Generac 0661-4 User Manual

Manual No. A5929
OWNER'S MANUAL

and Installation Instructions

Series NP-30G
AIR-COOLED
RECREATIONAL VEHICLE
GENERATORS
Model No. 0661-4
Revision 1 (02/04/98)
Printed in U.S.A,

GENERAL SAFETY RULES

THE MANUFACTURER SUGGESTS THAT THESE “RULES” FOR SAFE OPERATION BE
COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHI- A
CLE. SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERA- MSk
A
TORS OF THIS EQUIPMENT.
Study these SAFETY RULES carefully before operat ing or servicing applicable equipment. Become familiar with this Owner's Manual and with your generator.
Safe, efficient and reliable operation can only be achieved if generator is properiy installed, operated and maintained. Many accidents are caused by failing to follow simple and fundamental rules or precautions.
The manufacturer suggests that these GENERAL SAFETY RULES be copied and posted in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators and potential operators of equipment.

WARNING:

The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, hirth
defects, or other reproductive harm.
The manufacturer cannot possibly anticipate every cir cumstance that might involve a hazard. The warnings in this Manual and on tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a proce dure, work method or operating technique Generac does not specifically recommend, you must satisfy yourself that it is sate for you and others. You must also make sure the procedure, work method or operat ing technique that you chose does not render the gen erator to be unsafe.
For fire safety, the recreational vehicle generator must
be properly installed arid maintained. Installation mustA
always remain in compliance with applicable codes and standards. In addition, the generator must be installed in
comformance to the manufacturer's detailed installation instructions. Following installation, nothing must be done that might render the generator in noncompliance with such codes, standards and instructions.
The RV generator produce
A
dangerous electrical voltage gerous, and possibly fatak
gerous, and possibly fataC electrical shock. Avoid contact with bare wires, terminals, etc. while the unit is running. If you must work around an operat ing generator, stand on an insulated, dry surface to reduce shock hazard.
Never work on this equipment or handle any elec
trical device while standing in water, while bare foot, or while hands or feet are wet. Dangerous electrical shock will result.
Have the generator properly grounded (bonded)
during installation into the vehicle, 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
ductor to any generator part that might be removed or disassembled during routine mainte nance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 AWG copper wire minimum.
)roduces extremely high and
jes and can cause dan
con-equipped. DO NOT reconnect the bonding C(
In case of accident caused by electric shock, shut down the source of electrical power down at once. If this can not be done, free victim from live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a dry board, dry rope, or other non-conducting implement to free the victim from live conductor.
Inspect fuel system frequently for leaks or dam age. Repair or replace any damaged or leaking component immediately. Never attempt to change, alter or modify the generator fuel system in any way that might affect safety or compliance with applicable codes and standards.
The generator engine gives off DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentra
tions, can cause unconsciousness or even death. This exhaust system must have been properly installed, in strict compliance with applicable codes and standards. Following installation, you must do
nothing that might render the system unsafe or in
non-compliance with such codes and standards. The generator compartment must be completely vapor sealed from vehicle interior. There must be no possibility of exhaust fumes entering the vehi cle interior. Never operate this equipment with a leaking or defective exhaust system.
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, fuel leakage, oil leakage, etc.
Do not smoke around the generator. Wipe up any fuel and oil spills immediately. Never leave oily or fuel soaked rags in the generator compartment or on the generator itself. Keep the area around the gener ator clean and free of debris.
Adequate ventillation is required to expel toxic fumes and gasoline vapors from the generator compartment. Do not alter the installation of this equipment in any manner that might obstruct air and ventillation openings. Such openings must be kept clear and unobstructed.
Keep hands, feet, clothing, etc., away from drive belts, fans and other moving parts of this equip ment. Never remove any drive belt or fan guards while the unit is operating.
Inspect the generator periodically. Repair o all damaged or defective parts immediately
These ger
These generators can be converted to use LP gas propane) The qas ii low areas where even the slightest spark can ignite the gas and cause an explosion.
Before performing any maintenance on the gener ator set, disconnect its battery cables to prevent accidental start up. Disconnect the cable from the batteiy post indicated by a NEGATIVE, NEG or (-) first. Reconnect that cable last.
' • ■
as a fuel. LP gas is highly EXPLOSIVE.
gas IS heavier than’air and'tends to settle in
........................
or replace
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~|VE

IDENTIFICATION RECORD AND GENERATOR FEATURES

Please record the following information from the generator DATA DECAL or information decal.
1. Model Number___________________ 2.Serial Number
3.kW Rating,
5. Phase
_____
4. Rated Voitage,
6. Hertz
_________
_________________________
1, Generator Air Intake Screen
2. Engine Start/Stop Switch
3. Fuse
4. Circuit Breaker
5. Fuel Pump Primer
6. Generator AC Output Leads
7. 12 Volt Battery Connection
REFERENCE NUMBER IDENTIFICATION
8. Fuel Pump
9. Air Cleaner
10. Air Intake Tube
11. Carburetor
12. Oil Dipstick and Filler Tube
13. Data Decal
14. Hour Meter

TABLE OF CONTENTS

OPERATING INSTRUCTIONS
GENERAL SAFETY RULES.........................inside cover
IDENTiFICATION RECORD AND
GENERATOR FEATURES............................................. 1
READ THiS MANUAL THOROUGHLY
Operation and Maintenance............................................... 3
How to Obtain Service
GENERATOR FAMiLIARIZATiON
Generator Applicability....................................................... 4
Safety................................................................................. 4
Generator AC Connection System..................................... 4
OPERATING INSTRUCTiONS
Generator Control Panel
Automatic Choke................................................................ 5
Before Starting the Engine
Starting............................................................................... 6
Stopping the Generator...................................................... 6
Applying Loads to Generator Attention Required After Submersion
Operation in High Grass or Brush...................................... 6
Operating Precautions
Effects of Moisture and Dirt................................................ 7
Don't Overload the Generator............................................ 7
Automatic Low Oil Pressure Shutdown.............................. 7
High Temperature Shutdown
Overspeed.......................................................................... 7
Low Voltage
.......................................................................
SPECIFICATIONS
Fuel Requirements............................................................. 8
Engine Oil Requirements................................................... 8
Generator Specifications.................................................... 8
Engine Specifications......................................................... 8
MAINTENANCE
Checking Engine Oil Level................................................. 9
Change Engine Oil............................................................. 9
Change Oil Filter
Engine Air Cleaner............................................................. 9
Clean Air Intake Screen
Spark Arrestor Muffler.......................................................10
Engine Spark Plug
Fuel Filter..........................................................................10
Cleaning the Generator.....................................................10
Battery...............................................................................10
Service and Adjustments..................................................11
Throttle Linkage Adjustment.............................................11
Adjusting the Carburetor...................................................11
Adjusting Valve Clearance...........................................11-12
Major Service Manual
Exercising the Generator
Out of Service Protection
Return the Unit to Service after Storage
Service Dealer Location................................................... 12
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5-6
6-7
10
10
12 12 12 12
INSTALLATION INSTRUCTIONS
INSTALLATION SAFETY RULES..................................13
GENERAL INSTALLATION INFORMATION
Purpose of Scope...........................................................14
Safety.............................................................................14
Standards Booklet..........................................................14
Equipment Description
3
Engine-Generator Operating Speed...............................14
Generator AC Connection System
LOCATION AND SUPPORT
Generator Location.........................................................15
Generator Support..........................................................15
Suspended Mounting
Generator Restraint........................................................16
5
GENERATOR COMPARTMENTS
Compartment Seams......................................................16
Compartment Size..........................................................17
Compartment Construction.............................................17
Sound Insulation Materials
6 6
Compartment Floor Cutouts Acoustics’
.......................................................................
COOLING AND VENTILATION AIR Generator Air Flow Cooling Air Inlet Openings Compensating for Restrictions
7
Testing the Installation....................................................20
GASOLINE FUEL SYSTEM
7
EXHAUST SYSTEM ELECTRICAL CONNECTIONS
Electrical Junction Box Wiring
.............................................................................
Generator AC Connections
Conduit...........................................................................23
Isolating Different Power Sources Power Supply Cord Ground Fault Circuit Interrupters
9
BATTERY INSTALLATION OPTIONAL ACCESSORIES POST INSTALLATION TESTS
INSTALLATION CHECK LIST........................................29
MAJOR FEATURES AND DIMENSIONS
TROUBLESHOOTING...................................................31
ELECTRICAL DATA REPAIR PARTS
NOTES......................................................................42-43
CALIFORNIA EMISSIONSWARRANTY WARRANTY
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READ THIS MANUAL THOROUGHLY
If you don't understand any portion of this manual, contact Generac for a demonstration of actual start ing, operating and servicing procedures.
Throughout this publication and on tags and decals
affixed to the generator, DANGER and CAUTION blocks are used to alert you to special instruction about a particular operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These safety warnings cannot eliminate the hazards that they indicate. Strict compliance with the special
instructions while performing the service plus "com mon sense" are major measures to prevent acci dents.
The following definitions apply to DANGER, CAU TION and NOTE blocks found throughout the manual.
DANGER: AFTER THIS HEADING YOU CAN READ HANDLING, INSTALLING, OPERATING OR SERVIC ING INSTRUCTIONS THAT, IF NOT STRICTLY COM PLIED WITH, MAY RESULT IN PERSONAL INJURY.
CAUTION: After this heading you can read instruc
tions for handling, instaliing, operating or servicing the generator that, if not strictiy compiied with, may result in damage to equipment and/or property.
NOTE: After this heading you can read explanatory statements that require special emphasis.
These symbols indicate the following:
Points out important safety information and, if not followed, could endanger personal safety
and/or property of yourself and others.
Potential explosion hazard
Potential fire hazard
A
Potential electrical shock hazard
The operator (driver) is responsible for proper and safe use of the vehicle, equipment on the vehicle, and the safety of all vehicle occupants. We strongly rec ommend that the operator read this Owner's 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.

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 by an Authorized Dealer periodi cally. Normal maintenance service and replacement of parts are the responsibility of the Owner/Operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.
Proper maintenance and care of your recreational vehicle generator assures a minimum number of problems and keeps your operating expenses at a minimum. See your authorized Dealer/Distributor for service aids and accessories.

HOW TO OBTAIN SERVICE

When your recreational vehicle generator set requires servicing or repairs, simply contact an Authorized Service Facility for assistance. Service technicians are factoiy-trained and are capable of handling all of your service needs.
When contacting an Authorized Service Facility or the factory about parts and service, always supply the complete mode! number and serial number of your unit as given on its data plate.
The warranty on your generator is included in this Owner's Manual, as well as listings for repair parts.
A
SERVICE DEALER LOCATION
TO LOCATE THE NEAREST GENERAC SERVICING DEALER, PLEASE CALL OUR 800 NUMBER.
ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER.
1-800-333-1322
3

GENERATOR FAMILIARIZATION

GENERATOR APPLICABILITY

These generators have been designed and manufac tured for supplying electrical power for recreational vehicles. You should not modify the generator or use
it for any application other than for what it was designed. If there are questions pertaining to its application, write or call the factory. Do not use the
unit until you have been advised by a competent authority.
DANGER: FOR FIRE SAFETY, THE GENER ATOR MUST HAVE BEEN PROPERLY INSTALLED
A
IN COMPLIANCE WITH (1) ANS1119.2-1975/NFPA
501C-1974 "STANDARD FOR RECREATIONAL VEHICLES", PART III, "INSTALLATION OF ELEC TRICAL SYSTEMS." THE GENERATOR ALSO MUST HAVE BEEN INSTALLED IN STRICT COM PLIANCE WITH THE MANUFACTURER'S DETAILED INSTALLATION INSTRUCTIONS. AFTER INSTALLA
TION, DO NOTHING THAT MIGHT RENDER THE
UNIT IN NON-COMPLIANCE WITH SUCH CODES,
STANDARDS AND INSTRUCTIONS.
You can use this generator to supply electrical power for operating 120 volts, single phase, 60 Hertz, elec trical loads. These loads can require up to 3000 watts (3.0 kW) from the NP-30G.
SAFETY
Before using the generator set, carefully read GEN
ERAL SAFETY RULES inside the cover. Comply with these RULES to prevent accidents and damage to equipment and/or property. Generac suggests copy ing and posting the GENERAL SAFETY RULES in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators of this equipment.
GENERATOR AC CONNECTION
SYSTEIVI
This air-cooled NP Series generator can power 120­volt, single phase, 60 Hertz AC loads. The diagram below is a simple schematic (Figure 1) of the genera
tor’s AC connection system.
Figure 1 — Connection for 120 Voits Only
CAUTION; Do not overload the generator. Some installations may require that eiectricai loads be
alternated to avoid overloading. Applying exces­sively high electrical loads may damage the gener ator and may shorten its life. Add up the rated watts of all electrical lighting, appiiance, 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 electrical 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.
__4_
OPERATING INSTRUCTIONS

