Part No. 98772
OWNER’S
Manual
Series NP-66G
AIR-COOLED
RECREATIONAL VEHICLE
GENERATOR
Model No. 9600-3
Revision 0 (3/7/96)
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 INDUSTRIAL VEHICLE. SAFETY SHOULD BE STRESSED
TO ALL OPERATORS AND POTENTIAL OPERATORS OF THIS EQUIPMENT.
Study these SAFETY RULES carefully before operating
or servicing applicable equipment. Become familiar
with this Owner's Manual ana with your generator. Safe,
efficient and reliable operation can only be achieved if
enerator is properly installed, operated and main
lined. 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 industnal vehicle. Safety should be stressed to
all operators and potential operators of equipment.
The manufacturer cannot possibly anticipate every pos
sible circumstance that might involve a hazaro. The
warnings in this Manual ancfon tags and decals affixed
to the unit are, therefore, not all-inclusive. If you use a
procedure, work method or operating technique Generac does not specifically recommend, you must satisfy
yourself that it is safe for you and others. You must also
make sure the procedure, work method or operating
technique that you chose does not render the generator
to be unsafe.
• For fire safety, the industrial mobile generator must
be properly installed and maintained. Installation
must always remain in compliance with applicable
codes ana standards. In addition, the generator
must be installed in conformance to the manufac
turer’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 produces extremely high and
dangerous electrical voltages and can cause dan
gerous, and possibly fatal, 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 barefoot,
or while hands or feet are wet. Dangerous electri
cal shock will result.
• Have the generator properly grounded (bonded)
during installation onto 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
equipped. DO NOT reconnect t^e bonding conduc
tor to any generator part that might be removed or
disassembled during routine maintenance. If the
grounding conductor must be replaced, use only a
flexible conductor that is of No. 8 AWG copper wire
minimum.
Inspect the generator periodically. Repair or replace
all damaged or defective parts immediately.
In case of accident caused by electric shock, shut
down the source of electrical power down at once.
If this cannot be done, free victim from live conduc
tor. AVOID DIRECT CONTACT WITH THE VIC
TIM. Use a dry board, dry rope, or other non-con
ducting implement to free the victim from live con
ductor. If victim is unconscious, apply CPR (cardio
pulmonary resuscitation) and get m^ical help.
Inspect fuel system frequently for leaks or damage.
Repair or replace any damaged or leaking compo
nent immediately. Never attempt to change, alter
or modi^ 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 in
stalled, 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 vehicle
interior. Never operate this equipment with a leak
ing 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 operating conditions from
leaking exhaust gases, fuel leakage, oil leakage,
coolant leakage, etc.
Do not smoke around the generator. Wipe up any
fuel, oil and coolant spills immediately. Never leave
oily or fuel soaked rags in the generator compart
ment or on the generator itself. Keep the area
around the generator clean and free of debris.
Adequate ventilation is required to expel toxic
fumes and gasoline vapors from the generator com
partment. Do not alter the installation of this equip
ment in any manner that might obstruct air and
ventilation 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.
Some generators may use LP gas propane) as a
fuel. LP gas is highly EXPLOSIVE. The gas is
heavier than air and tends to settle in 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
battery post indicated by a NEGATIVE, NEG or (-)
first. Reconnect that cable last.
WARNING:
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
IDENTIFICATION RECORD
Please record the following infonnation, from the generator DATA PLATE or infoimation decal:
1, Model Number
3. kW Rating.
5. Phase
_____
»ODa.[
sERxes[
SERIAL f
CLASS F INSULATION AT 40*C CtMTlNUOUS OUTY
CALL 800-333-1322 — 24 HOURS A DAY
<
__________________
2. Serial Number_________________________
1 VOLISI J
1 AWSI 1
1 WATTS 1 1
PHASE-l HERTZ-60 RPH-VARIABLE
FOR SERVICE CENTER LOCATIONS
GENERAC CORPORATION
VAUKCSHA. VIS
U.S. AND FOREKM PATENTS PENDING
MAOe IN U.S.A.
4. Rated Voltage.
6. Hertz________
N
4
I -
TABLE OF CONTENTS
GENERAL SAFETY RULES
IDENTIRCATiON RECORD
READ THIS MANUAL THOROUGHLY
Operation and Maintenance........................................... 3
How to Obtain Service
GENERATOR FEATURES
......................
inside cover
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GENERATOR FAMIUARIZATION
Generator Applicabiiity................................................... 5
Installation...................................................................... 5
Safety 5
Generator AC Connection System................................. 5
OPERATING INSTRUCTIONS
Generator Control Panel
Automatic Choke............................................................ 6
Before Starting the Engine............................................. 6
Starting........................................................................... 7
Stopping the Generator.................................................. 7
Applying Loads to Generator
Operation in High Grass or Brush
Don’t Overload the Generator........................................ 8
Wattage Reference Guide
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ENGINE PROTECTIVE DEVICES
Automatic Low Oil Pressure Shutdown.......................... 9
High Temperature Shutdown......................................... 9
Overspeed...................................................................... 9
Low Voltage
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SPECIHCATIONS
1
3
3
4
6
7
7
8
9
Fuel Requirements........................................................10
Engine Oil Requirements
Generator Specifications...............................................10
Engine Specifications
MAINTENANCE
Checking Engine Oil Level
Change Engine Oil
Change Oil Filter...........................................................11
Engine Air Cleaner........................................................12
Spark Arrestor Muffler...................................................12
Engine Spark Plugs
Fuel Filter......................................................................12
MISCELLANEOUS MAINTENANCE
Cleaning the Generator.................................................13
Battery 13
Service and Adjustments
Throttle Linkage Adjustment
Adjusting the Carburetor
Major Service Manual..
Exercising the Generator
Out of Service Protection
Return the Unit to Service after Storage
TROUBLESHOOTING.....................................................16
ELECTRICAL DATA
REPAIR PARTS................
WARRANTY......................................................back page
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18 to 25
10
10
11
11
12
13
13
14
14
15
15
15
17
-2-
READ THIS MANUAL THOROUGHLY
If you don’t understand any portion of this manual,
contact Generac for a demonstration of actual starting,
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 instructions about
a particular operation that may be hazardous if per
formed irKXjrrectly or carelessly. Observe them care
fully.
These safety warnings cannot eliminate the hazards
that they indicate. Strict compliance with the special
instructions while performing the service plus “comnrton
sense” are major measures to prevent accidents.
The following definitions apply to DANGER, CAUTION
and NOTE blocks found throughout the manual.
DANGER: AFTER THIS HEADING YOU CAN
READ HANDLING, INSTALLING, OPERAT
A
ING OR SERVICING INSTRUCTIONS THAT, IF
NOT STRICTLY COMPLIED WITH, MAY RESULT
IN PERSONAL INJURY.
CAUTION: After this heading you can read Instruc
tions for handling. Installing, operating or servicing
the generator that. If not strictly complied 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
A
followed, could endanger personal safety and/or
property of yourself and others.
Potential explosion hazard
A Potential fire 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 recom
mend 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 equip
ment checked by an Authorized Dealer periodically.
