Generac Power Systems 00802-3 User Manual
Manual No, A9398
OWNER'S MANUAL
and Installation Instructions
Series lmpact-36G
AIR-COOLED
RECREATIONAL VEHICLE
GENERATORS
Model No. 00802-3
Revision 0 (1/28/99)
POWER SYSTEMS. INC.
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 VEHICLE.
SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS 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.
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 safe 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.
WARNING:
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
For fire safety, the recreational vehicle generator
must be properly installed and maintained.
Installation must 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
^The RV
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 bare
foot, or while hands or feet are wet. Dangerous
electrical 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 the bonding con
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.
and instructions.
roduces extremely high and
• 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
A
age. Repair or replace any oamaged 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
A
fuel, and oil immediately. Never leave oily or fuel
soaked rags in the generator compartment or on the
generator itself. Keep the area around the generator
clean and free of debris.
Adequate ventillation is required to expel toxic
A
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 or replace
all damagecfor defective parts immediately.
These generators can be converted to use LP gas
(propane) as a fuel. Liquid Propane gas is highly
EXPLOSIVE. The gas is heavier than air and
tends to settle in low areas where even the slight
est spark can ignite the gas and cause an explo
sion.
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.
IDENTIFICATION RECORD
Please record the following Information from the generator DATA DECAL or information decal.
1. Model Number
3.kW Rating.
5. Phase
___
________________
2. Serial Number
4. Rated Voltage.
6. Hertz
_______
____________________
REFERENCE NUMBER IDENTIFICATION
1. Generator Air Intake Screen
2. Engine Start/Stop Switch
3. Fuse
4. Circuit Breaker
5. Fuel Primer Switch
6. Generator AC Output Leads
7. 12 Volt Battery Connection (Partially hidden by 15)
8. Fuel Pump
9. Air Cleaner
10. Air Intake Tube
11. Carburetor
12. Oil Dipstick and Filler Tube
13. Data Decal
14. Hour Meter
15. Ignition Coil Assembly
— 1
TABLE OF CONTENTS
OPERATING INSTRUCTIONS
GENERAL SAFETY RULES...............................inside cover
IDENTIFICATION RECORD
GENERATOR FEATURES
................................................
..................................................
READ THIS MANUAL THOROUGHLY
Operation and Maintenance.................................................................. 3
How to Obtain Service........................................................................... 3
Service Dealer Location......................................................................... 3
GENERATOR FAMIUARIZATION
Generator Applicability.......................................................................... 4
Safety....................................................................................................... 4
Generator AC Connection System....................................................... 4
OPERATING INSTRUCTIONS
Generator Control Panel........................................................................ 5
Automatic Choke.................................................................................... 5
Before Starting the Engine
Starting.................................................................................................... 6
Stopping the Generator......................................................................... 6
Applying Loads to Generator................................................................ 6
Attention Required After Submersion
Operation in High Grass or Brush
Operating Precautions
Effects of Moisture and Dirt.................................................................. 7
Don't Overload the Generator............................................................... 7
.................................................................
.................................................
.......................................................
........................................................................
5-6
6-7
ENGINE PROTECTIVE DEVICES
Automatic Low Oil Pressure Shutdown
High Temperature Shutdown................................................................ 7
Overspeed............................................................................................... 7
Low Voltage............................................................................................ 7
..............................................
INSTALLATION INSTRUCTIONS
INSTALLATION SAFETY RULES
......................................
14
1
GENERAL INSTALLATION INFORMATION
1
Purpose and Scope
Safety......................................................................................................15
Standards Booklet.................................................................................15
Equipment Description.........................................................................15
Engine Generator Operating Speed....................................................15
Generator AC Connection System......................................................15
.................................................
,............................15
LOCATION AND SUPPORT
Generator Location...............................................................................16
Generator Support
Suspended Mounting............................................................................16
Generator Restraint...............................................................................17
................................................................................
16
GENERATOR COMPARTMENTS
Compartments.......................................................................................17
Compartment Size.................................................................................18
Compartment Construcion
Sound Insulation Materials
6
6
Compartment Floor Cutouts................................................................19
Acoustics................................................................................................19
..................................................................
..................................................................
18
18
COOLING AND VENTILATION AIR
Generator Air Row.................................................................................20
Cooling Air Inlet Openings...................................................................20
Compensating for Restrictions...........................................................21
7
Testing the Installation.........................................................................21
GASOLINE FUEL SYSTEM
Fuel Tank................................................................................................22
Generator Fuel Supply Line............................................................22-23
SPECIFICATIONS
Fuel Requirements................................................................................. 8
Engine Oil Requirements
Generator Specifications....................................................................... 8
Engine Specifications............................................................................ 8
......................................................................