GENERATOR CONTROL PANEL

Mounted on the generator control panel (Figure 2) are the following features:
Figure 2 — Typical Control Panel
FUEL PRilVIER
Before starting a cold engine (it has not been started in more than two weeks), you must press this switch
to bring fuel from the tank to the fuel pump. This rock
er type switch springs back into its original position
when you release It.
■ CHOKE SOLENOID
During engine cranking (start/stop switch at START), a solid state choke module signals the choke solenoid to actuate and cycle (choke on/choke off) until engine starts. The choke solenoid thus opens and closes the carburetor choke valve only when the engine is crank ing. When the engine starts, the choke cycling stops.
PRECHOKE
The choke system also has a temperature sensitive metal strip that adjusts the choke valve angle accord ing to ambient temperatures (i.e., in cold ambient temperatures the choke valve closes more). Once the engine starts, an element heats the temperature­sensitive strip to a normal operating condition, open ing the choke valve. This may take about 3 minutes in cooler weather.
BEFORE STARTING THE ENGINE
IMPORTANT: INSTRUCTIONS AND INFORMATION IN THIS MANUAL ASSUME THE GENERATOR HAS BEEN PROPERLY INSTALLED, CONNECTED, SERVICED, TESTED AND ADJUSTED BY A QUALI FIED INSTALLATION TECHNICIAN OF INSTALLA
TION CONTRACTOR.
INSTALLATION
START/STOP SWITCH
To crank and start the engine, hold this switch at its
START position. Release the switch when the engine starts. To stop an operating engine, press and hold the switch in its STOP position until the engine shuts off. The switch center position is the RUN position.
FUSE
Protects the engine DC control circuit against electrical overload. If the fuse element has melted open due to overloading, the engine cannot be cranked. If you must replace it, use only an identical replacement fuse.
■ CIRCUIT BREAKER
Protects generator's AC output circuit against over load, i.e., prevents unit from exceeding wattage/amperage capacity.
■ HOUR METER
Indicates the time the engine-generator has operated, in hours and tenths of hours. Use the hourmeter along with the periodic maintenance schedule for your generator set.
AUTOMATIC CHOKE
The engine is equipped with an automatic choke that consists of two main components — choke solenoid and prechoke.
Generator installation must have been properly com pleted so it complies with all applicable codes, stan dards and regulations and with the manufacturer's
recommendations.
ENGINE LUBRICATION
Have engine crankcase properly serviced with recom mended oil before starting. Refer to "Maintenance" and "Specifications" sections for oil servicing proce dures and recommendations.
CAUTION: Any attempt to crank or start the engine before you have properly serviced it with the recommended oil may result in engine failure.
■ FUEL SUPPLY
The engine must have adequate supply of proper fuel to operate. Before starting, check that sufficient fuel is available.
NOTE: On some Installations, the generator engine may “share” the vehicle’s gasoline fuel tank with the vehicle engine. Some installations may provide sepa rate fuel tanks for generator and vehicle engine.
■ COOLING AND VENTILATING AIR
Air inlet and outlet openings in the generator compart ment must be open and unobstructed for continued proper operation. Without sufficient cooling and venti lating air flow, the engine-generator quickly overheats, which causes it to automatically shutdown. Overheating could also damage the unit or your vehicle.
5
ENGINE EXHAUST GAS
Before starting the generator engine, you should be sure there is no way for exhaust gases to enter the vehicle interior and endangering people or animals. Close windows, doors and other openings in the vehi cle that, if open, might permit exhaust gases to enter the vehicle.
DANGER; THE GENERATOR ENGINE GIVES OFF DEADLY CARBON MONOXIDE GAS THROUGH ITS EXHAUST SYSTEM. THIS DANGER OUS GAS, IF BREATHED IN SUFFICIENT CONCEN
TRATIONS, CAN CAUSE UNCONSCIOUSNESS OR EVEN DEATH. DO NOT OPERATE THE GENERA TOR IF ITS EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED. SYMPTOMS OF CARBON MONOXIDE POISONING ARE (A) INABILITY TO
THINK COHERENTLY, (B) VOMITING, (C) TWITCH
ING MUSCLES, (D) THROBBING TEMPLES, (E) DIZZINESS, (F) HEADACHE, (G) WEAKNESS AND SLEEPINESS. IF YOU FEEL ANY OF THESE SYMP
TOMS, MOVE INTO FRESH AIR IMMEDIATELY. IF
SYMPTOMS PERSIST, GET MEDICAL HELP.
STARTING
IMPORTANT: 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 crank and start the generator engine, proceed as follows;
1. Turn OFF electrical loads, using whatever means provid
ed in your vehicle (such as a main line circuit breaker or transfer switch.
NOTE: If you start the engine with the start/stop switch on the generator control panel, turn OFF loads by setting the panel’s main breaker to the “OFF” or “OPEN” position. Electrical load circuits will be turned ON after the generator has started, stabilized and warmed up.
NOTE: You only need to use the fuel primer during
the initial startup, after the unit has not been used for
an extended period of time (two weeks) or the fuel line has been disconnected. The primer is used to prime the fuel pump and carburetor.
2. To crank and start the engine, hold the start/stop switch at START. Release the switch when the engine starts.
CAUTION: If the engine does not start after it has been cranking for 15 seconds, release the start/stop switch and try again. Holding the switch for longer than 15 seconds may damage the starter motor.
3. Let the engine run at no-load for a few minutes to stabi lize and warm up the engine.
4. Turn ON electrical loads, using whatever means provided (such as a main circuit breaker or transfer switch).
NOTE: If you start a warm generator engine, you
may press the start switch only slightly to engage the ignition system. However, you should press and hold
the starter switch for a minimum of two (2) seconds to
energize the field boost system. If you start the engine without energizing the field boost system, the generator produces no AC output.
STOPPING THE GENERATOR
1. Turn OFF all electrical loads, using whatever means pro
vided (such a main circuit breaker or transfer switch).
2. Let the generator run at no-load for a few minutes, to sta bilize internal engine-generator temperatures.
3. Place start/stop switch in its STOP position.
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.
■ LETTING ENGINE STABILIZE______________
The generator supplies correct rated frequency and voltage only at the proper governed speed. Some electrical appliances may be extremely sensitive to voltage and frequency. Incorrect frequencies and/or voltages can damage those appliances.
If electrical loads are applied at reduced operating
speeds, such loads imposed on the engine when suf
ficient power is not available may shorten engine life.
Never turn ON electrical loads until after the genera
tor engine has started and stabilized ON-speed.
ATTENTION REQUIRED AFTER
SUBMERSION
If the motor home generator has been submerged in water, it must NOT be started or operated. Following any submersion in water, have an authorized Generac Service Facility thoroughly clean and dry the generator.
OPERATION IN HIGH GRASS OR BRUSH
Never operate the generator while the vehicle is parked in high grass, weeds, brush or leaves. 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.
OPERATING PRECAUTIONS
Never operate the motor home generator set while the vehicle is parked over dry leaves, dry grass or any other combustible substance. The generator’s exhaust system becomes extremely got and can cause fire if it is too close to combustible materials.
The generator’s exhaust system gives off DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness and even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. Never operate the generator if it has a leaky exhaust system. Close windows in the vicinity of the generator exhaust outlet and take any other steps to prevent exhaust gases from entering rooms or areas occupied by people or animals.

EFFECTS OF MOISTURE AND DIRT

Keep the generator set as clean and dry as possible. Protect unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and moisture 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 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 wind ings. Salt (as from sea air) will also worsen the prob lem since it tends to absorb moisture from the air. Salt and moisture, when combined, form a good elec trical conductor.
DO NOT OVERLOAD THE GENERATOR
You can read the rated wattage/amperage capacity of your generator on the generator data decal (see “Identification Record” on Page 1).
Applying electrical loads in excess of the unit’s rated capacity will cause the engine-generator to automati cally shutdown.
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 gener ator’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.
• Induction type motors (such as those that 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 operated by the generator.
• On a new generator do not apply heavy electrical loads for the first two or three hours of operation.
ENGINE PROTECTIVE DEVICES
This generator has a computer that monitors oil pressure,
oil temperature, engine speed, and voltage output. This section discusses those protective devices.
AUTOMATIC LOW OIL PRESSURE SHUTDOWN
The engine is equipped with an oil pressure sensor that shuts down the engine automatically when oil pressure
is too low. If the engine shuts down by itself and the fuel tank has enough gasoline, check the engine oil level.
■ INITIAL STARTUP
During initial startup, a time delay built into the shut down control system allows oil pressure to build. The delay allows the engine to run for about 10 seconds before sensing oil pressure.
■ SENSING LOW PRESSURE
If the system senses low oil pressure during operation, the engine shuts down. If you do restart the engine after a low oil pressure shutdown and have not correct ed the oil level, the engine runs for about 10 seconds as described above then stops.
HIGH TEMPERATURE SHUTDOWN
A temperature switch with normally-open (N.O.) con tacts is mounted near the oil filter. If the temperature were to exceed a preset temperature, the switch con tacts close and the engine shuts down.
OVERSPEED
if engine speed is increased manually (or otherwise) beyond the control of the computer control system, the computer disables the load capability of the generator and shuts down the engine.
WARNING: DO NOT ATTEMPT A MANUAL ADJUST MENT TO CONTROL THE ENGINE SPEED. EQUIP MENT DAMAGE OR PERSONAL INJURY MAY RESULT.
LOW VOLTAGE
The computer monitors the voltage output of the gener ator. If voltage sensors indicate that voltage has dropped below a preset level, the engine will automati cally shut down. Once the unit has shutdown, the com puter is automatically reset when you restart the engine.
NOTE: The computer allows for the low voltage output that occurs during startup. A time delay that allows the engine to start and warm up is programmed into the monitoring system.
CAUTION: Before restarting a generator that has been shutdown, disconnect all loads the generator might power by whatever means provided, such as the recreational vehicle’s main circuit breaker.
■7
SPECIFfCATIOMS
FUEL REqumEMENTS
These generators are equipped with gasoline fuel systems as standard equipment. Specific installa tions may provide either a separate fuel tank for the generator, or the generator may “share” the vehicle engine’s fuel tank.
NOTE: Installations using a “shared” fuel tank may have a generator fuel pickup tube that is shorter 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 substi tute.
NOTE; Using “Unleaded” gasoline contributes to longer engine valve life by reducing lead and carbon
deposits.
CAUTION: Generac does not recommend using any gasoline containing alcohol, it must not con tain more than 10 percent ethanol and it must be removed from the tank during storage. Do NOT use any gasoline containing methanol. If you use gasoline with alcohol, inspect more frequently for
fuel leaks and other abnormalities.
ENGINE OIL REQUiREIVIENTS
Use only high quality detergent oil rated with API ser vice classification SF, SG or SH. The recommended oil weights include the following;
• During summer months: SAE 30. An acceptable substi tute is SAE 10W-30.
• During winter months: SAE 5W30. DO NOT USE SAE 10W-40.
Crankcase and oil filter capacity is about 950ml or about 1 U.S. quart. Use no special additives. See “Maintenance” section for oil level check and fill pro cedures.
GENERATOR SPECIFICATIONS
Model
....................................................................
Rated Maximum Continuous
AC Power Output
Rated Voltage Rated Maximum Continuous
Current at 120 volts
Phase............................................................Single Phase
Rated AC Frequency Maximum Battery
Circuit Current.....................................................15 AMPS
Recommended Battery
Cranking Current................................................400AMPS
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3000 watts (3.0 kW)
NP-30G
120 volts AC
25 AC amperes
60 Hz.
ENGINE SPECIFICATIONS
Type of Engine Cooling Method
Displacement................................220cc
Type of Governor..........................Electronic
Air Cleaner....................................Paper element
Starter...........................................12 volt DC electric
Ignition System.............................Solid state
Recommended Spark Plugs
Champion..................................RC12YC
Spark Plug Gap
.............................
............................
............................
GN-220 Air-cooled
0.030 inch (0.8mm)
8 —
MAINTENANCE
This section includes information about simple main tenance which includes the following tasks;
• Checking engine oil level.
• Changing engine oil.
• Changing oil filter.
• Changing the air cleaner.
• Cleaning the air intake screen.
• Cleaning spark plug.
• Cleaning fuel filter.
CHECKING ENGINE OIL LE¥EL
Check engine crankcase oil level at least every eight hours of operation, or before each use (Figure 3).
• Be sure the generator is as level as possible.
• Remove oil dipstick and wipe dry with clean, lint-free cloth.
• Install and tighten oil dipstick, then remove again.
• Oil should be at dipstick FULL mark. If necessary, add the recommended oil to the FULL mark only. DO NOT FILL ABOVE “FULL” MARK.
• Install and tighten oil dipstick cap before operating the engine.
NOTE: See “Engine Oil Requirements” on Page 8 for recommended oils.
Figure 3 — Oil Dipstick and Fill Tube
Install and tighten dipstick cap before operating engine.
Figure 4 — Location of Oil Drain Plug and Filter
CHANGE OIL FILTER
Replace the engine oil filter after the first 8 hours of
operation, every 50 operating hours thereafter.
• Turn oil filter counterclockwise to remove (Figure 4).
• Coat gasket of new filter with engine oil.
• Turn new filter clockwise until its gasket contacts lightly with the filter adapter. Then tighten with an additional 3/4 to one turn by hand.
• Run engine and check for leaks.
NOTE: Check the oil level and fill to FULL mark on
dipstick after checking for leaks. The filter will retain some oil.