Normal maintenance service and replacement of parts
are the responsibility of the. Owner/Operator and, as
such, are not considered defects in materials or work
manship within the terms of the warranty. Individual
operating habits and usage contribute to the need for
maintenance service.
Proper maintenance and care of your industrial mobile
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 industrial mobile generator set requires
servicing or repairs, simply contact an Authorized Serv
ice Station for assistance. Service technicians are fac
tory-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 com
plete model number and serial number of your unit as
given on its data plate.
Potential electrical shock hazard
The warranty on your generator is included in this
Owner's Manual, as well as listings for repair parts.
-3
GENERATOR FEATURES
REFERENCE NUMBER IDENTIFICATION
1. Generator Air Intake Screen
2. Engine Start/Stop Switch
3. 15 amp Fuse
4. 30 amp Circuit Breaker
5. Optional Remote Panel Receptacle
6. Generator AC Output Leads
7. 30 amp Circuit Breaker
8. Starter Contactor
9. Fuel Inlet
10. Fuel Pump Primer Switch
11. Fuel Pump
12. Oil Filter
13. Oil Drain Plug
14. Oil Dipstick and Filler Tube
■ 4-
GENERATOR FAMILIARIZATION
GENERATOR APPLICABILITY
The NP-66G generator has been designed and manu
factured 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 any questions pertaining to its application,
write or call the factory. Do not use the unit until you
have been advised by competent authority.
DANGER: FOR RRE SAFETY, THE GENER
ATOR MUST HAVE BEEN PROPERLY IN
A
STALLED IN COMPUANCE WITH (1) ANS1119^
1975/NFPA 5010-1974 “STANDARD FOR REC
REATIONAL VEHICLES”, PART III, “INSTALLA
TION OF ELECTRICAL SYSTEMS.” THE GENER
ATOR ALSO MUST HAVE BEEN INSTALLED IN
STRICT COMPLIANCE WITH THE MANUFAC
TURER’S DETAILED INSTALLATION INSTRUC
TIONS. AFTER installation, DO NOTHING
THAT MIGHT RENDER THE UNIT IN NON-COM
PLIANCE WITH SUCH CODES, STANDARDS AND
INSTRUCTIONS.
You can use your generator set to supply electrical
power for operating 120 and/or 240 volts, single phase,
60 Hz electrical loads. These loads can require up to
6600 watts (6.6 kW) of power, but cannot exceed 55 AC
amperes of current at 120 volts or exceed 27.5 AC
amperes at 240 volts.
Owners/Operators have the responsibility to make sure
that nothing is done that might render the installation
unsafe or in non-compliance with applicable codes,
standards and instructions.
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 copying
and posting the GENERAL SAFETY RULES to potential
operators of this equipment.
GENERATOR AC CONNECTION SYSTEM
These air-cooled NP Series generator sets are
equipped with dual stator AC power windings. These
two stator windings supply electrical power to customer
electrical loads by means of a dual 2-wire connection
system.
The generator may have been installed so that units
only power 120 volts AC loads (Figure 1); or you can
wire them to connect both 120 and/or 240 volts AC
electrical loads. Be sure to remove the jumper between
the circuit breakers when connecting for 120/240 volts.
CAUTION: Do not overload the generator. Some
installations may require that eiectrical ioads be
aiternated to avoid overloading. Appiying exces
sively high electrical loads may damage the gener
ator and may shorten Its life. Add up the rated watts
of all electrical lighting, appliance, tool and motor
loads the generator will power at one time. This
total should not be greater than the wattage capac
ity 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.
INSTALLATION
This Owner’s Manual has been prepared under the
assumption that a competent, qualified technician in
stalled the generator into an industrial vehicle. We also
assume the installer complied with all applicable codes,
standards and regulations pertaining to installation.
An INSTALLATION MANUAL was shipped with the
generator. That Manual contains manufacturer’s in
structions and recommendations for installing the unit
into an industrial vehicle. After installation, installers
should forward the Installation Manual to Owners/Operators for their information.
GROUNDED
NEUTRAL
Figure 1 — Connection for 120 Volts Only
-5-
OPERATING INSTRUCTIONS
GENERATOR CONTROL PANEL
Mounted on the generator control panel (Figure 2) are
the following features:
• Fuel Pump Primer: 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 rocker t^e switch springs
back into its original position when you release it.
• StarVStop 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, place the switch in its STOP position. The
switch center position is the RUN position.
• 15 amp Fuse: Protects the engine DC control
circuit against electrical overload. If the fuse ele
ment has melted open due to overloading, the en
gine cannot be cranked. If you must replace it, use
only an identical IS.amp replacement njse.
« Line Breakers; Protects generator’s AC output
circuit against overload, i.e., prevents unit from
exceeding wattage/amperage capacity. NP-66G
has one 20-amp and one 30-amp breaker.
NOTE: If the SeriesQ-66G has been reconnected for
dual voltage AC output (120/240 volts), you can install
line breakers having an amperage rating that is different
than stated above. The replacement line breakers con
sist of two separate breakers with a connecting piece
between the breaker handles (so that both breakers will
operate at the same time). If the unit is reconnected for
dual voltage, it is no longer RVIA listed.
Figure 1 — Optional Remote Panel (Model 9042)
AUTOMATIC CHOKE
The engine is equipped with an automatic choke that
consists of two main components—choke solenoid and
prechoke.
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 cranking. 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
according to ambient temperatures (i.e. in cold ambient
temperatures the choke valve closes more). Once the
engine starts, an element heats the temperature-sensi
tive strip to a normal operating condition, opening the
choke valve. This may take about 3 minutes in cooler
weather.
Figure 2 — Typical Control Panel
OPTIONAL REMOTE START/STOP PANEL
Optional remote mounted panels are available which
permit you to crank and start the generator from any
convenient location in the recreational vehicle. Figure 3
shows the Model 9042 remote panel which includes (a)
start/stop switch and (b) a generator run lamp.
You can also order Model 9043, a remote panel which
includes the (a) start/stop switch, (b) the generator run
lamp and (c) an hourmeter. The hourmeter provides a
continuous indication of engine-generator operating
time. Use the hourmeter for checking off periodic main
tenance requirements on the unit.
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 OR INSTALLA
TION CONTRACTOR.
• Installation: Generator installation must have
been properly completed so it complies with all
applicable codes, standards and regulations and
with the manufacturer’s recommendations.
• Engine Lubrication: Have engine crankcase
properly serviced with recommended oil before
starting. Refer to “Maintenance" and “Specifica
tions" sections for oil servicing procedures and rec
ommendations.
CAUTION: Any attempt to crank or start the engine
before you have properly serviced it with the recom
mended oil will result in an engine failure.
-6-
TTietoig^ must have adequstia
supply of proper fuel to Operate. Before starting,
check that sunicientfuel is available.
NOTE: On some installations, the generator en
gine may "share” the vehicle’s gasoline fuel tank
with vehicle engine. Sonte installations may pro
vide separate fuel tanks for generator and vehicle
engine.
Cooling and Ventilating Air: Air inlet and Outlet
openings in the generator compartment must be
c^n and unobstructed for continued proper opera
tion. Without sufficient cooling and ventilating air
flow, the engine-oenerator quickly overheats which
causes it to quickly shutdown. Overheating could
also damage the unit or your vehicle.
