Generac Power Systems 0661-5 User Manual

Download

Manual No. A9400

OWNER'S MANUAL

and Installation Instructions

Series NP-30G

AIR-COOLED

RECREATIONAL VEHICLE

GENERATORS

Model No. 0661-5

POWER SYSTEMS, INC.

Revision 0 (1/28/99) Printed in U.S.A.

GENERAL SAFETY RULES

COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHI- A

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 properly 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.

A 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 and instructions.

A 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 bare foot, or while hands or feet are wet. Dangerous electrical shock will result.

• Have the generator properly grounded (bonded) during installation into the vehicle, either by solid

mounting to the vehicle frame or chassis or by means of an approved bonding conductor. DO

NOT disconnect the bonding conductor, if so 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.

THE MANUFACTURER SUGGESTS THAT THESE “RULES" FOR SAFE OPERATION BE

CLE. SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF THIS EQUIPMENT.

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.

A Inspect fuel system frequently for leaks or dam-

^ age. Repair or replace any damaged or leaking

component immediately. Never attempt to change, alter or modify the generator fuel system in any way that might affect safety or compliance with applicable codes and standards.

• The generator engine gives off DEADLY carbon

WARNING:

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects, or other reproductive harm.

monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentra tions, can cause unconsciousness or even death. This exhaust system must have been properly installed, in strict compliance with applicable codes and standards. Following installation, you must do nothing that might render the system unsafe or in non-compliance with such codes and standards. The generator compartment must be completely vapor sealed from vehicle interior. There must be no possibility of exhaust fumes entering the vehi cle interior. Never operate this equipment with a leaking or defective exhaust system.

• Never use the generator or any of its parts as a step. Stepping on the unit can stress and break parts and may result in dangerous, fuel leakage, oil leakage, etc.

Do not smoke around the generator. Wipe up any

fuel and oil spills immediately. Never leave oily or

fuel soaked rags in the generator compartment or on the generator itself. Keep the area around the gener ator clean and free of debris.

A Adequate ventillation is required to expel toxic

^ fumes and gasoline vapors from the generator

compartment. Do not alter the installation of this equipment in any manner that might obstruct air and ventillation openings. Such openings must be kept clear and unobstructed.

• Keep hands, feet, clothing, etc., away from drive belts, fans and other moving parts of this equip ment. Never remove any drive belt or fan guards while the unit is operating.

• Inspect the generator periodically. Repair or replace

■ all damaged or defective parts immediately.

A These generators can be converted to 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.

A 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 AND GENERATOR FEATURES

Please record the following information from the generator DATA DECAL or information decai.

t.Modei Number___________________ 2.Serial Number

3.kW Rating.

5. Phase

____

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 Pump Primer

6. Generator AC Output Leads

7. 12 Volt Battery Connection (Partially hidden by #15) 15. Ignition Coil Assembly

8. Fuel Pump

9. Air Cleaner

10. Air Intake Tube

11. Carburetor

12. Oil Dipstick and Filler Tube

13. Data Decal

14. Hour Meter

OPERATING INSTRUCTIONS

GENERAL SAFETY RULES IDENTiFiCATiON RECORD AND

GENERATOR FEATURES........................................ 1

READ THiS manual THOROUGHLY

Operation and Maintenance How to Obtain Service

Service Dealer Location......................................................... 3

GENERATOR FAMiLiARIZATION

Generator Applicability.......................................................... 4

Safety....................................................................................... 4

Generator AC Connection System

OPERATING INSTRUCTIONS

Generator Control Panel........................................................ 5

Automatic Choke.................................................................... 5

Before Starting the Engine................................................. 5-6

Starting.................................................................................... 6

Stopping the Generator

Applying Loads to Generator................................................ 6

Attention Required After Submersion.................................. 6

Operation in High Grass or Brush........................................ 6

Operating Precautions........................................................ 6-7

Effects of Moisture and Dirt

Don't Overload the Generator............................................... 7

Automatic Low Oil Pressure Shutdown............................... 7

High Temperature Shutdown................................................ 7

Overspeed............................................................................... 7

Low Voltage............................................................................ 7

SPECIFICATIONS

Fuel Requirements................................................................. 8

Engine Oil Requirements

Generator Specifications....................................................... 8

Engine Specifications............................................................ 8

MAINTENANCE

Checking Engine Oil Level Change Engine Oil

Change Oil Filter..................................................................... 9

Engine Air Cleaner................................................................. 9

Clean Air Intake Screen

Spark Arrestor Muffler..........................................................10

Engine Spark Plug.................................................................10

Fuel Filter

Cleaning the Generator.........................................................10

Battery....................................................................................10

Service and Adjustments Throttle Linkage Adjustment Adjusting the Carburetor

Adjusting Valve Clearance..............................................11-12

Major Service Manual

Exercising the Generator

Out of Service Protection.....................................................12

Return the Unit to Service after Storage

Service Dealer Location

...............................................................................