CHANGE ENGINE OIL

Change engine oil after the first 8 hours of operation. Thereafter, change oil every 50 operating hours. Change oil more frequently if operating consistently
under heavy load or at high ambient temperatures.
• Warm up engine for at least five minutes, then shut down.
• With engine still warm from running, clean area around
oil drain plug and remove oil drain plug (Figure 4). Drain oil completely into a suitable container.
• When oil has drained, install and tighten drain plug.
• Remove oil dipstick and fill crankcase with the recom
mended oil (See Page 8). The engine crankcase can hold about 1 quart (950ml). DO NOT FILL ABOVE “FULL” MARK.
ENGINE AIR CLEANER
Paper Filter: Once every 25 operating hours or once each year (whichever comes first), clean or replace the paper filter (Figure 5). Follow these steps;
• Remove air cleaner cover, then remove paper filter.
• Clean air filter by gently tapping it on a solid surface. If the filter is too dirty, replace it with a new one. Dispose of the old filter properly.
• Clean air cleaner cover then insert new paper filter into cover and assemble them to the base of the air cleaner.
Figure 5 — Engine Air Cleaner Assembly
jperating
first), cle
PAPER FILTER
9
CLEAN AIR INTAKE SCREEN
Clean all foreign material from the air intake screen (Figure 6) at lease once every 100 hours of operation.
Clean more often if necessary.
Inspect the area around the generator exhaust muffler periodically and remove all grass, leaves, dirt, etc. from this area.
SPARK ARRESTOR MUFFLER
The spark arrestor must be maintained in effective
working order by the vehicle owner/operator. 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.
inspect and clean the spark arrestor every 100 hours
of operation. To remove the spark arrestor, remove the exhaust
tubing connected to the muffler and then remove the screw that attaches the arrestor to the muffler.
Replace the cone-shaped spark arrestor if torn, perfo rated or otherwise damaged.
ENGINE SPARK PLUG
Clean or replace engine spark plug and set gap to
0.030 inch (0.76mm) every 100 hours of operation (Figure 6). Clean by scraping or wire brushing and washing with commercial solvent. DO NOT BLAST CLEAN SPARK PLUG.
Figure 6 — Setting Gap on Spark Plug
CLEANING THE GENERATOR
Keep your generator set as clean and dry as possible. Dirt and moisture that are permitted to accumulate on electrical windings have an adverse affect on the insulation resistance of those windings.
Moisture that is allowed to remain in contact with windings will be retained in voids and cracks of the windings. Dirt makes the problem worse, since it tends to hold the moisture into contact with the wind
ings. Salt, as from sea air, worsens the problem since
it tends to absorb moisture from the air. The combina tion of salt and moisture makes a good electrical con ductor.
CAUTION! Do NOT use a forceful spray of water to clean the generator. Water will enter the generator interior and cause problems, and may also conta minate the generator fuel system.
BATTERY
All lead-acid storage batteries will discharge when not in use. Inspect the generator battery as follows:
■ ONCE WEEKLY_______________________
Inspect battery posts and cables for tightness, corro sion. Clean and/or tighten as necessary.
Also check battery fluid level, and, if necessary, fill
with DISTILLED WATER ONLY. DO NOT USE TAP
WATER IN BATTERY.
SET PLUG GAP AT 0.030 inch
CAUTION: Sparking can occur if wire terminal does not fit firmly over spark plug terminal end. If necessary, reform wire terminal to obtain a tight fit.
FUEL FILTER
Remove and replace fuel filter (Figure 7) every 100 hours of operation or once each year, whichever occurs first.
Figure 7 — Fuel Filter
■ EVERY SIX MONTHS
Have the battery state of charge and condition
checked by an automotive service facility. This should be done with an automotive type battery
DANGER: STORAGE BATTERIES GIVE OFF EXPLOSIVE HYDROGEN GAS. THIS GAS CAN
FORM AN EXPLOSIVE MIXTURE AROUND THE BAHERY FOR SEVERAL HOURS AFTER CHARG ING. THE SLIGHTEST SPARK CAN IGNITE THE GAS AND CAUSE AN EXPLOSION. 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 TOOLS OR EQUIPMENT
NEAR THE BAHERY.
DANGER: BAHERY ELECTROLYTE FLUID IS AN EXTREMELY CAUSTIC SULFURIC ACID SOLUTION THAT CAN CAUSE SEVERE BURNS.
DO NOT PERMIT FLUID TO CONTACT EYES, SKIN, CLOTHING, PAINTED SURFACES, ETC. WEAR PROTECTIVE GOGGLES, PROTECTIVE CLOTHING AND GLOVES WHEN HANDLING A BAHERY. IF YOU SPILL THE FLUID, FLUSH THE AFFECTED AREA IMMEDIATELY WITH CLEAR WATER.
__________________
hydrometer.
10
DANGER: DO NOT USE ANY JUMPER CABLES OR BOOSTER BATTERY TO CRANK AND START THE GENERATOR ENGINE. IF ANY BATTERY HAS DISCHARGED, REMOVE IT FROM THE VEHICLE FOR RECHARGING.
SERVICE AND ADJUSTMENTS
ENGINE SPEED
Engine speed is completely computer-controlled. There is no adjustment for speed on the unit. The computer adjusts the engine speed using an electron ic governor throttle control. The computer monitors the demand for power and adjusts the engine speed accordingly. This allows the engine to produce only the power required, resulting in fuel economy as well as lowering the overall noise emitted.
NOTE: The computer will disable the electrical load capabilities of the generator and enter a fault condi tion if you accelerate the throttle manually or any other way.
THROTTLE LINKAGE ADJUSTMENT
If needed, you can adjust the length of the linkage rod between the electronic governor lever arm and the carburetor throttle lever arm. This adjustment helps to
establish the proper travel relationship between the two lever arms. If this adjustment is not properly set, the computer will NOT have control of the full range of
engine speed. If the rod adjustment is set too short, the computer will not have access to wide open throt tle or “full power” conditions. If the rod adjustment is set too long, the computer will not have access to closed throttle or “no power” conditions.
Use the following procedure to assure the linkage rod is properly adjusted:
1. Start the generator, then shut it down right away. As the
engine coasts to a stop, observe from above the engine as the throttle lever on the carburetor rotates counter clockwise.
2. There should be a gap of 0.003 inch (0.08-0.5mm)
between stop tab on throttle lever arm and the stop block on the carburetor die casting (Figure 8).
CAUTION: Do not overbend the spring clip or the clip will lose its clamping force.
3.With pliers, lightly compress the spring clip on the carbu retor lever arm. This allows the linkage rod to slide freely through the clip. While the clip is compressed, rotate the throttle lever in the appropriate direction to increase or decrease the gap until there is 0.003 inch (0.08-0.5mm) clearance (Figure 9).
Figure 9 — Adjusting Throttle Linkage
4. Release spring clip so you can secure adjustment. This allows the carburetor and the electronic governor to be synchronized.
ADJUSTING THE CARBURETOR
The carburetor of your generator is preset at the fac tory. The carburetor should not be tampered with, as this will void the emission control system warranty. If your generator is used at altitudes in excess of 5000 feet, consult your Generac Authorized Service Facility
regarding high altitude jetting changes.
—11
ADJUSTING VALVE CLEARANCE
After the first 50 hours of operation, you should adjust the valve clearance in the engine.
When adjusting valve clearance, the engine should be at room temperature and the piston should be at Top Dead Center (TDC) of its compression stroke (both valves closed). Correct clearance is 0.001-
0. 003 inch (0.03-0.07mm). Adjust valve clearance as follows:
1. Loosen the rocker arm jam nut. Use an alien wrench to
turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge (Figure 10 on page 12).
Figure 10 — Adjusting Valve Clearance
ALLEN WRENCH
LOOSEN JAM NUT
2. When valve clearance is correct, hold the pivot ball stud with the alien wrench and tighten the rocker arm jam nut with a crows foot. Tighten the jam nut to 65-85 inch­pounds torque. After tightening the jam nut, recheck valve clearance to make sure it did not change (Figure 11).
Figure 11 — Tightening Jam Nut
MAJOR SERVICE MANUAL
To obtain a service manual for your generator, order it
from your dealer/distributor or contact the factory. Be sure to identify your unit’s MODEL NUMBER and SERIAL NUMBER.
EXERCISING THE GENERATOR
Generac recommends that you start and operate the generator at least once every seven days. Let the unit run for at least 30 minutes to “exercise” the engine.
OUT OF SERVICE PROTECTION
If you cannot exercise the generator every seven days and it is to be out of service longer than 30 days, prepare the generator for storage as follows:
• Start the engine and let it warm up.
• While the engine is stili warm from running, drain the oil completely. Refill crankcase with recommended oil. See “Specifications."
• Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase.
• Remove spark plug and add about 1/2 ounce (15ml) of clean, fresh engine oil into spark plug threaded opening. Crank engine several times to distribute oil, then install and tighten spark plug.
• Remove the battery and store in a cool, dry room on a
wooden board. Never store the battery on any concrete or dirt floor.
• Clean and wipe the entire generator.
RETURN UNIT TO SERVICE
AFTER STORAGE
To return the unit to service after storage, proceed as
follows:
• Check tag on engine for oil viscosity and classification. Verify that the correct recommended oil is used in engine. If necessary, drain and refill with proper oil.
• Check battery. Fill all cells to the proper level with distiiled water. DO NOT USE TAP WATER IN THE BATTERY. Recharge battery to 100% state of charge, or, if defective, replace the battery.
• Turn OFF all electrical loads, then start the engine.
• Let engine warm up.
• Apply electrical loads to at least 50% of the unit’s rated wattage capacity.
• When engine is thoroughly warmed up, shut it down.
THE GENERATOR IS NOW READY FOR SERVICE.
SERVICE DEALER LOCATION
TO LOCATE THE NEAREST GENERAC SERVICING DEALER, PLEASE CALL OUR 800 NUMBER.
ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER.
1-800-333-1322
12-
INSTALLATION SAFETY RULES
DANGER: FOR FIRE SAFETY, INSTALLATION OF A GENERATOR INTO A RECREATIONAL
VEHICLE MUST COMPLY STRICTLY WITH ARTICLE 551, NFPA 70; ANSI C1-1975; AND, ANSI A119.2-1975/NFPA 501C “STANDARD FOR RECREATIONAL VEHICLES” (PART 3, “INSTALLATION OF ELECTRICAL SYSTEMS”). IN ADDITION, THE MANUFACTURER'S INSTRUCTIONS AND RECOMMENDATIONS MUST BE COMPLIED WITH.
NOTICE TO INSTALLER
The installation Instructions have been published by Generac Corporation to aid in the installation of the products described in this manual. Generac assumes that installation personnel are familiar with the proce dures for installing such products, or similar products that Generac manufactures. Generac also assumes that personnel have been trained in the recommend ed installation procedures for these products and that such training includes (a) use of common hand tools, (b) use of special Generac tools, and (c) use of any tools and/or equipment from other suppliers.
We could not possibly know of and advise the recre ational vehicle trade of all conceivable methods, pro cedures or techniques by which to perform an installa tion. We could not know of the possible hazards that might result from each installation method, procedure or technique. We have not undertaken any such wide evaluation. Therefore, people who use a method, pro cedure or technique that Generac does not specifically
recommend must first completely satisfy themselves that their safety, the safety of the vehicle's occupants and the products's safety is not endangered by the
method, fDrocedure or technique selected.
Information, illustrations, specifications, etc., con tained in this Installation Manual are based on the lat est information available at the time of publication.
Every effort has been expended to be sure that such data is both accurate and current. However, the man ufacturer reserves the right to change, alter or other wise improve this product at any time without prior notice.
SAFETY RULES
A Gasoline is extremely FLAMMABLE and its
^ vapors are EXPLOSIVE. Do not permit smoking,
open flame, sparks or any source of heat in the vicinity while handling gasoline. Comply with all laws governing the storage and handling of gaso line.
Fuel lines must be properly installed, properly fastened and free of leaks. There must be no possibility of gasoline vapors entering vehicle interior.
You are required to install an approved, flexible, non-conductive fuel line between the generator fuel connection point and rigid fuel lines.
If the generator is converted to a liquid propane (LP) gas fuel system, install the unit so it com plies with all codes, standards and regulations pertaining to such systems. LP gas is highly
explosive. The gas tends to settle in low areas where even the slightest spark can ignite it and cause an explosion. Do not allow gas vapors to enter the vehicle.
Engine exhaust gases contain DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause uncon
sciousness or even death. Install the exhaust system in strict compliance with applicable codes, standards and regulations. There must be no possibility for exhaust gases entering the vehi cle interior and endangering people or animals.
A The generator set produces dangerously high
^ electrical voltage. Contact with bare wires, bare
terminals, etc., will result in extremely hazardous and possibly lethal electrical shock.
All applicable electrical codes, standards and regulations must be strictly complied with in the installation and use of this equipment.
The generator must be properly grounded (bond ed) to the vehicle chassis or frame.
A If the vehicle electrical circuits can be powered by
any other source of electricity (such as a “dock­side” power receptacle), there must be no possibil ity of connecting the different power sources to the
vehicle circuits at the same time. The “dockside”
futility) power source must be positively isolated
from the vehicle circuits whenever the generator is operating. Failure to isolate the vehicle circuits from the dockside power supply when the genera tor is running may result in damage to the genera tor or serious injury or death to dockside (utility) power workers due to backfeed of electrical ener
gy-
Never work on the equipment while standing in water, while barefoot, or while hands or feet are wet. Dangerous electrical shock will result.
Jewelry conducts electricity, which can cause dangerous electrical shock. Remove all jewelry (such as rings, watches, or bracelets) before working on this equipment.
The generator requires an adequate flow of air
for cooling and ventilation. Without sufficient cool ing air flow, the engine-generator quickly over heats, which causes serious damage to the gen erator, a fire or an explosion. Generator air inlet and outlet openings must be provided in strict compliance with the manufacturer's recommen dations.
Never work on this equipment while physically or
mentally fatigued. Stay alert at all times.
A Storage batteries give off EXPLOSIVE hydrogen
^ gas while charging. The battery used for cranking
and starting this generator should be installed in its own vented compartment. Provide adequate ventilation for the battery, to prevent explosive hydrogen gas from accumulating.
Never insert any tool or other object through openings in the generator interior, even if the unit is not running. You might seriously injure yourself or damage the equipment.
Staying alert and using “common sense” are major measures for preventing accidents.
13