Engine Exhaust Gases: Before starting the gen
erator 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 vehicle that, if open,
might permit exhaust gases to enter the vehicle.
DANGER: THE GENERATOR ENGINE
GIVES OFF DEADLY CARBON MONOXIDE
A
GAS THROUGH ITS EXHAUST SYSTEM. THIS
DANGEROUS GAS, IF BREATHED IN SUFFI
CIENT CONCENTRATIONS, CAN CAUSE UN
CONSCIOUSNESS OR EVEN DEATH. DO NOT
OPERATE THE GENERATOR IF ITS EXHAUST
SYSTEM IS LEAKING OR HAS BEEN DAMAGED.
SYMPTOMS OF CARBON MONOXIDE POISON
ING ARE (A) INABILITY TO THINK COHERENTLY,
(B) VOMITTING, (C) TWITCHING MUSCLES, (D)
THROBBING TEMPLES, (E) DIZZINESS, (F)
HEADACHE, (G) WEAKNESS AND SLEEPINESS.
IF YOU FEEL ANY OF THESE SYMPTOMS, MOVE
INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS
PERSIST, GET MEDICAL HELP. _________________
STARTING
IMPORTANT: Read the vehicle manufacturer’s instruc
tions. The owner/operator should become familiar with
the vehicle in which this generator is installed. Differ
ences exist between vehicles. For example, some ve
hicles 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 gener
ator to power certain DC lighting and other DC loads.
Z If you have rrotslarted the engine in more than twct
weeks, presstheFuel Pump PriniierswitchandhokK^
it for about 30 seconds to activate the automatic
shut-off function. However, if the engine Is warm,
skip Step 2.
3. To crank and start the engine, hold the start/stop
switch at START. Release the switch whertthe.^
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 can damage the starter motor.
4. Let the engine run at no-load for a few minutes to
stabilize and warm up the engine.
5. Turn ON electrical loads, using whatever meem
provided (such as a main circuit breaker or transfer
switch).
NOTE: If you start a warm generator engine, yoirmay
only press the start switch slightly to engage thaignitioR
system. However, you should press and hold the starter
switch for a minimum of two seconds to energize the
field boost system. If you start the engine without
energizing the field boost system, the generator pro
duces no AC output.
STOPPING THE GENERATOR
1. Turn OFF all electrical loads, using whatever
means provided (such a main circuit breaker or
transfer switch).
2. Let the generator run at no-load for a few minutes,
to stabilize internal engine-generator tempera
tures.
3. Press STOP on the start/stop switch. The engine
will come to complete stop.
APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator, ob
serve 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 cor
rect rated frequency and voltage only at the proper
governed speed, ^me electrical appliances may be
extremely sensitive to voltage and frequency. Incorrect
frequencies and/or voltages can damage those appli
ances.
To crank and start the generator engine, proceed as
follows:
1. Turn OFF electrical loads, using whatever means
provided in your vehicle (such as a main line circuit
breaker or transfer switch.
NOTE: If you start the engine with start/stop switch on
the generator control panel, turn OFF loads by setting
the panel’s main breakers to their “OFF” or “OPEN”
positions. Electrical load circuits will be turned ON after
the generator has started, stabilized and warmed up.
If electrical loads are applied at reduced operating
speeds, such loads imposed on the engine when suffi
cient power is not available may shorten engine life.
Never turn ON electrical loads until after the generator
engine has started and stabilized ON-speed.
- 7-
Do Not Overload the Generator: You can read the
rated wattage/amperage capacity of your generator on
the generator data plate (see “Identification Record” on
Page 1).
Applying electrical loads in excess of the unit’s rated
capacity can bum out the unit and any^ing connected
to it. Also, overloading trips main circuit breakers.
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 indi
cate their required watts on their nameplate or data
plate. For light bulbs, simply note the wattage rating
of the bulb.
WATTAGE REFERENCE GUIDE
RUNNING
WATTS
‘Air Conditioner (12,000 Btu)
Battery Charger (20 amp)
Belt Sander (3")
Chain Saw
Circular Saw (6-12/").........................................800 to 1000
Coffee Maker
‘Compressor (1 HP)
‘Compressor (3/4 HP)
‘Compressor (1/2 HP)
Curling Iron
‘Deep Freeze
Disc Sander (9“)...........................................................1200
Edge Trimmer................................................................500
Electric Nail Gun..........................................................1200
Electric Range (one element)
Electric Skillet
‘Furnace Fan (1/3 HP)
Hair Dryer
Hand Drill (Г)................................................................1100
Hand Drill (1/2")
Hand Drill (3/8“)
Hand Drill (1/4”)
Hedge T rimmer.............................................................450
Impact Wrench...............................................................500
‘Jet Pump.......................................................................800
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750 to 1000
1700
500
1000
1200
1000
2000
1800
1400
700
500
1500
1250
1200
1200
500
250
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^^¡2 times more watts of power
for starting than for running (for a few seconds
during motor starting). I 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.
Do not apply heavy electrical loads for the first two
or three nours of operation.
RUNNING
WATTS
Lawn Mower
Light Bulb
Microwave Oven
‘Milk Cooler
Oil Burner on Furnace
Oil Fired Space Heater (140,000 Btu)
Oil Fired Space Heater (85,000 Btu)..............................225
Oil Rred Space Heater (30,000 Btu)
‘Paint Sprayer, Airless (1/3 HP)
Paint Sprayer, Airless (handheld)
Radio..................................................................50 to 200
‘Refrigerator
Slow Cooker...................................................................200
‘Submersible Pump (1-1/2 HP)
‘Submersible Pump (1 HP)
‘Submersible Pump (1/2 HP)........................................1500
Sump Pump
‘Table Saw (10”)
Television
Weed Trimmer............................................................... 500
‘ Allow 2-1/2 times the listed watts for starting these
devices^
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.......................................1200
:.......................................100
;.......................................1100
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1750 to 2000
700
300
400
150
600
150
600
2800
2000
600
200 to 500
-8-
This section discusses some of the engine protective
devices, overload protection and breaking in a new
generator.
AUTOMATIC LOW OIL PRESSURE
SHUTDOWN
The engine is equipped with a normally-open (N.O.) oil
pressure switch (Figure 4). Engine oil pressure holds
the switch open during cranking and operation. Should
oil pressure drop below about 2-6 PSI, the switch con
tacts close and the engine automatcially shuts down.
Figure 4 — Switches for Engine Safety Shutdown
HIGH TEMPERATURE SHUTDOWN
An oil temperature switch (Figure 4) with normally-open
(N.O.) contacts is mounted near the oil filter. If oil
temperature were to exceed about 284°F (140°C), the
switch contacts close and the engine shuts down.
ADDITIONAL INFORMATION
OVER VOLTAGE PROTECTION
A solid state voltage regulator (Figure 6) controls the
generator’s AC output voltage. This regulator supplies
an excitation current to the rotor. By regulating the
rotor's excitation current, the strength of its magnetic
field is regulated and, in turn, the voltage delivered to
connected electrical loads is controlled. When the AC
frequency is 50 Hz, voltage is regulated at 120 volts
(voltage-to-frequency ratio is 2-to-1).
