: ...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 and tighten the oil fill cap and the dipstick before oper ating the engine Figure 3 1 Oil Dipstick Fill Tube and Location of Oil Drain Plug Oil Dipstick Oil Drain Hose Oil Fill 3 2 CHAN...

Page 14: ...6 Interlock the Air Cleaner Cover to hinge with the Air Cleaner Base 7 Align the Cover and gently push the top closed 8 Engage the yellow plastic knob and turn turn clockwise to secure Figure 3 3 Engine Air Cleaner Air Cleaner Base Air Cleaner Air Cleaner Cover Knob 3 4 CHECKING THE ENGINE SPARK PLUG Reset the spark plug gap or replace the spark plugs as necessary See the Service Schedule section ...

Page 15: ...be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with windings Salt as from sea air also will worsen the problem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor which is detrimen...

Page 16: ...ommon practice is to use a solution of 1 pound 500 grams bicarbonate of soda to 1 gallon 4 liters or 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 9 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation check the valve clearance in the engine adjust if necessar...

Page 17: ...m running drain the oil completely Refill the crankcase with SAE 5W 30 oil having API classification For Service SJ SL 4 Attach a tag to the engine indicating the viscosity and clas sification of the oil in the crankcase 5 Remove the spark plug and pour two or three tablespoons of clean fresh engine oil into the spark plug threaded openings Reinstall and tighten the spark plug 6 Remove the battery...

Page 18: ...16 Section 4 Notes Recreational Vehicle Generators ...

Page 19: ...PART II INSTALLATION INSTRUCTIONS DANGER ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION ...

Page 20: ...nds that the installation initial start up and maintenance of this equipment is carried out by an Authorized Service Dealer The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO...

Page 21: ...such as a rope or board to free the victim from the live conduc tor If the victim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equipment Jewelry can conduct electricity resulting in electric shock or may get caught in moving components causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Install...

Page 22: ... 3 ANSI C1 1975 and ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI A119 2 RVIA EGS 1 available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 available from the State of California Documents Section P O Box 1015 North Highlands CA 95660 6 CSA Electrical Bul...

Page 23: ...21 Section 1 General Information Recreational Vehicle Generators Figure 1 2 Major Features and Dimensions Drawing No 0G5519 C ...

Page 24: ...tor 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 If mounting the generator in an enclosed compartment the base of the generator must rest flat on th...

Page 25: ...partments for the location of the generator mounting holes Torque Bolts to 31 ft lbs Figure 2 3 Typical Generator Restraint 2 2 GENERATOR COMPARTMENTS Whether the generator set is being installed inside a compartment specifically manufactured to house a generator or inside a compart ment that the installer constructs the compartment MUST meet certain specifications as outlined in the following sec...

Page 26: ... 6 Types of Lock Seams After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved nonflammable sound insulating material See Sound Insulating Materials DANGER Do not install any flammable material directly above or around the compartment Heat transferred through the compartment structure may be sufficient to ignite char or discolor ...

Page 27: ...MPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items Figure 2 9 Engine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts See Generator Restraint DANGER Fuel lines and exhaust piping must not pen etrate into the vehicle living area 2 3 COOLING AND VENTILATING AIR It is absolutely essential that an ...

Page 28: ...26 Section 2 Installation Recreational Vehicle Generators Figure 2 9 Compartment Floor Cutout Drawing 0G4432 A ...

Page 29: ...ds that the fuel pickup tube be two to three inches 51 to 76 mm shorter than the vehicle engine s pickup tube This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods Do NOT tee the generator fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the sam...

Page 30: ...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 When installing replacing the tailpipe or spark arrestor compo nents verify that the tailpipe has a hole to securely fasten the spark arrestor components see Figures 2 11 and 2 12 Use only manufacturer supplied hardware Sub...

Page 31: ...ire gauge size should be large enough to handle at least 115 percent of the installed generator s rated maximum current If neutral conductors are used they must be the same size as other leg wires Route power supply conductors from generator AC output leads T1 red T2 white T3 black and the green ground wire through approved flexible conduit to the electrical junction box on the compartment wall If...