.................................................................

...........................................................

....................

..................................................

..........................................................

.......................................

........................................................

..................................................

......................................................

....................................................

........................................................

...............................................

.....................................................

......................................................

inside cover

10-11

............................

11 11

12 12

INSTALLATION INSTRUCTIONS

INSTALLATION SAFETY RULES............................13

GENERAL INSTALLATION INFORMATION

Purpose of Scope.....................................................................14

Safety........................................................................................ 14

Standards Booklet.................................................................. 14

9 9

Equipment Description............................................................14

Engine-Generator Operating Speed.......................................14

Generator AC Connection System

.........................................

LOCATION AND SUPPORT

Generator Location

Generator Support....................................................................15

Suspended Mounting...............................................................15

Generator Restraint..................................................................16

..................................................................

GENERATOR COMPARTMENTS

Compartments

Compartment Size....................................................................17

Compartment Construction.....................................................17

Sound Insulation Materials......................................................17

Compartment Floor Cutouts Acoustics

..........................................................................

...................................................

.................................................................................

COOLING AND VENTILATION AIR

Generator Air Flow...................................................................19

Cooling Air Inlet Openings.................................................19-20

Compensating for Restrictions...............................................20

Testing the Installation

GASOLINE FUEL SYSTEM

............................................................

.....................................

EXHAUST SYSTEM..................................................22

ELECTRICAL CONNECTIONS

Electrical Junction Box............................................................23

Wiring.........................................................................................23

Generator AC Connections

Conduit......................................................................................23

Isolating Different Power Sources..........................................24

Power Supply Cord Ground Fault Circuit Interrupters

BATTERY INSTALLATION

OPTIONAL ACCESSORIES

.....................................................

..................................................................

...........................................

.................................

25-26

.....................................

24 24

POST INSTALLATION TESTS.................................28

INSTALLATION CHECK LIST..................................29

MAJOR FEATURES AND DIMENSIONS

................

TROUBLESHOOTING..............................................31

ELECTRICAL DATA............................................32-33

REPAIR PARTS NOTES

.................................................................

CALIFORNIA EMISSIONSWARRANTY

WARRANTY

............................................

..............

..................................................

34 to 41

42-43

44-45

back page

— 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, will result in death or serious injury. Danger is limited to the most extreme situations.

WARNING: Indicates a potentially hazardous situa tion which, if not avoided, 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

The operator (driver) is responsible for proper and safe use of the vehicle, equipment on the vehicle, and the safety of all vehicle occupants. We strongly rec ommend that the operator read this Owner's Manual and thoroughly understand all instructions before

using this equipment. We also strongly recommend

instructing other occupants in the vehicle to properly start and operate the generator. This prepares them if they need to operate the equipment in an emergency.

OPERATION AND MAINTENANCE

It is the operator's responsibility to perform all safety checks; to make sure that all maintenance for safe operation is performed promptly; and to have the equipment checked by an Authorized Dealer periodi cally. Normal maintenance service and replacement of parts are the responsibility of the Owner/Operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty.

Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of your recreational vehicle generator assures a minimum number of

problems and keeps your operating expenses at a minimum. See your authorized Dealer/Distributor for service aids and accessories.

HOW TO OBTAIN SERVICE

When your recreational vehicle generator set requires servicing or repairs, simply contact an Authorized Service Facility for assistance. Service technicians are factory-trained and are capable of handling all of your service needs.

When contacting an Authorized Service Facility or the factory about parts and service, always supply the complete model number and serial number of your

unit as given on its data plate. The warranty on your generator is included in this

Owner's Manual, as well as listings for repair parts.

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) ANSI 119.2-1975/NFPA 501C-1994 “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 3000 watts

(3.0 kW) from the NP-30G.