FIELD BOOST
The Controller Circuit Board houses a field boost diode
and resistor which are not part of the automatic choke
circuit. These two components are part of a “field boosf
circuit (Figure 5). During engine cranking only, a posi
tive DC (battery) voltage is delivered through the diode,
resistor, brushes and slip rings, and to the generator
rotor. Application of this voltage to the rotor “flashes the
field” whenever it is started. Flashing of the field each
time the generator starts makes sure that a sufficiently
strong magnetic field is available to produce the re
quired “pick up” voltage in the stator windings.
The voltage regulator also incoiporates a “voltage surge
protection circuit.” This circuit prevents troublesome
surges in the generator AC output voltage. Voltage
surge is a common cause of damage to electronic
equipment.
-9-
2&-H0UR BREAK IN PERIOD
The first 25 hours of operation are for "breaking in” the
new generator. Correctly breaking in the generator is
essential to minimize fuel consumption and provide
meiximum engine performance. During this 25-hour
break in period, comply with the following:
• Run the unit at varying electrical loads, to help seat
engine piston rings properly.
• For the 75 hours of operation after the “break in"
period, avoid light electrical loads. Load the gener
ator at 50% (or nrrore) of its rated wattage capacity.
Repeated light loads during the break in period can
cause irhproper seating of engine piston rings,
which could cause blowby and nigh oil consump
tion.
• During the break in period, check engine oil level
frequently. It is normal for oil consumption to be
high during the breaking in period.
• After the 25-hour break-in period, complete the
tasks recommended under “25-Hour Check Up.”
25>HOUR CHECK UP
After the 25-hour break-in period, contact an authorized
service facility for the following maintenance. The vehi
cle owner is responsible for any charges:
Change engine crankcase oil and oil filter.
Check all fluid levels.
Inspect cooling and ventilation openings on the
vehicle.
Check engine carburetor adjustments.
Check engine ignition system.
Inspect entire electrical system.
Inspect the engine exhaust system.
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 bum 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.
-10-
SPECIFICATIONS
GENERATOR SPECIFICATIONS
Rated Maximum Continuous
AC Output
Rated Voltage
Rated Maximum Continuous
AC Current at 120 volts
Phase..................................................................................1
Rated AC Frequency
Driven Speed of Rotor
Rotor Poles..........................................................................2
* All units are reconnectable to 120/240 volts (dual
voltage) output. Units are not listed per RVIA/ANSI
when reconnected for dual voltage output.
A Rated maximum continuous current at 240 volts is
27.5 amperes.
...........................................
................................................
............................
...........................................
.........................................
6600 watts (6.6 kW)
120 Volts AC*
55 AC amperesA
60 Hertz
3600 RPM
ENGINE SPECIFICATIONS
Type of Engine
Cooling Method
Rated Horsepower.......................................16 at 3600 rpm
Displacement
Compression Ratio....................................................8.6 to 1
Cylinder Block
Type of Governor
Engine Governed Speed
Air Cleaner
Starter
.................................................
Ignition System..............................
Recommended Spark Plugs
Champion
AC................................................R45S
Fram Autolite
Spark Plug Gap
...........
...................................
.....................................................
...............................................................
.....................................
.....................................
.......................................
..........................................
..............
....................................
...............................
...........................
RC12 YC
65
0.030 inch (0.8mm)
Twin Cylinder
Aluminum with cast
Mechanical, fixed
Paper element with
foam pre-cleaner
12 volts DC electric
Solid state with
flywheel magneto
Air-cooled
480cc
iron sieeve
speed
2571 rpm
FUEL REQUIREMENTS
The NP-66G generator is equipped with a gasoline fuel
system as standard equipment. Specific installations
may provide either a separate fuel tank for the gener
ator, or the generator may “share" the vehicle engine's
fuel tank.
NOTE: Some 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 in the vehicle remains in the tank.
To reduce lead and carbon deposits use high quality
UNLEADED gasoline with the generator. Leaded
REGULAR grade gasoline is an acceptable substitute.
NOTE: Using “Unleaded” gasoline contributes to
longer engine valve life by reducing lead and carbon
deposits.
CAUTION: Generac does not recommend using
any gasoline containing alcohol (such as “gasohoi”). If you use any gasoline containing aicohol, it
must not contain more than 10 percent ethanoi and
it must be removed from the tank during storage.
Do NOT use any gasoiine containing methanol. If
you use gasoline with alcohoi, inspect more fre
quently for fuel leaks and other abnormalities.
ENGINE OIL REQUIREMENTS
Use a high quality detergent oil classified “For Service
SP and with an oil viscosity rating of SAE 10W-30 oil.
Do not pour in any additives to the recommended oil.
Engine crankcase capacity is 1.5 U.S. quarts. See
MAINTENANCE section for oil level check and filling
procedures.
-11
MAINTENANCE
This section includes information about simple mainte
nance 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 plugs.
CHECKING ENGINE OIL LEVEL
Check engine crankcase oil level at least every eight
hours of operation, or before you use it (Figure 7).
Figure 8 — Location of Oil Drain Plug
• When oil has drained, install and tighten oil drain
plug.
• Remove oil dipstick and fill crankcase with the rec
ommended oil (See Page 11). The engine crank
case can hold about 1.71iters. DO NOT OVERFILL
ABOVE “FULL” MARK.
• Install and tighten dipstick cap before operating
engine.
CHANGE OIL FILTER
Replace the engine oil filter after the first 25 hours of
operation, every 100 operating hours thereafter.
Figure 7 — Oil Dipstick and Fill Tube
• 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 OVERFILL ABOVE “FULL” MARK.
• Install and tighten oil dipstick cap before operating
the engine.
NOTE: See “Engine Oil Requirements” on Page 11 for
recommended oils.
CHANGE ENGINE OIL
Change engine oil after the first 25 hours of operation
(after the 25-hour break-in period. Page 10). Thereaf
ter, 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, remove oil
drain plug (Figure 8). Drain oil completely into a
suitable container.
•
• Turn oil filter counterclockwise to remove (Figure 9).
• Coat gasket of new filter with engine oil.
• Turn new filter clockwise until its gasket contacts
tightly with the filter adapter. Then tighten with an
addibonal 3/4 to one turn by hand.
• Run engine and check for leaks.
12-
ENGINE AIR CLEANER
Clean and re-oil the foam pre-cleaner every three
months or every 25 hours of operation, whichever oc
curs first. Service the foam pre-cleaner more frequently
if you operate the generator in extremely dusty or dirty
conditions (Figure 10):
Turn KNOB counterclockwise to loosen.
Remove COVER, FOAM PRE-CLEANER and PA
PER FILTER.
Remove foam pre-cleaner from cover.
Wash foam pre-cleaner in liquid detergent and
water.
Wrap foam pre-cleaner in a cloth and squeeze dry.
Saturate foam pre-cleaner in enoine oil. Squeeze
to rerTK}ve excess oil and to distribute oil.
Install foam pre-cleaner into cover, followed by
paper filter. Tabs at edges of paper filter must lock
into slots on cover.
Insert bottom locking tag of cover into slot. Install
cover, foam pre-cleaner and paper filter.