Page 32: ...STALLATION NOTE This generator is not equipped with an internal bat tery charger It is intended for use in systems where an external battery charger is installed by the RV O E M or an aftermarket installer 2 7 1 RECOMMENDED BATTERY Install a battery that meets the following requirements The battery must be a 12 volt automotive type storage bat tery For prevailing ambient temperatures above 32 F 0 ...

Page 33: ...31 Section 2 Installation Recreational Vehicle Generators Figure 2 14 Typical Transfer Switch Isolation Method Figure 2 15 Typical Installation With Isolation Receptacle ...

Page 34: ...g in receptacle Figure 2 17 is provided on the generator set Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit starting and stopping the generator engine from any convenient location inside the vehicle 2 8 1 REMOTE PANEL MODELS The remote panels mount a rocker type start stop switch a Generator Run advisory lamp and...

Page 35: ...mer switch will shorten this time 3 Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load see T...

Page 36: ...y installed 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 Conduit is properly installed and sealed Generator is properly bonded to the vehicle Generator is always isolated from other power sourc es BATTERY INSTALLATION Recommended battery is installed...

Page 37: ...ine spark plugs defective 6 Clean regap or replace as needed 7 Bad ignition magneto on engine 7 Replace if defective 8 Bad carburetor 8 Adjust repair or replace 9 Dirty air cleaner 9 Clean or replace as needed Engine starts hard runs rough 1 Dirty engine air cleaner 1 Clean or replace as needed 2 Automatic choke is sticking 2 Free choke linkage as needed 3 Defective spark plugs 3 Clean regap or re...

Page 38: ...36 Section 5 Notes ...

Page 39: ...37 Section 5 Notes ...

Page 40: ...38 Section 6 Electrical Data Recreational Vehicle Generators Wiring Diagram Drawing No 0G4221 C ...

Page 41: ...39 Section 6 Electrical Data Recreational Vehicle Generators Electrical Schematic Drawing No 0G4221 C ...

Page 42: ...40 Section 7 Exploded Views and Parts Lists Recreational Vehicle Generators Enclosure Drawing No 0G3881 E ...

Page 43: ...ING GASKET 30 0G3398 1 EXHAUST DIVIDER PANEL 31 0G3912 1 MUFFLER HOLD DOWN BRACKET 32 0G3400 1 ENCLOSURE EXHAUST SIDE PANEL 33 0G5240 1 FBR GLASS ENCLOSURE MFLR BACK 34 0G5242 1 FOAM EXHAUST END ENCL FRONT 35 0G5241 2 FBR GLASS ENCLOSURE MFLR SIDE 36 045756 9 SCREW HHTT M6 1 0X10 ZYC 37 0G5755 1 BUMPER 38 0G5761 1 STAND OFF 39 022473 1 WASHER FLAT 1 4 40 022097 1 WASHER LOCK 1 4 41 022287 1 SCREW ...

Page 44: ...42 Section 7 Exploded Views and Parts Lists Recreational Vehicle Generators Control Panel Drawing No 0G5489 G ...

Page 45: ...3689 1 C PNL FACE 32 092036 4 SCREW PPHM 6 32 X 1 4 SEMS 33 0A9611 1 FUSE 7 5AXBK AGC7 5NX 34 032300 1 HOLDER FUSE 35 0G4215 1 SWITCH RKRSPDT ON OFF ON ILLUM 36 082025 4 NUT HEX LOCK M5 0 8 NYINS ZINC ITEM PART NO QTY DESCRIPTION 37 0F9719 1 ASSY PCB VREG AIR COOLED 2006 38 0G3977 1 ASSY PCB RV CONTROLLER 39 0G3530 1 C PNL FRAME RV 40 075476 2 SCREW PPHM M4 0 7 X 16 41 090987 2 SCREW PPHM M3 0 5 X...

Page 46: ...44 Section 7 Exploded Views and Parts Lists Recreational Vehicle Generators Base Pulley Drawing No 0G7720 B ...