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.

SAFETY

Before using the generator set, carefully read GEN

ERAL SAFETY RULES inside the cover. Comply with these RULES to prevent accidents and damage to equipment and/or property. Generac suggests copy

ing and posting the GENERAL SAFETY RULES in potential hazard areas of the recreational vehicle. Safety should be stressed to all operators of this equipment.

GENERATOR AC CONNECTION

SYSTEM

This air-cooied NP Series generator can power 120volt, single phase, 60 Hertz AC loads. The diagram below is a simple schematic (Figure 1) of the genera tor's AC connection system.

Figure 1 — Connection for 120 Volts Only

____

BU\CK I

120 Volts

______

WHITE

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 enoine-generator has operated, in hours and tenths of hours. Use the hourmeter along with the periodic maintenance schedule for your generator set.

AUTOMATIC CHOKE

The engine is equipped with an automatic choke that

consists of two main components — choke solenoid and prechoke.

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 recommended oil may result in engine failure.

FUEL SUPPLY

The engine must have adequate supply of proper fuel to operate. Before starting, check that sufficient fuel is available.

NOTE: On some installations, the generator engine may “share” the vehicle’s gasoline fuel tank with the

vehicle engine. Some installations may provide sepa

rate fuel tanks for generator and vehicle engine.

■ COOLING AND VENTILATING AIR

Air inlet and outlet openings in the generator compart

ment must be open and unobstructed for continued

proper operation. Without sufficient cooling and venti

lating air flow, the engine-generator quickly overheats, which causes it to automatically shutdown. Overheating could also damage the unit or your vehicle.

— 5 —

ENGINE EXHAUST GAS

Before starting the generator engine, you should be sure there is no way for exhaust gases to enter the

vehicle interior and endangering people or animals. Close windows, doors and other openings in the vehi cle that, if open, might permit exhaust gases to enter the vehicle.

DANGER; The generator engine gives off deadly carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient con centrations, can cause unconsciousness or even death. Do not operate the generator if its exhaust system is leaking or has been damaged. Symtoms of carbon monoxide poisoning are (a) inability to think coherently, (b) vomiting, (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

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 CFF loads

by setting the panel’s main breaker to the “CFF” 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 longer than 15 seconds may damage the starter motor.

3. Let the engine run at no-load for a few minutes to stabi lize and warm up the engine.

4. Turn ON electrical loads, using whatever means provided (such as a main circuit breaker or transfer switch).

NOTE: If you start a warm generator engine, you may press the start switch only slightly to engage the ignition system. However, you should press and hold the starter switch for a minimum of two (2) seconds to energize the field boost system. If you start the engine without energizing the field boost system, the generator produces rfo AC output.

STOPPING THE GENERATOR

1. Turn OFF all electrical loads, using whatever means pro vided (such a main circuit breaker or transfer switch).

2. Let the generator run at no-load for a few minutes, to sta bilize internal engine-generator temperatures.

3. Place start/stop switch in its STOP position.

APPLYING LOADS TO GENERATOR

When applying electrical loads to the generator, observe these guidelines:

• Before applying electrical loads, let the generator stabilize and warm up for a minute or two.

• DO NOT overload the generator.

■ LEHING ENGINE STABILIZE

The generator supplies correct rated frequency and

voltage only at the proper governed speed. Some

electrical appliances may be extremely sensitive to voltage and frequency. Incorrect frequencies and/or voltages can damage those appliances.

If electrical loads are applied at reduced operating

speeds, such loads imposed on the engine when suf ficient power is not available may shorten engine life.

Never turn ON electrical loads until after the genera tor engine has started and stabilized ON-speed.

_____________

ATTENTION REQUIRED AFTER

SUBMERSION

If the motor home generator has been submerged in

water, it must NOT be started or operated. Following

any submersion in water, have an authorized Generac

Service Facility thoroughly clean and dry the generator.

OPERATION IN HIGH GRASS OR BRUSH

Never operate the generator while the vehicle is parked in high grass, weeds, brush or leaves. Such rnaterials 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 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.

EFFEaS OF MOISTURE AND DIRT

Keep the generator set as clean and dry as possible. Protect unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings.