GENERAL INSTALLATION INFORMATION

PURPOSE AND SCOPE OF MANUAL

These Installation Instructions have been prepared especially for the purpose of familiarizing installers
and owners of the applicable equipment with the pro
duct's installation requirements. Give serious consid eration to all information and instructions in the Manual, both for safety and for continued reliable
operation of the equipment.
Because of the different recreational vehicle models and the variations between the models, it would be extremely difficult, if not impractical, to provide detailed instructions on every installation possibility. For that reason, instructions and illustrations in this manual are general in nature. Illustrations are not intended to serve as detailed installation blueprints.
The installation should comply strictly with all applica ble codes, standards and regulations pertaining to the installation and use of this product. If any portion of this manual appears to be in conflict with such codes, standards or regulations, the applicable codes, stan dards or regulations must take precedence over the manual.
SAFETY
Before handling, installing, operating or servicing this equipment, be sure to read carefully the “Notice to Installer” and “Safety Rules” at front of this manual. Comply with all SAFETY RULES to prevent death, personal injury or damage to equipment and/or prop erty. Stress safety to all installers, operators and ser vice technicians who work on this equipment.
STANOAROS BOOKLETS
Installation, use and servicing of this equipment
should comply strictly with published standards, as well as the manufacturer's recommendations. The fol lowing standards booklets (latest revision) are avail able from the sources indicated:
1. NFPA Standard 501C, “Standard for Recreational Vehicles”, available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
2. NFPA 70, “NFPA Handbook of the National Electric Code”, obtained from same address as Item 1.
3. ANSI CM975 and ANSI 119.2-1975, available from the American National Standards Institute, 1430 Broadway, New York, NY 10018.
4. ANSI A119.2/NFPA 501C, 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 Bulletin 946, available from the Canadian
Standards Association, Housing and Constructions Materials Section, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3,
EQUIPMENT DESCRIPTION
Instructions and information in this section pertain to
Generac air-cooled generators — more specifically, the installation of NP30 recreational vehicle genera tors. These generators are designed specifically for
installing in recreational vehicles.
ENGINE GENERATOR
OPERATING SPEED
The generators are driven by single-cylinder engines. The engines drive revolving fields (rotors), high fre quency, permanent magnet alternators. The genera tors supply 120 volts AC at 60 Hertz. The generators revolving fields are driven at a variable speed depending on the instantaneous demand for power. Computers monitor that demand and adjust the engine speed to provide adequate power to the con nected loads.
GENERATOR AC CONNECTION
SYSTEM
The generators are equipped with single voltage AC connection systems. The following facts pertain to such a connection system:
• On the units, the 120 volts, connections system is pro tected by a circuit breaker.
• The AC connection system on all air-cooled generators use a GROUNDED neutral.
• A separate green ground wire is connected to the recre
ational vehicle's junction box.
_14__
LOCATION AND SUPPORT
GENERATOR LOCATION
The most desirable location for the generator set is between the vehicle's main frame members However, this is seldom possible. Most units must be installed on the side of the vehicle and are difficult to reinforce.
Many recreational vehicles have been factory equipped with an area for the generator set. Some vehicles may even have a generator compartment, provided by the vehicle manufacturer.
Plan the generator location based on the following:
• The generator set must be installed on a framework that is part of the recreational vehicle, as outlined in the para graph entitled “Generator Support.”
• The location must provide an access opening that is large enough to permit generator removal (unless the genera
tor is to be removed from underneath the supporting framework.
• The location must provide easy access to frequently ser
viced components, such as filters, oil drain, spark plug and other common maintenance parts.
• The location must provide sufficient room to allow mini mum clearance of at least 1 inch (2” recommended) between all sides and 1 inch (2” recommended) on top of
the generator. If sound insulation is to be used on com partment walls and ceiling, the minimum recommended applies to the space between the generator and such insulation.
• The location must provide adequate cooling and ventilat
ing air flow for the generator without a great deal of work
and expense.
GENERATOR SUPPORT
The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding. The metal framework on which the generator will rest and which
will restrain the generator set should consist of at
least two horizontal beams. These beams should con sist of (a) 1-1/2 inch square, 11 gauge steel tubing OR (b) 1-1/2 inch, 11 gauge angle iron. A typical sup porting frame with horizontal support tubing, is shown in Figure 12.
The generator can be installed so that it sits on top of the horizontal support tubing, if the vehicle design permits. Another method is to suspend the generator below the horizontal support tubing by means of suit able, structurally sound metal framework. The follow ing general rules apply:
• Vehicle construction MUST be capable of supporting the weight of the generator.
• Whether the generator is mounted above the horizontal
support tubing or suspended below the tubing, the sup porting frame used must be structurally sound.
• If the generator cannot be bolted directly to the support ing frame or support tubing, consider using additional
tubing, angle brackets or other supports to give the sup porting frame sufficient strength.
SUSPENDED MOUNTING
If you are going to suspend the generator below the horizontal support tubing, the suspension method you
use with the vehicle frame members must have the following: (a) be able to support the weight of the gen erator; and (b) provide sufficient restraint for the gen erator. One typical suspended mounting system is shown in Figure 13. The location of a suspended mounting system must be carefully planned, keeping the following general rules in mind:
• Protect the generator against road splash and debris.
Baffles or splash guards may be required to protect cer tain areas of the generator. To make sure the generator is adequately protected, road test the installation through mud, water and slush.
Figure 13 — Typical Suspended Mounting System
Figure 12 — Typical Horizontal Support Frame
permit adequate cooling and ventilating air flow to be supplied.
-_15_
GENERATOR RESTRAINT
Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing. These bolts must pass through (a) the generator mounting base, (b) the compartment floor, if a compartment is used, and (c) the supporting
framework (Figure 14). All bolts must be long enough
so that when tight, at least 3 threads are visible past the retaining lock nuts. Refer to “COMPARTMENT” section for location of generator mounting holes.

GENERATOR COMPARTMENTS

Figure 14 — Typical Generator Restraint
The generator set may or may not be installed inside a compartment that is constructed specifically for housing a generator. This section applies to generator compartments when they are installed. The following general rules apply to compartments:
The generator compartment should be either constructed of, or lined with, 26 gauge galvanized steel.
IMPORTANT: ALUMINUM IS NOT AN ACCEPT ABLE ALTERNATIVE TO GALVANIZED STEEL, DUE TO ALUMINUM'S LOW MELTING POINT.
If the compartment is lined with galvanized steel, it may be constructed of any material. Generac recommends that the compartment be construct ed of 1/2-inch thick plywood, with the floor made of a double thickness of plywood for added strength.
All seams, splices and joints of the compartment walls (unless vapor tight by design) should be
caulked.
Figure 15 — Types of Lock Seams
IMPORTANT: CAULKING MUST BE DONE SO
THAT THE CAULKING MATERIAL WILL STAY IN
PLACE PERMANENTLY. PRESSING SUCH MATE RIALS AS PUTTY TAPE ONTO JOINTS AND SEAMS WILL NOT MEET THAT REQUIREMENT. A HIGH QUALITY SILICONE RUBBER SEALANT IS RECOMMENDED.
Holes and openings through the compartment walls for passage of electrical conduit, conduc
tors, etc, into vehicle living area must be sealed
vapor-tight with silicone rubber base sealant.
If you use flexible metal conduit, seal the conduit
at the end where it terminates inside the junction
box. Flexible metal conduit is NOT vapor tight
along its entire length.
Seams and joints of the galvanized steel (whether used as a liner or the compartment itself) must be lapped and mechanically secured. Such seams may be manufactured, welded, bolt ed, riveted, or screwed. Manufactured lock seams are shown in Figure 15.
ACME
DOUBLE LOCK DOUBLE SEAM
GORDON SEAM LOCK SEAM
STANDARD LAP JOINT
— 16
OFFSET
LOCK

COMPARTMENT SIZE

Plan the compartment size carefully. Provide a mini mum of at least 1 inch (2” recommended) of clearance between the generator and compartment walls and
1 inch (2” recommended) of clearance between the generator and the ceiling AFTER you have lined the compartment with metal, and AFTER you have installed sound insulation (Figure 16).
NOTE: Refer to the “Dimensions and Features” draw ing in the back of this manual.
Figure 16 — Provide Clearance Around Generato
PLYWOOD
COMPARTMENT
—INSULATION
11NCH MINIMUM CLEARANCE ON ALL SIDES
TOP VIEW OF
GENERATOR
METAL UNING-
|2"
RECOMMENDED)
1 INCH MINIMUM CLEARANCE
ABOVE
GENERATOR (2” RECOMMEND
ED)
• Vapor seal all compartment seams and joints, to prevent
poisonous, flammable or explosive vapors from entering the vehicle interior. Refer to the sealant information as noted below.
NOTE: Silicone rubber base sealant is an acceptable caulking material. Pressing putty tape onto compart ment joints and seams is NOT acceptable.
After the compartment has been metal lined and vapor sealed, line the compartment interior walls and ceiling with an approved, non-flammable sound insulating material. See “Sound Insulating Materials.”
DANGER: DO NOT INSTALL SOUND INSU LATION OR ANY ABSORBENT MATERIAL
A
ON THE COMPARTMENT FLOOR INTERI OR. SUCH MATERIALS WILL BECOME SOAKED WITH COMBUSTIBLE OR EXPLO SIVE VAPORS AND LIQUIDS AND WILL BECOME A FIRE HAZARD.
Openings in compartment walls for passage of electrical conduit, conductors, hoses, cables, etc., must be made vapor tight with suitable caulking material.
Flexible conduit must be sealed internally at the end where it terminates inside a compartment's
electrical junction box.
NOTE: The preceding is required because flexible conduit, due to its unique construction, is not vapor­tight along its entire length.

COMPARTMENT CONSTRUCTION

The generator compartment should be constructed of 1/2 inch thick plywood. Make the compartment floor a double
thickness of 1/2 inch plywood with the grain of the wood
at cross section for added strength (Figure 17).
Figure 17 — Typical Compartment Construction
Line the entire compartment interior with 26 gauge galva nized steel as described above.
Line the exterior (underside) of the compartment floor
with 26 gauge galvanized steel.
DANGER: DO NOT INSTALL ANY FLAMMABLE MATERIAL DIRECTLY ABOVE OR AROUND THE
A
COMPARTMENT. HEAT, TRANSFERRED THROUGH THE COMPARTMENT STRUCTURE, MAY BE SUF FICIENT TO IGNITE, CHAR OR DISCOLOR SEAT CUSHIONS, FIBERBOARD AND OTHER FLAMMA BLE MATERIALS. YOU MAY NEED TO USE APPROVED NON-FLAMMABLE INSULATING MATERIALS IN HIGH TEMPERATURE AREAS.