MAINTENANCE
Checking Engine Oil Level.................................................................... 9
Change Engine Oil
Change oil filter.................................................................................... 9
Engine Air Cleaner.............................................................................9-10
Clean Air Intake Screen........................................................................10
Spark Arrestor Muffler..........................................................................10
Engine Spark Plug................................................................................10
Fuel Filter...............................................................................................10
Cleaning the Generator........................................................................11
Battery....................................................................................................11
Service and Adjustments
Throttle Linkage Adjustment..........................................................11-12
Adjusting the Carburetor......................................................................12
Adjusting Valve Clearance...................................................................12
Major Service Manual...........................................................................13
Exercising the Generator.....................................................................13
Out of Service Protection.....................................................................13
Return the Unit to Service after Storage
Service Dealer Location
.................................................................................
....................................................................
............................................
.......................................................................
EXHAUST SYSTEM
Mufflers and Spark Arrestors
8
Type of Exhaust System.......................................................................23
Exhaust System Safety
..............................................................
.......................................................................
23
23
ELECTRICAL CONNECTIONS
Electrical Junction Box
Wiring......................................................................................................24
9
Generator AC Connections..................................................................24
Conduit...................................................................................................24
Isolating Different Power Sources......................................................25
Power Supply Cord...............................................................................25
Ground Fault Circuit Interrupters
BATTERY INSTALLATION
OPTIONAL ACCESSORIES
11
POST INSTALLATION TESTS...........................................29
INSTALLATION CHECK LIST............................................30
........................................................................
.......................................................
...........................................
26-27
...............................................
24
25
28
TROUBLESHOOTING........................................................31
MAJOR FEATURES AND DIMENSIONS...........................32
ELECTRICAL DATA...........................................................33
13
13
REPAIR PARTS.........................................................34 to 41
NOTES..........................................................................42 - 43
CALIFORNIA EMISSIONS WARRANTY
WARRANTY
..........................................................
.....................
back page
44 - 45
— 2 —
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, WARNING, CAU
TION and NOTE blocks are used to alert you to spe
cial 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 WARN
ING, CAUTION and NOTE blocks found throughout
the manual.
DANGER; Indicates an immediately hazardous sit
uation which, if not avoided, wiii resuit in death or
serious injury. Danger is iimited to the most
extreme situations.
WARNING: Indicates a potentially hazardous situa
tion which. If not avoid^, could result in death or
serious Injury.
CAUTION: Indicates a potentially hazardous situa
tion which, if not avoided, may result in minor or
moderate injury. Caution may also be used to alert
against unsafe practices.
NOTE: Indicates a statement of company policy as
the message relates directly or indirectly to the safety
of personnel or protection of property.
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
Potential electrical shock hazard
A
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 industrial
mobile generator assures a minimum number of prob
lems and keeps your operating expenses at a mini
mum. See your authorized Dealer/Distributor for ser
vice aids and accessories.
HOW TO OBTAIN SERVICE
When your mobile generator set requires servicing or
repairs, simply contact an Authorized Service Facility
for assistance. Service technicians are factorytrained 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 model number and serial number of your
unit as given on its data decal.
The warranty on your generator is included in this
Owner's Manual, as well as listings for repair parts.
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 generator must have
been properly installed in compliance with (1)
ANS1119.2-1975/NFPA 501C-1974 “Standard for
Recreational Vehicles”, Part III, “Installation of
Electrical Systems.” The generator also must have
been installed in strict compliance with the manu
facturer’s detailed installation instructions. After
installation, 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 3600 watts
(3.6 kW) of power for the NP-36G series. The maxi
mum current at 120 volts is 30 amperes.
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
CONNEQION SYSTEM
These air-cooled NP Series generator sets power
120-volt, 30 amp AC loads for the NP-36G model.
The diagram below is a simple schematic (Figure 1)
of the generator’s AC connection system.
Figure 1 — Connection for 120 Volts Only
CAUTION: Do not overload the generator. Some
installations may require that electrical loads be
alternated to avoid overloading. Applying 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
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 PRIMER
Before starting a cold engine you must press this
switch to bring fuel from the tank to the carburetor.
This rocker type switch springs back into its original
position when you release it.
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 autorriatic 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 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
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 rec
ommended 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.
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 deadiy
carbon monoxide gas through! its exhaust system.
This dangerous gas, if breathed in sufficient con
centrations, can cause unconsciousness or even
death. Do not operate the generator if its exhaust
system is ieaking or has been damaged.
Symptoms of carbon monoxide poisoning are
(inability to think coherently, (b) vomiting, (c)
twitching muscles, (c) throbbing temples, (e) dizzi
ness, (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
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 panei’s main breaker to its “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 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 ionger
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 as 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. Hold 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.
■ LEHING ENGINE STABILIZE
The generator supplies correctly 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.
_______________
AHENTION 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 hot and can
cause a fire if it is too close to combustible materials.
— 6 —
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.
EFFEQS 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 oenerator 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 electrical
conductor.
DO NOT OVERLOAD
THE GENERATOR
You can read the rated wattage/amperage capacity of
your penerator 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.
This generator has a computer that monitors low oil pres
sure, oil temperature, engine speed, and low voltage out
put. 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 opera
tion, the engine shuts down. If you do restart the
engine after a low oil pressure shutdown and have
not corrected the low 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 engine tempera
ture were to exceed a preset temperature, the switch
contacts close and the engine shuts down.