Page 47: ...GASKET LOWER BLOWER HOUSING 24 0G7670 1 FRAME GT530 RV MOUNTING 25 0E0588 1 SPACER SAFETY BOLT 375 I D 26 0G4702 2 SCREW HHC 5 16 18 X 3 SPC 27 029451 1 5ft TAPE ELEC UL FOAM 1 8 X 1 2 28 0G3426 1 DUCT AIR OUT 29 0G5676 1 GASKET AIR OUT DUCT 0G5676A 1 GASKET AIR OUT DUCT OPPOSITE SIDE 30 0G4692 1 SCREEN BOTTOM AIR OUT 31 022473 3 WASHER FLAT 1 4 M6 ZINC 32 0A2110 3 SCREW SWAGE 1 4 20 X 1 2 ZYC 33 ...

Page 48: ...46 Section 7 Exploded Views and Parts Lists Recreational Vehicle Generators Engine Accessories Drawing No 0G7718 G ...

Page 49: ...P 48 0F0452B 8 HOSE 3 8 I D ITEM PART NO QTY DESCRIPTION 49 0G4426 1 ASSY OIL DRAIN FITTING 50 0G3386 1 OIL FILTER SUPPORT 51 0A2311 2 SCREW SWAGE 1 4 20 X 1 52 070185B 1 OIL FILTER 53 0D9235 1 OIL PRESSURE SWITCH 5 PSI 54 0G4793 1 SWITCH THERMAL 270F 55 043182 2 WASHER LOCK M3 56 0C1085 2 SCREW PPHM M3 0 5 X 8 58 0G4576 1 BRACKET OIL CHECK TUBE 59 0A2110 1 SCREW SWAGE 1 4 20 X 1 2 60 0G3407 1 WRA...

Page 50: ...48 Section 7 Exploded Views and Parts Lists Recreational Vehicle Generators 530 RV Engine Drawing No 0G7719 B ...

Page 51: ...G 26 077168 12 SCREW HHC M8 1 25 X 56 27 084186 4 WASHER VALVE SPRING 28 088156 2 SEAL VALVE STEM 29 0C4390 4 VALVE SPRING 30 0C3733 4 VALVE RETAINER 31 0C3592 8 KEEPER VALVE SPRING 32 077161 4 STUD ROCKER ARM 33 077160 4 ROCKER ARM 34 076307 4 JAM NUT ROCKER ARM 35 0E9353A 2 PUSH ROD GUIDE PLATE 36 0E9304 1 CYLINDER HEAD CYL 1 37 0C3591 2 INTAKE VALVE 38 0C3590 2 EXHAUST VALVE 39 0E9351 2 GASKET ...

Page 52: ...50 Section 7 Exploded Views and Parts Lists Recreational Vehicle Generators Rotor Stator Drawing No 0G3953 B ...

Page 53: ...7H 1 RTR 200 4 5AD1 RV 0G3878H 1 RTR 200 5 5AD1 RV 0G3879H 1 RTR 200 6 5AD1 RV 14 0G3893H 1 STR 200 4 5AD1 RV 0G3894H 1 STR 200 5 5AD1 RV 0G3895H 1 STR 200 6 5AD1 RV 15 0G3381 1 UPPER BEARING CARRIER 16 022129 4 WASHER LOCK M8 5 16 17 045771 4 NUT HEX M8 1 25 G8 CLEAR ZINC 18 066386 1 ASSEMBLY BRUSH HOLDER 19 066849 2 SCREW HHTT M5 0 8 X 16 20 0G3542 1 FAN UPPER ALTERNATOR 21 022131 1 WASHER FLAT ...

Page 54: ...omponent thereof has failed due to abuse neglect improper maintenance or unapproved modifica tions or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time not to excee...

Page 55: ...related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions related part 4 Repair or replacement of any warranted emissions related part under this ECS Warranty shall be performed at no charge to the owner at a Generac Authorized Warranty Service Facility 5 When the engine...

Page 56: ...nty Policies and Procedures Guide THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Guardian generators that utilize non Generac replacement parts Costs of normal maintenance adjustments installation and start up Repairs or diagnostics performed by individuals other than Guardian Generac authorized dealers not authorized in writing by Generac Power Systems Failures caused by any contaminated ...

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