SOUND INSULATING MATERIALS

Once installers have determined that compartments are properly constructed and metal lined, they can add acoustical material. This may include additional sealant or Insulating material, to reflect noise away from the vehicle interior.
Sound insulating materials should be of a non-flam mable type. One excellent insulating material is a 1 inch thick fiberglass having a 2-pound density. When fiberglass is used, its coated side should face toward
the compartment interior.
Using a combination of sound insulating materials can often reduce noise more effectively than a single material. For example, a sheet of lead or visco-elastic material, along with a layer of other acoustical materi
al, is more effective than when a single material is
used.
—17
COMPARTIVIENT FLOOR CUTOUTS
You must provide openings in the generator compart
ment for the following items (Figure 18):
• Engine exhaust and cooling air outlets
• Generator cooling air inlet
• Four holes for passage of generator mounting bolts. See “Generator Restraint” on Page 16.
DANGER: FUEL LINES AND EXHAUST PIPING MUST NOT PENETRATE INTO VEHICLE LIVING AREA.
ACOUSTICS
If excessive noise levels should become a problem,
the installer may wish to consider the following:
• Using special sound insulating materials.
• Construction of a special noise abatement compartment.
IMPORTANT; ANY METHOD USED TO REDUCE NOISE MUST NOT ADVERSELY AFFECT THE FLOW OF COOLING AND VENTILATING AIR INTO
OR OUT OF THE COMPARTMENT.
In addition to the effective use of sound insulating
materials, construction of a special noise abatement compartment might be considered to reduce noise levels. Such a compartment might be constructed as
follows (Figure 19):
» Use 5/8-inch thick or 3/4-inch thick plywood in the com
partment.
• Construct the compartment floor of a double thickness of 5/8-inch or 3/4-inch plywood.
Line the compartment interior walls and floor, as well as
the underside of the floor, with 26-gauge galvanized steel. Vapor seal all compartment seams and joints. Over the galvanized steel lining, install a selected combi
nation of acoustical materials as mentioned in “Sound Insulating Materials.”
DANGER; DO NOT INSTALL ANY INSULATION OR OTHER ABSORBENT MATERIALS ON THE INTERI OR OR UNDERSIDE OF THE COMPARTMENT FLOOR.
Seal all compartment door edges to prevent noise leak age around the door perimeter.
Line the compartment door interior (except for air open ings) with suitable, fire proof sound insulation (such as 1­inch thick fiberglass with a 2-pound density).
Figure 19 — Typical Noise Abatement
Figure 18 — Compartment Floor Cutout
COOLING AND VENTILATING AIR
It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be sup plied to the generator set. Without sufficient air flow, the engine-generator quickly overheats. Such over
heating can cause serious operating difficulties and
may also cause fire and personal injury. The installer
must make sure that sufficient air is available to the generator for cooling, ventilating and combustion. The installer must also provide for a path for exhausting the cooling air to the exterior of a compartment, if so equipped.
DANGER; NEVER USE DISCHARGED COOLING AIR FOR HEATING OR PERMIT SUCH AIR TO ENTER THE VEHICLE INTERIOR. THIS AIR CON TAINS DEADLY CARBON MONOXIDE GAS AND OTHER POISONOUS, FLAMMABLE OR EXPLO SIVE GASES.
GENERATOR AIR FLOW
Engine operation drives cooling fans for the 2-stage cooling air system. A pressure fan draws cooling air into the top of generator and into the side of the con trol panel (Figure 20). This air flow cools the engine­generator and electronic components. The second part of cooling system, a suction fan, draws air that is heated from a hot engine into a collector pan at the base of the unit. This heated air (although cooler than exhaust muffler) is directed across the muffler to cool it. The heated air flow is then deflected out the bottom
toward the ground.
Figure 20 — Air Flow Through Engine-Generato
NOTE: Screening, louvers, or expanded metal that cover air openings restrict air flow that you must com pensate for by making the actual air opening propor tionately larger. See “Compensating for Restrictions.”
Figure 21 — Air Inlet in Compartment Door
10 SQUIRE INCHES (OPTIONAL OPENINGS)
40 SQUIRE INCHES UNRESTRICTED (MINIMUM OPENING)
For conventional compartment mounted units, the air inlet is generally provided in the compartment door.
IMPORTANT: IF YOU PLAN TO INSTALL THE GEN ERATOR IN A COMPARTMENT, BE SURE TO LEAVE AT LEAST ONE (1") INCH OF CLEARANCE BETWEEN THE GENERATOR AND COMPART MENT WALLS AND CEILING. INCLUDE 26 GAUGE GALVANIZED STEEL LINING AND SOUND INSULA
TION WHEN YOU MEASURE FOR THIS 1 INCH
CLEARANCE.
When the unit is installed on a suspended mounting system, one of several different methods of supplying air flow may be used as follows:
• Provide a door in the vehicle skirt having an air inlet opening (Figure 22).
COOLING AIR INLET OPENINGS
Ideally, you should provide three air inlet openings, whether the generator is housed in a conventional compartment or not. Two of the openings should be 10 square inches and located as shown in Figure 21. The third opening should provide for a minimum of 40 square inches unrestricted and be located lower on the compartment door.
19
Figure 22 — Suspended Mount: Inlet Door
Using ductwork (Figure 23). The installer must be sure air is available to the top of the generator since air inlets are located at the top.
Figure 23 — Air Inlet Using Ductwork
By providing an opening in the vehicle skirt and space
above the generator for cooling air flow (Figure 24).
Recommended clearance above the top of the generator
is at least 2 inches.
Figure 24 — Air Inlet in Vehicle Skirt
COMPENSATING FOR
RESTRICTIONS
Such materials as screening, louvers, or expanded metal can restrict the free flow of air. Compensate for this restriction by making the actual air opening pro portionately larger.
Some materials may offer only a 60 percent “free air inlet area.” Other more efficient materials may provide up to a 90 percent free air inlet area. The percentage of free air inlet opening is usually available from the material supplier or manufacturer.
TO DETERMINE THE ACTUAL AIR INLET OPEN
ING SIZE REQUIRED, DIVIDE 40 SQUARE INCHES BY THE PERCENTAGE OF FREE AIR INLET AREA FOR THE MATERIAL YOU WILL USE.
For example: If you plan to use screening with an 80% free air inlet area, divide 40 by 0.8, which results
in 50 square inches. Minimum actual size of air inlet opening in this case is 50 square inches. An opening that measures 4 inches wide by 12-1/2 inches long provides the required air flow (4 x 12.5 = 50 square inches).
TESTING THE INSTALLATION
Generac recommends testing the installation to be sure adequate cooling air flow is available to the unit before placing the unit into service. If the unit shows signs of overheating, you will need to enlarge the air openings. Never place a unit into service until absolutely certain that cooling and ventilation is ade quate.
IMPORTANT: YOU MUST TEST THE INSTALLA
TION ESPECIALLY IF YOU BRING IN AIR FROM BELOW THE GENERATOR SET.
20
GASOLINE FUEL SYSTEM
Installing a gasoline fuel system (Figure 25) for recre ational vehicle generator sets must comply with applicable codes, standards and regulations. The entire fuel system must be completely free of leaks. There must be no possibility of gasoline vapors enter ing the vehicle interior.
Figure 25 — Generator Fuel System
FUEL
INLET
CARBURETOR
DANGER: GASOLINE IS HIGHLY FLAMMABLE
AND ITS VAPORS ARE EXPLOSIVE. COMPLY
A
WITH ALL CODES, STANDARDS AND REGULA TIONS PERTAINING TO GASOLINE FUEL SYS TEMS USED IN RECREATIONAL VEHICLE GENER ATORS. PROPERLY INSTALL AND MAINTAIN THE FUEL SYSTEM AND KEEP IT ENTIRELY FREE OF LEAKS. GASOLINE VAPORS MUST NOT ENTER
THE VEHICLE INTERIOR.
FUEL PUMP
CAUTION: Do NOT tee the generator fuel supply line into the vehicle engine fuel suppiy line. If this is done, the generator will be starved of fuel when both engines are operating at the same time. Also, while the vehicle engine is not running, generator operation may drain the vehicle engine supply line, making it difficult to start the vehicle engine.
GENERATOR FUEL SUPPLY LINE
RIGID FUEL LINES
Those lines used to supply fuel from a tank to the generator must comply with applicable codes, stan dards and regulations. The following general rules apply to rigid fuel lines;
• Rigid lines should be of annealed, seamless, drawn alu minum or steel.
• Lines and fittings must comply with SAE J512F, “Standard Automotive Fittings”, or with ANSI B126.26 (latest edition).
• Route the fuel line so that at least 2 inches of clearance is maintained between the line and any exhaust system parts.
• Do not attach electrical wiring to fuel lines. Route the
wiring so it cannot come into contact with any fuel line.
• Route fuel lines so if they leak, fuel does not drip onto any electrical or exhaust system parts.
• Use non-ferrous metal straps without sharp edges to
secure fuel lines.
Factory installed generator fuel system components include (a) fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and (d) interconnecting lines and
fittings. Connect a fuel supply line to the fuel filter
inlet. Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines.
FUEL TANK
Either the generator must share the vehicle engine's fuel tank, or you must install a separate fuel tank for
the generator set. All fuel tanks installed on the vehi
cle must be constructed, installed, and restrained so it complies with applicable codes, standards and regu lations.
If the generator is to share the vehicle engine's tank, separate fuel pickup tubes are required for the engine and the generator. Generac recommends that you make the fuel pickup tube 2 to 3 inches shorter than the vehicle engine's pickup tube. This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods.
— 21
FLEXIBLE FUEL LINE
Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines. This prevents breaking of the line caused by vibration, shifting, settling or movement. The following rules apply;
• The flexible hose must comply with SAE J30B, “Standard
for Fuel and Oil Hose". It must be approved for use with
gasoline.
• The hose should be at least 6 inches longer than is need
ed to prevent the hose from rupturing if the generator shifts or settles.
* •

EXHAUST SYSTEM

The generator exhaust system must be safely and properly installed. Only approved mufflers and other exhaust system parts must be used. A properly installed exhaust system must be vapor tight, quiet and completely safe.
CAUTION: Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping. This causes excessive back pressure on the generator engine. Also, water from one engine can damage the other engine.
DANGER: THE GENERATOR ENGINE GIVES OFF DEADLY CARBON MONOXIDE GAS THROUGH ITS EXHAUST SYSTEM. THIS DANGEROUS GAS, IF
BREATHED IN SUFFICIENT CONCENTRATIONS, CAN CAUSE UNCONSCIOUSNESS OR EVEN DEATH. SYMPTOMS OF CARBON MONOXIDE POI SONING ARE (a) INABILITY TO THINK COHERENT LY, (b) VOMITING, (c) TWITCHING MUSCLES, (d) THROBBING IN TEMPLES, (e) DIZZINESS, (f) HEADACHE, (g) WEAKNESS AND SLEEPINESS. IF ANY OF THESE SYMPTOMS ARE EXPERIENCED, MOVE INTO FRESH AIR IMMEDIATELY. IF SYMP TOMS PERSIST, GET MEDICAL ATTENTION. DO NOT OPERATE THE GENERATOR UNTIL ITS EXHAUST SYSTEM HAS BEEN INSPECTED AND REPAIRED.

MUFFLERS AND SPARK ARRESTORS

Exhaust mufflers and spark arrestors that Generac sup plies meet code and standard requirements, and are approved by the U.S. Forest Service. Use only mufflers and parts approved by Generac. Any person(s) installing an unapproved muffler, or an unapproved exhaust system part, or modifying an exhaust system in any way that might cause a hazard, is liable for any damage, injury or warranty expense that might be caused by such unapproved installation or modification.
Failure to provide and maintain a spark arrestor may be in violation of the law. If this generator is used on
any forest covered, brush covered, or grass covered
unimproved land, you must provide a spark arrestor.
The vehicle owner or operator must maintain this device 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.
EXHAUST SYSTEM SAFETY
• Maintain a clearance of at least 3 inches (76mm) between exhaust system parts and any combustible material (such as wood, felt, cotton, organic fibers or other like material). If you cannot maintain the 3-inch
clearance, locate, insulate or shield the exhaust part(s)
so that the temperature of any combustible material is not raised more than 117°F (65°C) above the ambient air
temperature.
• Extend the exhaust system at least one inch (25mm) past
the outer edge of the vehicle. Do not terminate the exhaust system under the vehicle.
• Terminate the exhaust tailpipe such that exhaust gases
will not be drawn back into the generator compartment and recirculated.
• If there is any possibility of the tailpipe or muffler being damaged, protect these damage prone areas by means of a protective device (such as a “skid bar”).
• Install the generator exhaust system according to safe automotive practices.
• Use enough exhaust system hangers to prevent any part of the system from being dislocated.
• Use exhaust system parts recommended by Generac. Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person(s) installing such unauthorized parts.
• Do not terminate the exhaust system under any opening,
window or vent which can be opened or is not perma nently sealed from the vehicle interior.
• Exhaust piping must be large enough to prevent exces sive back pressure on the generator engine.
• Never tee the generator engine exhaust pipe into the
vehicle engine exhaust piping. This causes excessive
back pressure on the generator engine. Also, water from
one engine can damage the other engine.
• Plan exhaust system installation carefully. Comply with all
applicable codes, standards and regulations.
Figure 26 — Exhaust System