When moisture is allowed to remain in contact with windings, some of the moisture will be retained in voids and cracks in the insulation. This causes a reduced insulation resistance and will eventually cause problems. Dirt will make the problem worse, since dirt tends to hold moisture in contact with wind ings. Salt (as from sea air) will also worsen the prob lem since it tends to absorb moisture from the air. Salt and moisture, when combined, form a good electrical conductor.

DO NOT OVERLOAD THE GENERATOR

You can read the rated wattage/amperage capacity of your generator on the generator data decal (see “Identification Record” on Page 1).

Applying electrical loads in excess of the unit’s rated capacity will cause the engine-generator to automati cally shutdown.

To avoid overloading, add up the wattage of all con nected electrical lighting, appliance, tool and motor loads. This total should not be greater than the gener ator’s rated wattage capacity.

• Most lighting, appliance, tool and motor loads indicate their required watts on their nameplate or data plate. For light bulbs, simply note the wattage rating of the bulb.

• If a load does not show its rated wattage, multiply that load’s rated VOLTS times AMPS to obtain WATTS.

• Induction type motors (such as those that run the vehicle’s furnace fan, refrigerator, air conditioner, etc.) need about 2-

1/2 times more watts of power for starting than for running (for a few seconds during motor starting). Be sure to allow for this when connecting electrical loads to the generator.

First, figure the watts needed to start electric motors in the system. To that figure, add the running wattages of other items that will be operated by the generator.

• On a new generator do not apply heavy electrical loads for the first two or three hours of operation.

ENGINE PROTECTIVE DEVICES

This generator has a computer that monitors oil pressure, oil temperature, engine speed, and voltage output. This section discusses those protective devices.

AUTOMATIC LOW OIL PRESSURE SHUTDOWN

The engine is equipped with an oil pressure sensor that shuts down the engine automatically when oil pressure is too low. If the engine shuts down by itself and the fuel tank has enough gasoline, check the engine oil level.

■ INITIAL STARTUP

During initial startup, a time delay built into the shut down control system allows oil pressure to build. The delay allows the engine to run for about 10 seconds before sensing oil pressure.

■ SENSING LOW PRESSURE

If the system senses low oil pressure during operation, the engine shuts down. If you do restart the engine after a low oil pressure shutdown and have not correct ed the oil level, the engine runs for about 10 seconds as described above then stops.,

HIGH TEMPERATURE SHUTDOWN

A temperature switch with normally-open (N.O.) con tacts is mounted near the oil filter. If the temperature were to exceed a preset temperature, the switch con tacts close and the engine shuts down.

_____________________

___________

OVERSPEED

If engine speed is increased manually (or otherwise) beyond the control of the computer control system, the computer disables the load capability of the generator and shuts down the engine.

WARNING: Do not attempt a manuaUadjustment to control the engine speed. Equipment damage or personai injury may result.

LOW VOLTAGE

The computer monitors the voltage output of the gener

ator. If voltage sensors indicate that voltage has dropped below a preset level, the engine will automati cally shut down. Once the unit has shutdown, the com

puter is automatically reset when you restart the

engine.

NOTE: The computer allows for the low voltage output that occurs during startup. A time delay that allows the engine to start and warm up is programmed into the

monitoring system.

CAUTION: Before restarting a generator that has been shutdown, disconnect all loads the generator might power by whatever means provided, such as the recreational vehicle’s main circuit breaker.

— 7 —

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 tank during storage. Do NOT use any gasoline containing methanol. If you use gasoline with alcohol, inspect more frequently for fuel leaks and other abnormalities.

FUEL CONSUMPTION (IN GALLONS PER HOUR):

LOAD GASOLINE

HALF

FULL

0.13

0.20

0.40

ENGINE OIL REQUIREMENTS

Use only high quality detergent oil rated with API ser vice classification SF, SG or SH. The recommended oil weights include the following:

• During summer months; SAE 30. An acceptable substi

tute is SAE 10W-30. ' During winter months;

10W-40.

Crankcase and oil filter capacity is about 950ml or about 1 U.S. quart. Use no special additives. See “Maintenance” section for oil level check and fill pro cedures.

SAE 5W30. DO NOT USE SAE

GENERATOR SPECIFICATIONS

Model................................................................NP-30G

Rated Maximum Continuous

AC Power Output........................3000 watts (3.0 kW)

Rated Voltage Rated Maximum Continuous

Current at 120 volts...............................25 AC amperes

Phase........................................................Single Phase

Rated AC Frequency...........................................60 Hz.