Once each year or every 100 operating hours (which
ever comes first), replace the paper filter. The new
replacement filter must be a flame retardent type.
FOAM
PRE
CLEANER
COVER
Figure 11 —Areas to Clean on Air Intake Screen
ENGINE SPARK PLUGS
Clean engine spark plugs and reset gap to 0.030 inch
(0.8mm) every 100 hours of operation (Figure 12).
Clean by scraping or wire brushing and washing with
commercial solvent. DO NOT BLAST CLEAN SPARK
PLUGS.
CAUTION: Sparking can occur If wire terminals do
not fit firmly over spark plug terminal ends. If nec
essary, reform wire terminals to obtain a tight fit
KNÒB
Figure 10— Engine Air Cieaner
CLEAN AIR INTAKE SCREEN
Clean all foreign material from the air intake screen
(Figure 11) at least 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.
FUEL FILTER
Remove and replace fuel filter (Figure 13) every 100
hours of operation or once each year, whichever comes
Figure 13 — Fuel Filter
-13-
MISCELLANEOUS MAINTENANCE
SPARK ARRESTOR MUFFLERS
If the generator is not equipped with a spark arrestor
exhaust muffler and is to be used on any forest covered,
brush covered or grass covered unimproved land, you
may have to install a spark arrestor. The spark arrestor
must be maintained in effective working order by the
vehicle owner/operator.
For assistance in ordering, installing and maintaining
spark arrestor exhaust mufflers, contact your nearest
authorized service facility.
Exhaust mufflers supplied by Generac are spark ar
restor types. Generac exhaust mufflers for RV gener
ators do not have a spark arrestor screen, but are of the
more efficient “toroid" or “swirP type. To remove carbon
and combustion deposits from such mufflers, remove
the PLUG from muffler and run engine for about 15
minutes. Shut engine down, let the muffler cool and
install the plug.
WARNING: BE SURE TO RE-INSTALL THE
PLUG FROM THE MUFFLER TIGHTLY. EN
A
GINE VIBRATION COULD CAUSE A LOOSE PLUG
TO FALL OUT. WITHOUT THE PLUG IN PLACE,
HOT ENGINE EXHAUST IS DIRECTED OUT THE
OPENING. THIS HOT EXHAUST, DEPENDING ON
THE INSTALLATION, COULD BE DIRECTED TO
AREAS NOT ABLE TO WITHSTAND THE EX
TREME HEAT SUCH AS WOODEN FLOOR
BOARDS OR OTHER FLAMMABLE MATERIALS.
THIS COULD RESULT IN A FIRE.
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 insu
lation resistance of those windings.
Moisture that is allowed to remain in contact with wind
ings 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 windings. Salt, as from
sea air, worsens the problem since it tends to absorb
moisture from the air. The combination of sait and
moisture makes a good electrical conductor.
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 contami
nate the generator fuel system.
BATTERY
All lead-acid storage batteries will discharge when not
in use. The generator battery should be inspected as
follows:
Once Weekly: Inspect battery posts and cables for
tightness, corrosion. Clean and/or tighten as needed.
Also check battery fluid level, and, if necessary, fill with
DISTILLED WATER ONLY. DO NOT USE TAP
WATER IN BATTERY.
Every Six Months: Have battery state of charge and
condition checked by automotive service facility. This
should be done with automotive type battery hydrome
ter.
DANGER: STORAGE BATTERIES GIVE
OFF EXPLOSIVE HYDROGEN GAS. THIS
GAS CAN FORM AN EXPLOSIVE MIXTURE
AROUND THE BATTERY FOR SEVERAL HOURS
AFTER CHARGING. THE SLIGHTEST SPARK
CAN IGNITE THE GAS AND CAUSE AN EXPLO
SION. SUCH AN EXPLOSION CAN SHATTER THE
BATTERY AND CAUSE BLINDNESS OR OTHER
INJURY. ANY AREA THAT HOUSES A STORAGE
BATTERY MUST BE PROPERLY VENTILATED.
DO NOT ALLOW SMOKING, OPEN FLAME,
SPARKS OR ANY SPARK PRODUCING TOOLS
OR EQUIPMENT NEAR THE BATTERY.
DANGER: BATTERY ELECTROLYTE FLUID
IS AN EXTREMELY CAUSTIC SULFURIC
A
ACID SOLUTION THAT CAN CAUSE SEVERE
BURNS. DO NOT PERMIT FLUID TO CONTACT
EYES, SKIN, CLOTHING, PAINTED SURFACES,
ETC. WEAR PROTECTIVE GOGGLES, PROTEC
TIVE CLOTHING AND GLOVES WHEN HANDLING
A BATTERY. IF YOU SPILL THE FLUID, FLUSH
THE AFFECTED AREA IMMEDIATELY WITH
CLEAR WATER.
DANGER: DO NOT USE ANY JUMPER CA
BLES OR BOOSTER BATTERY TO CRANK
A
AND START THE GENERATOR ENGINE. IF ANY
BATTERY HAS DISCHARGED, REMOVE IT FROM
THE VEHICLE FOR RECHARGING.
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 MODEL NUMBER and SERIES.
-14-
DRIVE BELTS
The engine drives the generator rotor by means of a
pulley and drive belt arrangement. The drive train, drive
belt and pulleys are warranted for the life of the gener
ator. Drive belt tension was properly adjusted before
the unit was shipped from the factory. If you suspect
that drive belt tension is incorrect, contact an authorized
service facility.
Remove spark plugs and pour about two or three
tablespoons of clean, fresh engine oil into spark
plug mreaded openings. Crank engine several
times to distribute oil, then install and tighten spark
plugs.
Remove the battery and store in a cool, dry room
on a wooden board. Never store the battery on any
concrete or wooden floor.
Clean and wipe the entire generator.
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.
• Close the fuel shutoff valve in the fuel supply line
and let the engine “run out of gas."
• While the engine is still warm from running, drain
the oil completely. Refill crankcase with SAE 10W30 oil having API classification “For Service SF."
• Attach a tag to the engine indicating the viscosity
and classification of the oil in the crankcase.
RETURN THE UNIT TO SERVICE AFTER
STORAGE
To return the unit to service after storage, proceed as
follows:
• Check tag on engine for oil viscosity and classifica
tion. 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
distilled water. DO NOT USE TAP WATER IN THE
BATTERY. Recharge battery to 100% state of
charge, or, if defective, repiace the battery.
• Turn OFF all electrical loads, add gasoline if neces
sary, 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.
■15-
TROUBLESHOOTING
PROBLEM
Engine won’t crank
Engine cranks, won't start
Engine starts hard,
run rough.
POSSIBLE CAUSE(S)
1. 15 amp fuse blown.
2. Loose, corroded or defective battery
cable(s).
3. Battery is discharged or defective.
4. Defective starter contactor.
5. Defective starter motor.
6. Defective controi relay (CR1).
1. Out of fuel.
2. Fuel shutoff valve is closed.
3. Fuel pump not operating.
4. Automatic choke not operating
properly.