TYPE OF EXHAUST SYSTEM

The NP-30G generator has a configuration for a bot tom out exhaust system and is equipped with such an exhaust muffler (Figure 26).
•22
ELECTRICAL CONNECTIONS
Be sure to read “Generator AC Connection System” on Page 4.
The following general rules apply to electrical connec tions in a recreational vehicle;
• Qualified electricians who are familiar with applicable codes,
standards and regulations should install electrical wiring.
• The wiring should comply with codes, standards and reg ulations. The National Electric Code (NFPA 70), as well
as state and local codes, apply.
• Switches and circuit breakers should be of a type approved
for use in recreational vehicles and must be mounted and installed to prevent damage from road shock.
• Wiring must be of adequate size, with approved insulative qualities, and properly supported.
Conduit and wire openings into generator compartment (if used) must be vapor-sealed, to prevent entry of flam mable, explosive or poisonous gases into the vehicle.
ELECTRICAL JUNCTION BOX
Install an approved, square electrical junction box that has a blank cover on the interior or exterior wall of the area you plan to install the generator (NOT on the generator). Route the generator's AC output leads
into this junction box through approved flexible con duit. This is the point of first termination for generator AC output leads.
WIRING
• Wiring should be of stranded copper to reduce chance
that vibration may cause breakage.
• Wire gauge size of wires should be large enough to han
dle at least 115% of the installed generator's rated maxi mum 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 (black) and T2 (white) and the green ground wire through approved flexible conduit to the electrical
junction box on the compartment wall.
If flexible metal conduit is used between the generator and the compartment junction box, the conduit end that
terminates the compartment junction box, must be vapor­sealed. Flexible metal conduit is NOT vapor tight along its entire length.
• From the junction box route power suppiy wires through approved conduit to either (a) double-pole, double-throw transfer switch, or (b) approved isolation receptacle. Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being con nected to two different power supplies at the same time (such as generator and dockside power).
• Conductors must be rated 221°F (105°C) or must be of a larger conductor size.
GENERATOR AC CONNECTIONS
Generator AC output leads T1 (black) and T2 (white) come out of the generator as shown in Figure 27. Lead T1 (black) is “hot.” Lead T2 (white) is the “neu tral” lead and is internally connected to ground. The green lead (0) connects to ground in the junction box of the recreational vehicle.
Figure 27 — Generator AC Output Leads
Line T1 (black) is protected against overload by the circuit breaker (CB1). Use line T1-T2 to operate 120
volts, 1-phase, 60 Hz, AC loads.
CAUTION: Do NOT connect electrical loads in excess of any circuit breaker rating or you will
A
develop problems with circuit breaker tripping, which causes a loss of AC output. Also, do NOT exceed the generator's rated wattage capacity. Add the watts or amperes of ail lighting, appliance, tool and motor loads the generator will operate at one
time. This total should be less than the unit's rated
wattage/amperage capacity.
CONDUIT
Route the conductors between the generator and the junction box through approved, flexible conduit. The following general rules apply:
• Cut wiring to the required length and allow extra wire for
junction box connections.
• Carefully prepare conduit ends, to prevent sharp edges
from cutting through wiring insulation.
• Route conduit so it does not interfere with generator
movement.
• If you use metallic conduit, vapor seal the end of the con
duit where it enters the junction box. Do this because flexible metallic conduit is not vapor proof along its entire length.
„23
iSOLMINC DIFFEREMT
GROUND FAULT CIRCUIT
POWER SOURCES
Conductors from the junction box must terminate in a double pole, double throw transfer switch (Figure 28). An alternate method for isolating different power sources is by using an isolating receptacle (Figure 29 on Page 25). Whichever method you use, you must be certain that both power sources are NOT connect ed at the same time.
POWER SUPPLY CORD
The power supply cord must comply with all applica ble codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected.
Figure 28 — Transfer Switch Isolation Method
INTERRUPTERS
The National Electric Code (NFPA 70, 551-7) requires that you install ground fault circuit interrupters (GFCIs) on all external and some internal electrical receptacles. Contact your manufacturer or dealer for recommendations.
■24
BATTERY INSTALLATION
RECOMMENDED BATTERY
Install a battery that meets the following require
ments:
• Battery must be a 12 volt, automotive type storage bat tery.
• For prevailing ambient temperatures above 32°F (0“C), use a battery rated 70 amp-hours and capable of deliver ing 360 cold cranking amperes.
• For prevailing ambient temperatures below 32°F (0°C), use a battery rated 95 amp-hours and capable of deliver ing 450 cold cranking amperes.
IMPORTANT: IF THE BATTERY IS TO BE USED TO POWER OTHER VEHICLE ACCESSORIES, AS
WELL AS START THE GENERATOR, YOU MAY
NEED A BATTERY WITH A LARGER CAPACITY.
_25~
BATTERY CABLES
Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes starting problems. For best cold weather starting, the voltage drop between battery terminals and the gen erator connection point should not exceed 0.12 volts per 100 amperes of cranking current.
Select battery cables based on (a) cable length, and (b) prevailing ambient temperatures. Generally, the longer the cable and the colder the weather, the larg er the cable size must be as shown in the chart below.
CABLELENGTH
in Feet (meters)
Oto 10 (Oto 3)
11 to 15 (3.4 to 4.5)
16 to 20 (4.5 to 6)
‘For warm weather, use No. 2 cable up to 20 feet.
CABLE SIZE
2*
0
000

BATTERY CABLE CONNECTIONS

1. Connect the battery cable from the battery post or termi nal indicated by a POSITIVE, POS or (+) to the large lug
on the starter contactor as indicated in Figure 31.
2. Connect the battery cable from the battery post indicated by a NEGATIVE, NEG or (-) to the frame ground connec tion (Figure 30).
NOTE: If the generator compartment is grounded to the vehicle chassis, you need not connect a NEGA TIVE battery cable to the frame ground on the gener ator base. Connect the negative cable to the frame
ground of the chassis.
3. Connect cables so the connectors are clean and tight.
Figure 30 — Connecting Battery Cables
BATTERY COWPARTMENT
Install the generator battery in its own, vented com partment. Place the battery compartment away from any source of heat, sparks or flame.
Provide ventilation openings in the battery compart ment. The minimum size of openings should be 2
square inches at the top of the compartment. Mount the battery on a strong, rigid supporting structure, where leaks and spills of battery fluid will not cause damage.
26
OPTIONAL ACCESSORIES
A plug-in receptacle (Figure 31) is provided on the gen erator set, near the AC connection wires. Use this
receptacle to connect an optional remote-mounted start/stop panel to the generator. Installation of such a panel will permit you to start and stop the generator engine from any convenient location inside the vehicle.
Figure 31 — Remote Panel Plug-in Receptacle

REMOTE PANEL MODELS

■ MODEL 9042 _______________
This remote panel (Figure 32) mounts a rocker type start/stop switch and a “Generator Run’* advisory lamp. The lamp will turn on to indicate the engine is
running.
_________
MODEL 9043
This panel mounts a rocker type switch, a “Generator
Run" lamp and an hourmeter (Figure 33). Use the hourmeter in conjunction with the periodic mainte nance schedule for your generator.
Figure 33 — Model 9043 Remote Panel
o o
GENERAC R.V. GENERATOR

REMOTE PANEL CABLES

Interconnection cables are available from Generac for connecting the optional remote panels to the genera tor receptacle.
• To order a 10-foot long, 4-wire cable, specify Model 9045.
• To order a 30-foot long, 4-wire cable, specify Model 9046.
Figure 32 — Model 9042 Remote Panel
©
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R.V.
©
27
POST INSTALLATION TESTS
The air cooled generator set was factory tested and adjusted using gasoline as fuel. You should not be required to adjust the unit any further except under special circumstances.
WARNING; DO NOT MAKE ANY UNNECESSARY ADJUSTMENTS. FACTORY SEHINGS ARE COR RECT FOR MOST APPLICATIONS. WHEN MAKING ADJUSTMENTS, HOWEVER, BE CAREFUL TO AVOID OVERSPEEDING THE ENGINE.

BEFORE INITIAL START UP

Before starting, complete the following:
1, Check engine crankcase oil level and, if necessary, fill to
dipstick FULL mark with the recommended oil. Do not fill above FULL mark.
2- Check the fuel supply. Fuel lines must have been proper
ly purged and leak tested in accordance with applicable
iuei-gas codes. All fuel shutoff valves in the fuel supply
lines must be open.
DANGER; IF AN LP (PROPANE) GAS FUEL SYS TEM HAS BEEN INSTALLED, IT MUST HAVE BEEN PROPERLY TESTED FOR LEAKS BEFORE OPER ATING THE SYSTEM IN COMPLIANCE WITH ANSI A119.2/NFPA 501C. NO LEAKAGE IS YOU MUST BE SURE NO GASEOUS FUEL VAPORS ENTER THE VEHICLE INTERIOR.
PERilTTED.
6. Turn off all electrical loads by setting the generator main circuit breaker to “OFF” or “OPEN.”
7. Let the unit run at no-load for a few minutes to stabilize
internal engine-generator temperatures. Then, shut down
the engine.
IMPORTANT: THE GENERATOR SET WAS THOR OUGHLY TESTED AND ADJUSTED AT THE FAC TORY BEFORE SHIPPING. NO ADDITIONAL ADJUSTMENT SHOULD BE NECESSARY. ONLY QUALIFIED SERVICE TECHNICIANS WHO HAVE
BEEN TRAINED SHOULD PERFORM ADJUST
MENTS OUTLINED IN THIS MANUAL.

TESTING UNDER LOAD

Apply electrical loads equal to about 75-100% of the unit's rated wattage/amperage capacity.
Let the unit run at least 30 minutes with load applied.
During this part of the test, check that the unit is not
running excessively hot and that adequate cooling air flow is available. You must not allow the unit to over
heat during prolonged operation. NOTE; The generator engine is equipped with a high
temperature switch. The switch has normally-open (N.O.) contacts. When the temperature is too high, switch contacts close, and engine shuts down auto matically.:
IMPORTANT: GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLING.

INITIAL START

When absolutely certain that the unit has been prop
erly installed and prepared for use, start the engine as
follows:
1. Turn off all electrical loads. Do this by setting the genera
tor main circuit breaker to the “OFF” or “OPEN” position.
2. Refer to the Owner's Manual shipped with unit for crank
ing and starting instructions. The engine may require more cranking for initial starting since the fuel lines have to be primed.
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 “Testing Under Load". Run the unit at least 30 minutes with loads applied.
28-
INSTALLATION CHECK LIST
LOCATION AND SUPPORT ELECTRICAL CONNECTIONS
___
1. The NP generator is properly located.
___
2. The generator is properly supported.
___
3. The generator is properly restrained.
COMPARTMENT ___
1. Compartment construction is proper.
___
2. Holes/openings are vapor-sealed.
___
3. Compartment size is correct.
___
4. Compartment is vapor-sealed.
___
5. Sound insulation is O.K.
___
6. Floor cutouts properly completed.
COOLING and VENTILATING AIR
_1. Air flow is adequate. _2. Air inlet opening is correct.
^3. Compensate for restrictions
_4. Installation has been tested
GASOLINE FUEL SYSTEM
___
1. Fuel tank complies with code.
___
2. Fuel system properly installed.
___
3. Fuel system checked for leaks.
_1. Comply with code requirements.
_2. Junction box properly installed.
„3. Wiring meets all standards.
A- All connections are correct.
_5. Conduit properly installed and sealed. _6. Generator properly bonded to vehicle.
BATTERY INSTALLATION
_1. Recommended battery is installed. _2. Recommended cables are installed. _3. Cables are clean and tight. „4. Cables are properly connected. „5. Proper ventilation is provided.
POST INSTALLATION TESTS
J. All tests properly completed.
OPTIONS AND ACCESSORIES Check that remote start/stop panels (if used) are
properly installed. If an hourmeter kit is installed, check that job was
done properly. If any other options and accessories are installed,
check that they were installed properly.
EXHAUST SYSTEM
___
1. Complies with code requirements.
___
2. Properly and safely installed.
DATE OF INSTALLATION
NAME OF INSTALLER
SIGNATURE OF INSTALLER
_________
_
29-
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CLEAR-MINIMUM
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TROUBLESHOOTING

PROBLEM
Engine won't crank.
Engine cranks but won't start. 1.
Engine starts hard, runs rough.
Engine starts, shuts down
when Start/Stop switch is
released.
POSSIBLE CAUSES
15 amp fuse is blown
1. Loose corroded or defective
2. battery cables. Defective engine Start/Stop switch. 3.
3. Defective starter contactor.
4. Defective starter motor. 5.
5. Low or defective battery.
6.
Out of fuel. Fuel pump is defective.
2.
Open Wire #14 from Eng. Control Bd. 3.
3,
4. Engine is flooded.
Spark plug defective. 5.
5.
Air cleaner plugged or damaged
1. Defective spark plug.
2.
1. Engine oil is low. Engine is overheated.
2. Defective Low Oil Pressure System
3. Defective Engine Control Board
4. Defective Computer Control Board 5.
5.
REMEDY
1. Replace 15 amp fuse Tighten, clean or replace
2. as necessary.
Replace Start/Stop switch.
4. Replace contactor. Replace starter motor.
6. Change or replace battery.
Replenish fuel.
1.
2. Replace fuel pump. Reconnect wire.
4. Wait 5-10 min. before trying. Clean, regap or replace plug.
1. Clean or replace as needed.
2, Clean, regap or replace plug.
1. Check oil; add as needed.
2. Check for adequate ventilation.
3. Have serviced/replaced.
4. Have board serviced/replaced. Have board serviced/replaced.
Start/Stop switch at Stop, engine continues to run. 2.
No AC output from generator. 1.
1. Defective Start/Stop switch Open/disconnected wire #18 between Start/Stop switch and Engine Control
3. Open/disconnected wire #0 between Start/Stop switch & Engine Control Bd.
4. Defective Engine Control Board
Check circuit breaker. Check vehicle circuit breaker & fuses. 2.
2.
Transfer sw. set to NORMAL position. 3.
3.
4. Generator internal failure
31
1. Replace switch.
2. Reconnect or close wire.
3. Reconnect or close wire.
4.
Replace board.
1. Reset to ON or CLOSED. Reset and replace if necessary. Set to GENERATOR position.
Take generator to an
4. Authorized Generac facility.

