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)
CORPORATION
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
....
~|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
.............................
................................................
...................................
...............................................
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 —
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