5. Engine is flooded.
6. Fuel filter is clogged.
7. Defective Controller Circuit Board
8. Engine spark plugs defective.
9. Bad ignition magneto on engine.
10. Bad carburetor.
11. Dirty air cleaner.
1. Dirty engine air cleaner.
2. Automatic choke is sticking.
3. Defective spark plugs.
4. Defective ignition magneto.
REMEDY
1. Replace blovm fuse.
2. Tighten, clean or replace, as
necessary.
3. Recharge or replace battery.
4. Replace starter contactor.
5. Replace starter motor.
6. Replace control relay.
1. Refill fuel tank.
2. Open fuel shutoff valve(s).
3. Repair or replace pump.
4. Repair, replace or acyust.
5. Wait 5-10 minutes: try again.
6. Replade filter if clogged.
7. Replace bad circuit board.
8. Clean, regap or replace as needed.
9. Replace if defective.
10. Adjust, repair or replace.
11. Clean or replace as needed.
1. Clean or replace as needed.
2. Free choke linkage as needed.
3. Clean, regap or replace.
4. Replace it if defective.
Engine starts, then
shuts down.
No AC output voltage 1. Main breakers open.
1. Engine oil level is low
2. Bad control relay (CR1).
3. Bad low oil pressure switch.
4. Bad control relay (CR2).
2. Transfer switch (if so equipped)
is set to wrong position.
3. Failure in vehicle electrical system.
4. Generator component failure.
1. Add oil as needed.
2. Replace if bad (CR1).
3. Replace, if bad.
4. Replace bad relay (CR2).
1. Cloase main breakers.
2. Reset transfer switch.
3. See vehicle manual.
4. Contact an authorized service facility.
-16-
Drawing No. 92116
ELECTRICAL DATA
-77-
EXPLODED VIEW — BASE AND PULLEYS
Drawing No. 91356
O' O 00 o
CN O' CO o>
18-
00
CN
I
cs
N.
00
00
_________________REPAIR PARTS — BASE AND PULLEYS
Drawing No. 91356
ITEM PART NO.QTY. DESCRIPTION ITEM PART NO. QTY.
1
2 90141 1 Ground Cable
86318
3 46911
4 25017
5 46526 10
6 22129
7
8 77603 2 5/16“-18x 3-1/2" Bolt
72391
9 22259
10 52858
11
12 29459
51730
13 75215
14
73146
15 75209
16
73174 1
1 Mounting Base 43
4
8
Rubber Mount 45
3/8"-16x 1/2“ Capscrew
M10 Lock Washer 47 75711
2 M8 Lock Washer 56 73179
2 Rubber Mount Skid
2
6
2
Z
2 Spring Center Washer 63
5/16-18 Hex Nut
M8-1.25 Flanged Lock Nut
M8-1.25 X 60mm Capscrew 61 74951
Belt Tension Spring 62
4 Nylon Slide
2 Nylon Slide Support
Exhaust Manifold
17 79678 2 Exhaust Manifold Gasket
18
55173
19 72383
20 90859
21
22
75224-F 1 Engine Pulley 73
73106-F 1 Alternator Pulley 74 77681
23 75216
24
49451
25 42633
26
77017 1 Blower Housing Guide 78
27 73118
28 74906 5
29 91123
30 72375
31
32
73185
22097
4 M8-1.25 X 20mm Capscrew
2
1 Cover Plate - External
1
1 Pulley Retainer Washer 76
1 3/8"-24
1
Collector Pan Gasket
40" Poly Vinyl 4L Belt
X
1" Capscrew
3/8"-24 X 2-1/2" Capscrew 79
M6-1.00 X 20mm Screw 80
1 Fuei Pump Bracket
1 Blower Housing 82
1 Blower Housing Spacer
6
M6 Lock Washer
33 77682 1 M5-0.8 X 80mm Capscrew
34 75242 4 Generator Mounting Spring
35 49813 2
36
45757 2 M6-1.0 X 25mm Capscrew
37 90475
38
87769
39 87768
40 87770
42 26925
1
1 Fuel Filter
1
1
1 3/8“ NPT Oil Drain
M6-1.00HexNut
Fuel Pump
1/8" Pipe to 1/4“ Tube Fitting
Fuel Line
44
46
57 70185
58
59
60
64
65
66
67
69
70
71
75
77
81
83
85
87 77643 2 Exhaust Outlet Gasket
90
91
92 74908
93
94
95
96
97
75710-A 1
74958
1
67871 1 0-ring Cap
75712 1 0-ring Drain
1
1
1
77667 1
74948 3 5/16" Fitting
74950 1
73134
1
1
38750 3
74949
68548
1
1
62684 1
29289
75281
—
1
74027 2
43182
75237
2 M3 Lock Washer
4
1
75474 1
90800
1 Exhaust Elbow
74907 1
75226
56893
75229
75227
1 Air Cover
14
1
1
79246 8 M6-1.0 X 16mm Capscrew
22473
72384-C
4
1
22447 1
90088
1
10 M5-0.8
81105 2 5/16'-18 Flange Nut (special)
23897
67210
6 M5 Flat Washer
1
45756 9 M6 X 10mm Taptite Screw
22131
1
DESCRIPTION
Oil Fill and Drain Tube
Cap and Dipstick Assembly
0-ring Adaptor
Oil Fitter Support
Oil Filter (FRAM PH #3614)
Oil Pressure Switch
Outer Oil Tube
Inner Oil Tube
Oil Pad Adaptor
M6-1.00 X 30mm Capscrew
5/16" 90-degree Fitting
Oil Pad Gasket
Grounding Lug
1/16"
X 8’
Foam Tape
High Temperature Switch
M3-0.5 Pan Head Screw
Spring Retainer Washer
LOS 2-wire Vinyl Cap
17“x42"x2" Vinyl Cap
1-1/8" Exhaust Clamp
#10-24 X 1/2* Screw
Slide Pan Gasket
Slide Pan
with lock washer
M6 Flat Washer
Exhaust Outlet Cover •
M8 Toothed Lock Washer
Vinyl Coated Clamp
X
10mm Screw
Decal — Ground
M10 Flat Washer
-19-
EXPLODED VIEW — ALTERNATOR & PANEL
Drawing No. 92118
-20-
___
___________
Drawing No. 92118
REPAIR PARTS — ALTERNATOR & PANEL
ITEM PART NO.
1 75995
2
77004-G
QTY.
3 87845-G
4 73159
5
6 72379
7
8
31971 1
77006
52858 8 M8-1.25 Flange Lock Nut
9 66386
10 66849
11 27756
12
13
14
15
86314
75234 1 Resistor
22473 3
22097
16 74095
17 90141
18
19
20
21 10-74260
22
22447 1 Shakeproof Lock Washer
74906
92234 1 Controller Circuit Board
22129
23 22259 2
24
86316
25 53650
26 91915
27 75244 1
28
29
66476 2 M6-1.0x12mm Capscrew
56739
30 75476
31
32
33
22264 4 M4 Lock Washer
97939
90987 2 M3-0.5 X 15mm Capscrew
DESCRIPTION
1
1 Rotor Assenibly
1
1 Ball Bearing
Lower Bearing Carrier
Stator Asseinbly
Ball Bearing
1 Upper Bearing Carrier
4 Stator Stud
1
2 M5-0.80X 15mm
Brush Holder
4 Nylon Washer
1 Generator Top Housing
Flat Washer
5
1 M6-1.00
2
4
1 Starter Cable
2 5/16“ Lock Washer
M6 Lock washer
X
60mm Capscrew
Ground Cable
M6-1.00 X 20mm Screw
5/16"-18Hex Nut
1
1 4-pin Connector
1 Connector
Panel Sheet Metal
Remote Harness
with lock washer
1
3
1
Starter Contactor
M4-0.7 X 16mm Capscrew
Battery Charge Rectifier
ITEM PART NO.