ELECTRICAL DATA

Drawing No. A2420
13'
......
CUSTOER SUPPLIED
BATTERY
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BCR - BATTERY CHARGE RECTIFIER CBl - CIRCUIT BREAKER CC - CHOKE CQIL CCB - COMPUTER CONTROL BOARD CH - CHOKE HEATER ECB ~ ENGINE CONTROL BOARD FI ~ FUSE, ISA FP - FUEL PUMP ON GASOLINE
C - GENISTOR HM - HOUR METER НТО - SVITCH, HIGH TEMPERATURE OIL
IC - IGNITION COIL IИ - IGNITION MODULE IS - IGNITION SENSOR LI - LIGHT, RUN (OPTI[WAD LDP - SWITCH, LOW OIL PRESSURE
M - STEPPER MOTOR THROTTLE CONTROL R1 - RESISTOR^ 500 OHM, 50 WATTS R2 - 1 OHM, 50 WATTS SC - STARTER CONTACTOR SM - STARTER MOTOR SWl - SWITCH, START/STDP SW2 - SWITCH, FUEL PUMP PRIME SPI - SPARK PLUG
-S-- LUG, BARREL TC - TERMINAL, CONNECTOR 4 TAB FTL - TIME DELAY FILTER
LEGEND
SHUT43FF VALVE ON L/P
(CLOSES Ш HIGH TEMPERATURD
(OPENS ON HIGH P^^SSURE)
И T !
1814170
CUSTOMER AC CONNECTION
32-
Drawing No. A2420
ELECTRICAL DATA
33
EXPLODED VIEW — LONG BLOCK
Drawing No. A6202
K 5
34-
Drawing No. A6202
REPAIR PARTS -- LONG BLOCK
ITEM
1 2 3 4 5
6
7 8
10 11 13 14 17 18 19
21 21704
22 78691
23
24
25
PART NO.
76380 76389 88411 1 72657
77176 88057 76390 83379A 89923 89213G 81695 90604 78699B 3 A2477 89096
76367
76362 78692 1
26 78606 28
30 31 88401 32 33 34
36
37 90082 38 90081 39 40
42 43 77161 44 45 46 47 48 49 50 51 83153 52
89230
86293
88590 83152 76381 21705B 1
88396A 2 83235 96362
77160 76307 88403 77168 88413B 1 78629
90388 2
92977
53 84186
54 58
88156 72347
QTY.
1
1 PISTON PIN
2 1 1 2
1
1
1
2
1 CUP, BREATHER BAFFLE
1 1 1 1 1 1
4
6 2
2 SPRING, VALVE 1 DOWEL PIN, 0 10 x20 LONG 1 2
1 VALVE, EXHAUST 1
2 TAPPET
1 GASKET, ROCKER COVER
2
2 ROCKER ARM
2
1 PLATE, PUSH ROD GUIDE
5
2 GASKET, BREATHER
1 1 ASSEMBLY-SUMP, OIL 2 1 SEAL VALVE-INTAKE 1
DESCRIPTION
ASSEMBLY, CONNECTING ROD, CAP & BOLTS
SET, PISTON RING (STD. SIZE)
PIPE PLUG-1/4 NPT COVER, BREATHER PISTON, 75 DIA. RETAINER, PISTON PIN
ASSEMBLY, CRANKSHAFT AND GEAR
SEPARATOR, OIL BREATHER
ASSEMBLY, CRANKCASE
SEAL, OIL-CRANKSHAFT
SLEEVE, DOWEL 0 12 ASSEMBLY, CAMSHAFT GASKET, CRANK CASE FLANGE GASKET, CYLINDER HEAD RETAINER, OIL PRESSURE SPRING SPRING, OIL PRESSURE BALL, OIL PRESSURE BOLT, THREAD FORMING-M5 SCREW & LOCK WASHER, M6-1 x 12 LONG HHFC, M8-1.25X35 LONG RETAINER, VALVE SPRING
GEROTOR, INNER BOLT, CONNECTING ROD
ASSEMBLY, CYLINDER HEAD W/GUIDES & SEATS
VALVE, INTAKE
PUSH ROD
STUD, BALL PIVOT
NUT, ROCKER ARM
HEADBOLT, M8 x 52MM
COVER, ROCKER
BOLT, TAPTITE-M6 X 12 LONG
GEROTOR, OUTER
WASHER, WEAR-VALVE SPRING
SPARKPLUG, CHAMPION RC12YC
CaD
o>
m
X
o
Q
m
m
Q
m
m
o
3
100
__
FAN HOUSING
TO UPPER
Drawing No. A5971
ITEM PART NO.
1 90306 1
2
94583 83312 2
3 4 81810 5 70185 6 86730 7 89476 8 40976
9 99948 1
11 22127 1
12 22097 9
14 92059 15 86706
16
17
18 19
20 90051 21 78631
22 96459 23 86709
24 35586 2 25 86710 1 26 87993
89477 1 89478 1 90192 1 90881A 1
27 49815 28 90536
29 90021 30 94665 1
31 93859 32 A5892 1 33 91437 1
34 003-91297 1
35 86673 1 36 78601 1 37 38 39
86674 78609
66449C
40 49226
41 42 A5898 1
43
44
45 86735 46 47488 4 47 22159 4
48
49 91306
50 51
52 86736
80934
86692 1
74908 3
31879 4
36544 1
89473 1
QTY.
1 2
DESCRIPTION ITEM
ENGINE, LONG BLOCK FLYWHEEL, FAN WASHER, CONICAL 55 HEX NUT, Ml 6-1.5 56 005-91297
1 FILTER, OIL 1
TUBE, EXHAUST OUTLET
1 GASKET, EXHAUST
4
1 1
2
1
1
1
1 2 1 1
1
1
2
4 4
1
1
1
1
SOCKET HD. CAPSCR., M8-1.25x20 LG
STARTER.
EATON/GfeNERAC
NUT, 1/4-20 LOCKWASHER, 1/4-M6
STEPPER MOTOR SPEED
r.nNTRni
ROD, THROTTLE CONTROL CLIP, ADJUSTMENT SNAP, RETAINING WASHER, CARBURETOR ASSY., CARBURETOR GASKET.
CARBiSl>ACER/HEAD
GASKET, CARBiSKIRT GASKET J3ARB./INLET
ADAPTOli
ADAPTOR, CARB. INLET 74 HOSE CLAMP-BAND 1.50" HOSE, CARB. INLET 76 ELBOW, AIR CLEANER
OUTLEf HEX HD. CAPSCR.,
M5-.8X 16 GASKET, AIR CLEANER
OUTLET BRACKET, AIR CLEANER
SUPPORT HOUSING, FAN-UPPER FAN, GENERATOR ASS., MAGNET HOUSING HUB. MAGNET HOUSING
ASSEMBLY TEMP SWITCH WIRE BASE, AIR BOX ELEMENT, AIR FILTER 87 COVER, AIR BOX 88 BOLT, AIR CLNR. COVER HEX HD. CAPSCR.,
M6-1 X 80 LOCKWASHER, M5 RETAINING RING,
STATOR STATOR ASSEMBLY 97 ADAPTOR,STATOR TAPTITE, M5-0.8X 10 100 COVER, CHOKE MOUNT SCREW, 4-40 X .188“ LOCKWASHER-NO. 4 103 FLATWASHER-NO. 4 104 SOLENOID, CHOKE 105 PIN, COTTER 3/32" x 1/2"
LONG ASSY„ BI-METAL &
HEATER LINKAGE, CHOKE
control
REPAIR PARTS -- GENERATOR
PART NO. QTY. 53 54
45756 4 83512 91526 4
1 1
57 58
59 61 39253 3 HEX HD. CAPSCR„ 62 63
64 65 66
67 68 69 70
71 86701 1 BRCKT., ENG. MNT FRONT
72 73
75
77 78 79
80
81 90613 1 COVER, BREATHER 82 59635
83
84 85 86
90
91
94 96
99
101
102
106 107 108 109
42907 22129
74906 4
22511 3 HEX HD. CAPSCR., 22237
55822 22264 89050 2
82774 1 59637 4 TAPTITE 3/8"-16 X .75" LG 86697 1 ASSY. IGNITION SENSOR 86704 3 SPACER, ENG. MOUNT
86702 1 38353 3 RUBBER MOUNTS
89263 1 ASSY., OIL FILL CAP 90071 1 0-RING, 1.062" I.D. 94637 1 OIL FILL TUBE 90072 1 0-RING .562" I.D. 86708 1 CARBURETOR SPACER 87478 1 GASKETJ3IL FILTER
96627
3 HEX HD. CAPSCR„
11
3 2 2 LOCKWASHER-M4
1 BRCKT., STARTER SIDE
1 #8 X 3/8 PLASTITE SCREW
002-91297 1 STARTER WIRE 004-91297 1
59636 1 88905 1 EXTENSION SPRING
92800 1 WRAPPER, ENGINE TOP 89062 1 23762 3 WASHER.EXTERNAL
22447 23484P 1 SNAP BUSHING
23897 5 #10-M5 FLAT WASHER 94090 1 SWITCH-THERMAL, OIL TEMP. 86675A 1 ADAPTOR, OIL FILTER 77667 1 SWITCH, OIL PRESSURE 86714 1 SCREEN, OIL PICK-UP 52617 1 94643 74027 2 43182 2 90387 1 92079 A5620 66849 2
3
1 GASKET, OIL DRAIN PLUG
4 HEX HD. TAPTITE M6-1 x 25 LG 1 TIME DELAY FILTER
DESCRIPTION
M6-1 X 10 TAPTITE TAPTITE M8-1.25X 15 LG. M5-0.8X12 MM SCREW OIL PRESS. SWITCH WIRE
M8-1.25X 16 LONd LOCKWASHER-M8 HEX HD. CAPSCR„
M6-1 X 20LG. TAPfiTE
M8-1.25x20 LONd 3/8-16x1.25" LONd
LOCKWASHER-3/8 PHMS, M4- .7x8 LONG
PHILLIPS PAN HD. MACH. SCR.-M6-1 X 90 LONG
WOODRUFF KEY-4 X 19
BRCKT., ENG. MNT. REAR
ADAPTOR ENGINE MNT. CANAL
TEMP SWITCH GROUND WIRE
PLASTITE SCREW,
#4 X .37 LONG
HOSE, BREATHER SHAKEPrtOOF-#10
WASHER. INTERNAL
SHAKEPSOOF, .25“
DRAIN PLUG, M12 x 1.75" LG SCREW, М3 X5"LONG
LOCKWASHER, М3 AIR CLEANER DECAL
TAPTITE, M5-0.8X 16
37

