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 —
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
©
lEi
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-
OD
О
CLEAR-MINIMUM
О
3
“Л
m
>
3
т
т
>
Z
о
g
пп
Z
ш
о
Z
ш
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
-ll|l|h—Ì
SC
•{ |“~16
—©I
151413181110987654321 JSJ3
15fl4
lE_
-15-^
IC 1
T
1
J
90-
CC
66 13
"I
SPI
4 5-
тэт
4 4-
-----
SSl
1
15
—В5"^о^д-|>-—--j
ISA
INDING77
17—
-17 * vSTART
SVI
■1 В ^‘-AsTCF
LDP “
1-
- 0 -
-17-
-14-
-18-
—[Ц I
REMDTE z § S
PANEL g g d a
CQNNECTDR з i U В
REMOTE PANEL
COPTIDNAL)
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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