34 86317
35 75235
36 82737
37
38
39
41
42
49813
49815
43182
54502 1 3A Circuit Breaker
67444 1
43 83049
44
49226
45 51716
46 90145
47 90145
48 25105
49
50
51
86315
90734 4
22985
52 32300
53
54
22676
87798
55 92113
56
57
58
75210-A 1
23365
51715
59
60
90157
QTY. DESCRIPTION
1
4
Panel Support Bracket
M5-0.8 X 30mm Capscrew
4 Vibration Mount
4
1
2
M6 Hex Nut
M5-0.8 X 16mm Capscrew
M3 Lock Washer
M5 Shakeproof Washer
1
6
4
1
1 30A Circuit Breaker
4
1
1
1
1
1
1
Voltage Regulator
M5 Lock Washer
M5-0.80 Hex Nut
30A Circuit Breaker
No. 6-32 Screw
with lock washer
Panel Cover
M4-0.7 X16mm Capscrew
and Flat Washer
M4 Flat Washer
Fuse Holder
15 Amp Fuse
Start/Stop Switch
Fuel Pump Switch
Terminal Block
1
1
M4 Shakeproof Washer
M4-0.7 Hex Nut
NOT USED ON THIS UNIT
1
Decal — C.B. Rating 30 Amp
60 NOT USED ON THIS UNIT
61
62
63
89438-B
31791
23897
64 74908
65
66
23484-S
75763
1
1
1
1
1
1
Customer Connection Decal
Hose Clamp
M5 Flat Washer
M5 X 10mm Taptite Screw
Bushing
Battery Cable Boot
-21
EXPLODED VtEW — CARBURETOR AND AIR CLEANER
Drawing No. 93733
ITEM PART NO. QTY.
1 73112B 1 Carburetor Assembly
2 74962-C
3 70155
1 Governor Spring
1 Governor Lever
DESCRIPTION
4 70108 1 Govemor-to-Carburetor Rod
5 56893 5
6 74961 1
7 47227
8 37398
9 73131
10 66476 2 M6-1.0x12mm Hex Screw
11
12 70125 1 Anti-Lash Spring
13
70575 2 M6-1.0 X 25mm Hex Screw
73374
14 74947
1
1 Hex Lock Nut (nylon)
1 Air Cleaner Support Bracket
1 Choke Support Bracket
1
No. 10-24 X 1/2" Screw
Governor Adjuster Bracket
Governor Adjuster Screw
Choke Control Rod 32 70594
15 89473 1 Bimetal Choke Assembly
16 91306 1 Choke Solenoid
17
77091 1
Cotter Pin
-22-
ITEM
PART NO. QTY.
18 31879 4
19 22159 4
20
21
22
72536
87770
23 74946 1
25 47662-T 1
26
27
28
91351
75252 1
73130 1
29 40173 2
30 66829 2
31
75944 1
33 77075
DESCRIPTION
No. 4 Flat Washer
No. 4 Lock Washer
NOT USED WITH THIS UNIT
2
1
No. 4-40 X 1/4" Screw
5/16" dia. Fuel Line
Choke Link
4-1/2" long Fuel Hose
1
Air Cleaner Decal
Carburetor Overhaul Kit
Flywheel Assembly
Hose Clamp (screw type)
1/8" dia. X 1/8" long Rivet
Governor Spring Bracket
2
M6-1.0 X 93mm Capscrew
with washer
1
Choke Coil Cover
Drawing No. 89403
EXPLODED VIEW — ENGINE SHEET METAL
ITEM
1
2
3
4
5
PART NO. QTY.
67877
67198-N 1 Belleville Washer
67890
87865
7 86313
8 56893 23
10
11 74916
12 74908 9
13
87750 1 Flywheel Scroll
73190
14 78858
15
16
17
19
20
78859
74902 2 Wrapper— Barrel
66476
73191
42907 2 M8-1.25 X 16mm Capscrew
DESCRIPTION ITEM
1
1
6
X
25 Woodruff Key 22
21
23
1
M20-1.50 Hex Nut 24
1 Flywheel Access Plug 25
1 Engine Housing Top
No. 10-24 X 3/8" Screw
26
27
28
1
No. 2 Base Cover 29
M5 X 10mm Taptite Screw
1 No. 2 Cylinder Wrapper
1
Valley Cover 33
1 No. 1 Cylinder Wrapper
2
M6-1.00 X 12mm Capscrew
30
31
35
with lock washer
1
No. 1 Base Cylinder Cover
-23-
34
36
PART NO.
22129
75246
10-74260
74900
73186
81108
22717-B
22717-A
67866
77001
73132
87858A
29289
87858B
50277
QTY.
2
4
1
1 Starter Cover
1
1
1
2 Rubber Grommet
1 O-ring
1
2 Spark Plug Boot
1
2 ft. Foam Tape
DESCRIPTION
M8 Lockwasher
3/8“-16x 1-1/4“ Screw
No. 16 Wire Assembly
Crankcase Wrapper
Snap Bushing
Rubber Grommet
Oil Fill Plug
Ground Wire Assembly
#2 cylinder
1
1
Ground Wire Assembly
#1 cylinder
Oil Drain Decal
EXPLODED VIEW — GN ENGINE PARTS
Drawing No. 79216
24-
________________
Drawing No. 79216
EXPLODED VIEW — GN ENGINE PARTS
-25-
EXPLODED VIEW — GN ENGINE PARTS
Drawing No. 79216
57
/
44 d
43m
6CE>
YALYC DYIRHAUI KIT 1
35-|
33-
1-33
-41
52
92-
46-
AREOUIRES SPECIAL TOOLS TO INSTALL
SEE REPAIR MSTRUCTKIN MANUAL
21 I"22"
63'
-39
'73
Q'-59
'^“1—38
\
---0—62
-2(5-
__
_______________REPAIR PARTS LIST — GN-480 ENGINE
Drawing No. 79216
ITEM
1 69331
2
3
4
5
6
PART NO.