ENGINE PROTECTIVE DEVICES
OVERSPEED
If engine speed is increased manually (or othenwise)
beyond the control of the computer control system,
the computer disables the load capability of the gen
erator and shuts down the engine.
WARNING: Do not attempt to physically adjust or
control the engine speed. Equipment 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 out
put that occurs during startup. A time delay that
allows the engine to start and warm up is pro
grammed into monitoring the 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 —
SPECIFICATIONS
FUEL REQUIREMENTS
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 generator during storage. Do
NOT use any gasoline containing methanol. If you
use gasoline with alcohol, inspect more frequently
for fuel leaks and other abnormalities.
FUEL CONSUMPTION (IN GALLONS PER HOUR):
LOAD GASOLINE
NO 0.13
HALF
FULL
0.20
0.40
ENGINE OIL REQUIREMENTS
The recommended oils 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
one (1) quart. Use no special additives. See
“Maintenance” section for oil level check and fill pro
cedures.
GENERATOR SPECIFICATIONS
Model..............................................................Impact-36G
Rated Maximum Continuous
AC Power Output
Rated Voltage............................................120 volts AC
Rated Maximum Continuous
Current at 120 volts
Phase
...........................................................
Rated AC Frequency................................................60 Hz.
Maximum Battery
Recommended Battery
Cranking Current
..............................
..................................
..............................................
3600 watts (3.6 kW)
30 AC amperes
Single Phase
400 amps
ENGINE SPECIFICATIONS
Type of Engine
Cooling Method..................................................Air-cooled
Displacement............................................................220cc
Type of Governor
Air Cleaner
Starter..................................................12 volt DC electric
Ignition System
Recommended Spark Plugs
Spark Plug Gap...................................0.030 inch (0.8mm)
......................................................
...............................................
.................................................
.................................................
.............
Champion RC12YC
GN-220
Electronic
Paper element
Solid state
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.
CHECKING ENGINE OIL LEVEL
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.
Figure 3 — Oil Dipstick and Fill Tube
<f=.
* Install and tighten dipstick cap before operating engine.
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).
Figure 4 — Oil Drain Plug and Engine Oil Filter
• 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 oil level and fill to full mark after
checking for leaks. Filter will retain some oil.
NOTE: See “Engine Oil Requirements” on Page 8 for
recommended oils.
CHANGE ENGINE OIL
Change engine oil after the first 8 hours of operation.
Thereafter, change oil every 50 operating hours.
Change oii more frequentiy 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).
10;
Figure 5 — Engine Air Cleaner Assembly
Follow the steps on page
PAPER
FILTER
— 9 —
• 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 to the base of the air cleaner.
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.
Figure 6 — Clean Air Intake Screen
ENGINE SPARK PLUG
Clean engine spark plug and set gap to 0.030 inch
^.76mm) every 100 hours of operation (Figure 7).
Clean by scraping or wire brushing and washing with
commercial solvent. DO NOT BLAST CLEAN SPARK
PLUG.
Figure 7 — Setting Gap on Spark Plug
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 8) every 100
hours of operation or once each year, whichever
occurs first.
Figure 8 — Fuel Filter
10 —
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 wind
ings will be retained in voids and cracks of the wind
ings. 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 salt
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 probiems, and may also conta
minate the generator fuel system.
BAHERY
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.
■ EVERY SIX MONTHS
Have the battery state of charoe and condition
checked by an automotive service facility. This should
be done with an automotive type battery hydrometer.
DANGER; Storage batteries give off explosive
hydrogen gas. This gas can form an explosive
mixture around the battery for several hours after
charging. The siightest spark can ignite the gas
and cause an explosion. Such an expiosion can
shatter the battery and cause biindness or other
injury. Any area that houses a storage battery
must be properly ventilated. Do not allow smok
ing, open flame, sparks or any spark producing
tools or equipment near the battery.
_______________________
___________________
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.
THROHLE 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. It 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 snort,
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 9).
Figure 9 — Gap Between Stop Tab
and Stop Block
DANGER; Battery electrolyte fluid is an extremely
caustic sulfuric acid solution that can cause
severe burns. Do not permit fiuid to contact eyes,
skin, clothing, painted surfaces, etc. Wear protec
tive goggies, protective clothing and gloves when
handling a battery. If you spill the fluid, fiush the
affected area immediately with clear water.
DANGER; Do not use any jumper cables or boost
er battery to crank and start the generator engine.
If any battery has discharged, remove it from the
vehicle for recharging.
—11 —
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 10).
Figure 10 — Adjusting Throttle Linkage
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 11).
Figure 11 — Adjusting Valve Clearance
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 12).
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 5,000
feet, consult your Generac Authorized Service Facility
regarding high altitude jetting changes.
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:
Figure 12 — Tightening Jam Nut
Tighten Jam Nut to
65-85 inch-pounds
(7-10 N-m)
— 12 —
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 PROTEQION
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 still 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 openings.
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 earthen 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 distilled
water. DO NOT USE TAP WATER IN THE BATTERY.
Recharge battery to 100% state of charge, or, it 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
— 13-
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