EXPLODED VIEW — SHEET METAL

Drawing No. 20741
K 2 '*
Sir'
J \
r
11
// /
A
'' // / / <7
% ' /
4
1
o <0
38-
Drawing No. 20741
REPAIR PARTS — SHEET METAL
ITEM PART NO.
BB7D5 2 3 4 A3666 5 6 7 8 9
10 12 13 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34
35
36 37 48031C 38 39 23762 40 41 22264 42 79246 44 47 48 49 50 82580D 51 52 51713 53 54 89045 55
56 91526 57 23897 58 59 A3638 60 22159 61 56893 62 A5767
49813 86718
74908 20150 22129 39414 45770 49226 89680
94670 89471 86731A 86715 86726 86671 86727 1 86719 20519 90141A 86724 90475
28740 22127 22097 86729 90518 89048 90537 1 22145 30340
23484D
22471
22447 3 39450 92000 30340
86311
007-91297
20149
75494
QTY.
1 2 M6-1.0 HEX NUT
1
1 WRAPPER, BOX
22
1
4
4 HEX HD. CAPSCR., M8 -1.25 x 35 LG 10 18
1 1 1 1 1 1 1
1 1 FRAME 1 1
1 PUMP, FUEL
1 3 3 1 1 1
4 FLAT WASHER- M8
1
5
1 SNAP BUSHING
9 2 #8 HEX NUT 2 #8 LOCK WASHER 2
1 1/8' X 3/16" NPT 90 DEG. BARBED FITTING 1 BRACKET, MUFFLER HANGER 1 1/4" FUEL LINE (8" LONG) 1 1 FUEL FILTER 4 M5 PLAIN WASHER 1 STARTER CONTACTOR GROUND WIRE 1 SEAL, WASHER EXHAUST PIPE 1 4 M5-0.8x12 MM CAPSCREW 4 M5 FLATWASHER 7 #10 -16 X 5/8, SELF DRILLING SCREW 1 WRAPPER, END PANEL 2 2 CRIMPTITE, 10-24x1/2" 1
DESCRIPTION PCATCrOIVlUER
SEAL RUBBER EXTRUSION
TAPTITE, M5-0.8 X 10 LONG CUSTOMER MOUNTING RAILS LOCK WASHER- M8
HEX HD. CAPSCR., M5- 0.8x 10 LOCK WASHER - M5 SPARK ARRESTOR U-BOLT, W / SADDLE & NUTS DEFLECTOR, AIR OUT ASSEMBLY, MUFFLER HOUSING, LOWER FAN
SKIRT, CARB. BAFFLE COVER, ROCKER SPARK PLUG SIDE PAN,BELLY
GROUND STRAP PLATE, BASE COVER
BARBED 90 1/8“ X 1/4" HEX NUT, 1/4-20 LOCK WASHER- 1/4"- M6 CONTACTOR, STARTER BOOT, CONTACTOR SEAL, OIL FILTER HOLE RETAINER, SEAL
■'1/4" FUEL LINE - 4" LONG 1/4" HOSE CLAMP
EXTERNALSHAKEPROOF
HEX HD. CAPSCR., M-6 -1.0x16 LONG W / LOCKWASHER
WASHER, INTERNAL SHAKEPROOF, 1/4"-M6
3/16" CARBURETOR LINE (4" LONG)
CUSTOMER MOUNTING RAIL
#10 LOCKWASHER
HEX HD. CAPSCR., M5-0.8 x6 LG
39
EXPLODED VIEW — CONTROL PANEL
Drawing No. 20740
CO fO
■40
Drawing No. 20740
REPAIR PARTS — CONTROL PANEL
ITEM
1
PART NO. QTY. 91526 10
DESCRIPTION ITEM M5-0.8X12MM PHILUPS
PAN HD. MACH. SCR.
20093
2
20092
3 4 36937
1 1
BOX, CONTROL TOP BOX, CNTL. PANEL
#10-32x1" PHILLIPS
2
PAN HD. MACH. SCR.
PHILLIPS PAN HD.
75476
5
5
MACH. SCR., M4x16 TAPTITE M5- .8x10
74908
6
8
LONG
SNAP BUSHING
1
1
90° CONNECTOR RV CONTROL BOARD
1
CIR. BREAKER, 30A. 44 001-91297 1 GROUND WIRE
1
LOCK WASHER-M6 45
2
LOCK WASHER-M5
12
HEX NUT-M4
2
HEX NUT- M6 ASSEMBLY, COIL SPACER, IGNITION
7 23484M
20107 1
8
92234
9 10 90145 11
12
22097 86711 1 IGNITION MODULE
13 49226 14 51715
15
49813 2
16 89049
17 89047 2
COIL MOUNT
18
19
22985 23897 8
20 20091 1 21
23484E
22 87798 1
4 M4 FLAT WASHER
M5 FLAT WASHER CNTL. PANEL, FRONT
^ 1
SNAP BUSHING SWITCH, SPDT
ROCKER "
23 92113 1
SWITCH, SPSTMOM ROCKER
24
25 32300 1 26 80939 1
22676
1
FUSE, 15A. AGC
FUSE HOLDER EXTRUSION,
CONTROLLER
27 1 RECTIFIER, BATTERY
65795
CHARGE 28 22264 14 29 22158 2
30
31
20105B 86275
1
1
LOCK WASHER-M4
#10-32 HEX NUT
PANEL DECAL GENISTOR, TRIAC
MODULE
32 83492 33
43181
ASSEMBLY, PCB CCG
1
TAPTITE, M3-0.5 X10MM
4
PAN HD. MACH. SCR.
PART NO. QTY. DESCRIPTION 34 43182 4 LOCK WASHER-M3 35
89744
1 RESISTOR, POWER
1 OHM
36 83491 1 RESISTOR, POWER
500 OHM 37 38
45756 86722 1 BRACKET, HEAT
4
TAPTITE M6-1 xIOLG.
SINK-PCB 40 51716 2 41 42 43
7521OA 91281 1 86738A
1
1 TRIAC MODULE
HEX NUT-M5 TERMINAL BLOCK 12 PIN CON. ASSY.
HARNESS
91282A
1
CUSTOMER WIRE HARNESS
46
91269A
1
REMOTE PANEL
HARNESS 47 23484D 1 SNAP BUSHING 48
82121A 2
CLAMP, CONTROL
PANEL HARNESS
49 20106 1 HARNESS, CONTROL
PANEL (NOT SHOWN
FOR CLARITY)
50 25105 2 #6-32 X 1/4" PHILLIPS
ROUND HD. MACH.
SCREW
51 84867 4 52 51718 4
RUBBER U-CHANNEL
M4-0.7X 10MM HEX
HD. CAPSCREW
53 77604
1
HOUR METER
54 34028 2 #4-40 X 3/8 LG ROUND
HD
55 22159 2
#4 LOCKWASHER 56 27771 2 #4-40 HEX NUT 57
36933 2
PPHMS 10-32 x3/8"LG. 58 21532 1 CONDUIT, 1/2" 59 60
A1491 23762
1 CONN. 1/2"
2 SHAKEPROOF LOCK
WASHER, EXTERNAL
TOOTH #io
62
29333A
1
BLACK TIE WRAP,
7" LG
-~41 —
NOTES
■42
NOTES
43-

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board ("CARB") and Generac Corporation are pleased to explain the Emission Control Systet,. Warranty on your new recreational vehicle equipment engine. In California, new utility and lawn and garden equipment
engines must be designed, built and equipped to meet the State's stringent anti-smog standards. Generac Corporation will warrant the emission control system on your recreational vehicle equipment for the periods of time listed below provided there has been no abuse, neglect, unapproved modification, or improper maintenance of your recreational vehicle equip
ment engine. Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Also included
may be the compression release system and other emission-related assemblies. Where a warrantable condition exists, Generac Corporation will repair your recreational vehicle equipment engine at no
cost to you for diagnosis, parts and labor.
MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1995 and later model year utility and lawn and garden equipment engines are warranted for two years as hereinafter noted. If, during such warranty period, any emission-related part on your engine is defective in materials or workmanship, the part will be repaired or replaced by Generac Corporation.
OWNER'S WARRANTY RESPONSIBILITIES:
As the recreational vehicle equipment engine owner, you are responsible for the performance of the required maintenance listed in your owners manual. Generac Corporation recommends that you retain all receipts covering maintenance on your recreational vehicle equipment engine, but Generac Corporation will not deny warranty solely due to the lack of receipts or
for your failure to provide written evidence of the performance of all scheduled maintenance. As the recreational vehicle equipment engine owner, you should, however, be aware that Generac Corporation may deny
you warranty coverage if your recreational vehicle equipment engine or a part thereof has failed due to abuse, neglect ,
improper maintenance or unapproved modifications.
You are responsible for presenting your recreational vehicle equipment engine to a Generac Corporation Authorized Servi^ Outlet as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed
30 days.
Warranty service can be arranged by contacting either a Generac Corporation Authorized Service Outlet or by contacting Generac Corporation at:
GENERAC CORPORATION PH: (414) 544-4811
P.O. BOX 8 FX: (414) 544-0179
WAUKESHA, Wl 53187
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty ("ECS Warranty") which is provided to you by Generac Corporation pursuant to California law. See also the Generac Corporation Limited Warranties for Generac Corporation which is enclosed herewith on a separate sheet and also is
provided to you by Generac Corporation. The ECS Warranty applies only to the emission control system of your new engine. To the extent that there is any conflict in terms between the ECS Warranty and the Generac Corporation Warranty, the ECS Warranty shall apply except in any circumstances in which the Generac Corporation Warranty may provide a longer warran
ty period. Both the ECS Warranty and the Generac Corporation Warranty describe important rights and obligations with
respect to your new engine.
Warranty service can only be performed by a Generac Corporation Authorized Service Outlet. At the time of requesting warranty service, evidence must be presented of the date of the sale to the original purchaser. The purchaser shall pay any charges for making service calls and/or for transporting the products to and from the place where the inspection and/or war
ranty work is performed. The purchaser shall be responsible for any damage or loss incurred in connection with the trans
portation of any engine or any part(s) thereof submitted for inspection and/or warranty work.
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty ("ECS Warranty") for 1995 and Later Model Year Utility and Lawn and Garden Equipment Engines;
^.Applicability: This warranty shall apply to 1995 and later model year utility and lawn and garden equipment engines. The
ECS Warranty Period (“ECS Warranty Period") shall begin on the date the new engine or equipment is delivered to its origi nal, end-use purchaser and shall continue for 24 consecutive months thereafter.
B. General Emissions Warranty Coverage: Generac Corporation warrants to the original, end-use purchaser of the new engine
or equipment and to each subsequent purchaser that each of its utility and lawn and garden equipment engines is:
1. Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pur suant to its authority, and
2. Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, will cause a warrant ed emissions - related part to fail to be identical in all material respects to the part as described in the engine manufac turer's application for certification.
C. The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
1. Any warranted, emissions-related parts which are not scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac Corporation according to Subsection (4) below. Any such part repaired or replaced under the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period.
2. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of '' repair or replace as necessary" shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for any remainder of the ECS Warranty Period.
3. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the period of time prior to first scheduled replacement point for that part. If the part fails prior to
the first scheduled replacement, the part shall be repaired or replaced by Generac Corporation according to Subsection (4)
below. Any such emissions-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 Corporation Authorized Service Outlet.
5. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS Warranty is in fact defective, provided that such diagnostic work is performed at a Generac Corporation Authorized Service Outlet.
6. Generac Corporation shall be liable for damages to other original engine components or approved modifications proxi­mately caused by a failure under warranty of any emission-related part covered by the ECS Warranty.
7. Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to meet the expected demand for such emission-related parts.
8. Any Generac Corporation authorized and approved emission-related replacement part may be used in the performance of any ECS warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac Corporation ECS warranty obligations.
9. Unapproved add-on modified parts may not be used to modify or repair a Generac Corporation engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac Corporation shall not be liable hereunder for failures of any warranted parts of a Generac Corporation engine caused by the use of such an unapproved add-on or modified part.
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:
1. Carburetor assembly and its internal components. a. Fuel filter b. Carburetor gaskets c. Fuel pump (if so equipped)
2. Air cleaner assembly a. Air filter element b. Intake pipe/manifold
3. Ignition system including: a. Spark plug b. Ignition module
4. Catalytic muffler (if so equipped) a. Muffler gasket (if so equipped) b. Exhaust manifold (if so equipped)
5. Crankcase breather assembly and its components, a. Breather connection tube
GENERÂC’S THREE - YEAR LÎMiTED WARRANTY FOR RECREATIONAL VEHICLE HP GENERATORS
Generac warrants to the original purchaser that its generators will be free from defeas in materials or work manship for the period set forth below from date of original purchase. During said warranty period, Generac
will, at its option, repair or replace any part which, upon examination by Generac or Generac Authorized
Distributors and/or Dealers, is found to be defective under normal use and service.
THREE - YEAR WARRANTY SCHEDULE
1. All NP series generators used in a recreational vehicle shall be warranted for a period of three (3) years or 2,000 hours of operation, whichever occurs first. All parts, labor, removal and reinstallation shall be covered for the first two years. Parts and labor on selected generator and engine parts shall be covered during the
third year or 2,000 hours, whichever occurs first. These selected parts are limited to: the main Rotor and
Stator, Computer Control Board (if applicable) with regard to the generator; the Cylinder Block, Cylinder Head, Crankshaft, Piston, Valve, Valve Lifter, and Manifolds with regard to the engine.
2. The drive train belt and pulleys on NP air-cooled generators (if applicable) used in recreational vehicles shall be warranted against failure due to defective materials or normal usage for the life of the generator. For the original owner, this drive train warranty shall include parts and labor plus $50.00 payment upon return of the failed belt or pulley by the original owner. For succeeding owner, this power train warranty shall cover belt or pulley parts only.
3. Rental units, demonstrators, prime power, or commercial applications, such as construction or utility, are war ranted for (1) one year or 2,000 hours, whichever comes first.
THIS WARRANTY DOES NOT COVER:
• Costs of maintenance, installation and startup.
• Failures due to (a) normal wear and tear from GN engine, or (b) accident, misuse, abuse, negligence or improper installation.
• Products which are modified or altered in a manner not authorized by Generac in writing.
Any accidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of defective parts.
• Failure due to misapplication.
• Telephone, telegraph, teletype or other communication expenses.
• Living or travel expenses of persons performing service.
• Any and all transportation/travel expenses.
• Rental equipment used while warranty repairs are being performed.
• Overtime labor. » Starting batteries, fuses, light bulbs, and engine fluids.
**NORMAL WEAR: As with all mechanical devices, engines need periodic parts service and replacement to per
form well. This warranty will not cover repair when normal use has exhausted the life of a part or an engine.
THERE IS NO OTHER EXPRESS WARRANTY. GENERAC HEREBY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE TO
THE EXTENT PERMITTED BY LAW. THE DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DIS
CLAIMED IS LIMITED TO THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR CONSE QUENTIAL, INCIDENTAL, OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED. Some states do not allow limitations on low long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights, which vary from state to state.
For service, see your nearest GENERAC authorized warranty service facility or call 1-800-333-1322. Warranty ser
vice can be performed only by a GENERAC authorized service facility. This warranty will not apply to service at any other facility. At the time of requesting warranty service, evidence of original purchase date must be pre sented.
GENERAC CORPORATION® P.O. BOX 8 Waukesha, Wl 53187
TELEPHONE; (414) 544-4811 FAX: (414) 544-4851
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