69333
67805
79234
79235
70169
7 69332
8 72301
9 72315
10
11 70596
12
13
14
15
16
70190
69336
69325 8
67888
72334 1 Crank Shaft Assembly
75247
17 67924
18
19
20 75249
21
22
23
24
25
26
27
67878 9
75248
69327
75250 2
75251
72346
69316
69317 2
67816
28 69320
29 70513
30
31
70584
70530
32 72358
33 69379
34
35
67895
70594 2
36 67158
37 68574
38
39
68554 1
68573
40 70506
QTY. DESCRIPTION
1 Cylinder Assembly 51
1 Sleeve Bearing 52
1 Oil Seal 53
1 No. 1 Cylinder Head Assam. 54
1 No. 2 Cylinder Head Assam.
4 Sealing Washer 56
2
1 Breather Assembly
1
2
1 Breather Tube
1
Cylinder Head Gasket 57
Breather Gasket
Breather Screw
Oil Sump Gasket
Cylinder Head Bolt 63
2
■■ 1
1
3/6" NPT Oil Drain Plug 64 72365
Oil Sump Assembly 66
Oil Seal Assembly
Oil Sump Bolt
2 Standard Piston Assembly 69
2 Standard Piston Ring Set 70
4
Piston Locking Ring 71 75266
Standard Piston Ring
2 Connecting Rod Assembly 73
4 Connecting Rod Bolt 74
2 Exhaust Valve
Intake Valve
4
4
4
4
1 Camshaft Assembly
1
2 Carburetor Mounting Gasket
2
Valve Spring 77 67911
Valve Spring Retainer
Valve Keeper
Valve Tappet
Intake Manifold 82
Intake Manifold Gasket
Carburetor Mounting Bolt
4
1
Intake Manifold Mounting Bolt
1/8" NPT Plug Pipe
Governor Shaft Seal
1
1 Oil Galley 0-ring
Oil Pump 0-ring
41 70554 1 Carburetor Spacer
42 70568
43 75253
44
45
67885
75254 4
46 70535
47
48
75255
75256
49 75257
50
67891
4
4
4
Rocker Arm Stud
Washer Valve Cover Seal
M6 Nylon Nut
Valve Adjust Screw
1
1
2 Starter Motor Bolt
4
1
Oil Screen
Starter Motor
Brush Assembly
Ignition Armature Assembly
ITEM
PART NO.
72536
72347 2 R12YC Champion Spark Plug
75258
75259
55
75260
75261
66480
58
59
60
61
75269
72361
72362
70199
62 72366
72367
65
68555
67806
67 75262
68
75263
75264 1
75265
72
75267
68572
75272 2 Spark Plug Terminal
75
76
70122 2 Valve Stem Seal
67910
78 67813
79
80
81
75268
75270
70592 1 Air Cleaner Base
73123
83
84
85
86
87
88
70593
72300
67156 2 Air Cleaner Base Screw
69341
80011
70597 1 Air Inlet Tube
89 69358
90
91
92
93
67920
69328
70547
70536
94 70577
95
96
70599
70567 2 Rocker Arm Shaft
97 70566
98
99
100
101
75271 1
67897 2
91481
91480
QTY. DESCRIPTION
2 Ignition Armature Screw
1
1 Breather Screw Washer
1
1
1 Air Cleaner Gasket
1
1 Governor Shaft Bushing
1
1 Breather Baffle
1 Cotter Pin
1
1
2
Engine Gasket Kit
Starter Drive Assembly
Clutch Assembly
Armature Assenk)ly
Governor Shaft Bushing
Governor Fork
Governor Shaft Washer
Crankcase Dowel
4 Cylinder Head Dowel
1 Breather Seal Screw
1 Breather Seal Screw
Starter Gear
1
1
1
2
2
2 Exhaust Valve Seat
4
1 Retainer and Pin
1
1
1
1
1
1
1
2
2
1
1
4
4
4
Starter End Cap Assembly
Commutator Cap Assembly
Starter Housing Assembly
Oil Pump Screw
Intake Valve Seat
Valve Guide
Roll Pin
Air Filter
Air Cleaner Cover
Air Cleaner Cover Screw
Foam Pre-cleaner
Brush Set Spring
Breather Deflector
Valve Cover Gasket
Valve Cover
Oil Pump Assembly
Governor Slider
Push Rod
Rocker Arm Assembly
Rocker Arm Support
Valve Overhaul Kit
Exhaust Gasket
1
1
Gasket and Cap Assembly
Rocker Arm Cover
-27-
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 System
Warranty on your new recreational vehicle generator 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 for the periods of time listed below provided there has
been no abuse, neglect, unapproved modification, or improper maintenance of your recreational vehicle generator 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 generator 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 recreational vehicle generator 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 generator 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 generator 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 generator engine owner, you should, however, be aware that Generac Corporation may deny
you warranty coverage if your recreational vehicle generator engine or a part thereof has failed due to abuse, neglect,
improper maintenance or unapproved modifications.
You are responsible for presenting your recreational vehicle engine to a Generac Corporation Authorized Service 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.BOX8 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 warranty
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.
IF YOU HAVE ANY QUESTIONS REGARDING YOUR WARRANTY RIGHTS AND RESPONSIBILITIES, YOU SHOULD CONTACT
GENERAC CORPORATION AT 1-800-222-3136
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (‘ECS Warranty') for 1995 and Later Model Year recreational vehicle generator Engines:
^Applicability: This warranty shall apply to 1995 and later model year recreational vehicle generator engines. The ECS
Warranty Period (*ECS Warranty Period") shall begin on the date the new engine or equipment is delivered to its original,
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 recreational vehicle generator 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 EC5 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 EC5 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 EC5 Warranty Period. If any such part fails during the EC5 Warranty Period, it shall be
repaired or replaced by Generac Corporation according to 5ubsection (4) below. Any such part repaired or replaced under
the EC5 Warranty shall be warranted for any remainder of the EC5 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 EC5 Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary' shall not reduce the EC5 Warranty Period. Any such part repaired or replaced under the EC5
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 proxi-
mately 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
1. Fuel Metering System,
a. Gasoline carburetor assembly (if so equipped)
1) Fuel filter (if so equipped)
2) Carburetor gaskets
3) Fuel pump
a. LP/Natural gas carburation assembly
1) Fuel controller
' 2) Mixer and its gaskets (if so equipped)
3) Carburetor and its gaskets (if so equipped)
4) Primary gas regulator (if so equipped)
5) LP liquid vaporizer (if so equipped)
INCLUDE THE FOLLOWING;
2. Air cleaner assembly
a. Air filter element
b. Intake pipe
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
GENERAC’S THREE-YEAR UMITED WARRANTY FOR RECREATIONAL VEHICLE NP GENERATORS
Generac warrants to the original purchaser that its generators will be free from defects in nuterials or
workmanship 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 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 (if so equipped) on NP air-cooled generators 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 up>on return of the failed belt or pulley by the original owner. For succeeding owners,
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 warranted for (1) one year or 2,000 hours, whichever comes first.
All warranty expense allowances are subject to the conditions defined in the published “GENERAC
POLICIES AND PROCEDURES" manual.
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 incidental, consequential or indirect damages caused by defects in materials or work
manship, 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 sen/ice.
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.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. SPECIFI
CALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE. Some states do no allow limitations on how long an implied warranty lasts,
so the above limitation may not apply to you. GENERAC’S ONLY LIABILITY SHALL BE THE REPAIR
OR REPLACEMENT OF PARTS AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE
FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A
RESULT OF GENERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of
incidental or consquential damages, so the above limitation may not apply to you. Buyer agrees to make
no claims against generac based on negligence.
This warranty gives you specific legal rights, and you may also have other rights, which vary from state
to stale.
GENERAC CORPORATION, P.O. Box 8, Hwy 59 and Hillside Road, Waukesha, Wl 53187
Telephone (414) 544-4811 FAX (414) 544-4851
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