Recommended Battery Cranking Current

...........................................

120 volts AC

400AMPS

ENGINE SPECIFICATIONS

Type of Engine............................GN-220

Cooling Method

Displacement..............................220cc

Type of Governor........................Electronic

Air Cleaner

Starter

.........................................

Ignition System Recommended Spark Plugs

Champion

Spark Plug Gap

..........................

..................................

...........................

................................

..........................

Air-cooled

Paper element 12 volt DC electric Solid state

RC12YC

0.030 inch (0.8mm)

8 —

MAINTENANCE

This section includes information about simple main tenance which includes the following tasks:

• Checking engine oil level.

• Changing engine oil.

• Changing oil filter.

• Changing the air cleaner.

• Cleaning the air intake screen.

• Cleaning spark plug.

• Cleaning fuel filter.

CHECKING ENGINE OIL 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.

NOTE: See “Engine Oil Requirements” on Page 8 for recommended oils.

Figure 3 — Oil Dipstick and Fill Tube

Install and tighten dipstick cap before operating engine.

Figure 4 — Location of Oil Drain Plug and Filter

CHANGE OIL FILTER

Replace the engine oil filter after the first 8 hours of

operation, every 50 operating hours thereafter.

• Turn oil filter counterclockwise to remove (Figure 4).

• Coat gasket of new filter with engine oil.

• Turn new filter clockwise until its gasket contacts lightly with the filter adapter. Then tighten with an additional 3/4 to one turn by hand.

• Run engine and check for leaks. NOTE: Check the oil level and fill to FULL mark on

dipstick after checking for leaks. The filter will retain some oil.

CHANGE ENGINE OIL

Change engine oil after the first 8 hours of operation.

Thereafter, change oil every 50 operating hours.

Change oil more frequently if operating consistently under heavy load or at high ambient temperatures.

• Warm up engine for at least five minutes, then shut down.

• With engine still warm from running, clean area around oil drain plug and remove oil drain plug (Figure 4). Drain oil completely into a suitable container.

• When oil has drained, install and lighten drain plug.

• Remove oil dipstick and fill crankcase with the recom mended oil (See Page 8). The engine crankcase can hold about 1 quart (950ml). DO NOT FILL ABOVE “FULL" MARK.

ENGINE AIR CLEANER

Paper Filter: Once every 25 operating hours or once each year (whichever comes first), clean or replace the paper filter (Figure 5). Follow these steps:

• Remove air cleaner cover, then remove paper filter.

• Clean air filter by gently tapping it on a solid surface. If the filter is too dirty, replace it with a new one. Dispose of the old filter properly.

• Clean air cleaner cover then insert new paper filter into cover and assemble them to the base of the air cleaner.

Figure 5 — Engine Air Cleaner Assembly

PAPER FILTER

— 9 —

CLEAN AIR INTAKE SCREEN

Clean all foreign material from the air intake screen

(Figure 6) at lease once every 100 hours of operation.

Clean more often if necessary.

Inspect the area around the generator exhaust muffler periodically and remove all grass, leaves, dirt, etc. from this area.

ENGINE SPARK PLUG

Clean or replace engine spark plug and set gap to

0.030 inch (0.76mm) every 100 hours of operation (Figure 6). Clean by scraping or wire brushing and washing with commercial solvent. DO NOT BLAST CLEAN SPARK PLUG.

Figure 6 — Setting Gap on Spark Plug

CAUTION! Do NOT use a forceful spray of water to clean the generator. Water will enter the generator interior and cause problems, and may also conta minate the generator fuel system.

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.

_____________

_________

SET PLUG GAP AT 0.030 inch

CAUTION: Sparking can occur if wire terminal does not fit firmly over spark plug terminal end. If necessary, reform wire terminal to obtain a tight fit.

FUEL FILTER

Remove and replace fuel filter (Figure 7) every 100 hours of operation or once each year, whichever occurs first.

Figure 7 — Fuel Filter

■ EVERY SIX MONTHS

Have the battery state of charge and condition

checked by an automotive service facility. This should

be done with an automotive type battery hydrometer.

DANGER: Storage batteries give off explosive hydrogen gas. This gas can form an explosive mixture aroung the battery for several hours after cahrging. The slightest spark can ignite gas and cause an explosion. Such an explosion can shat ter the battery and cause blindness or other injury. Any area that houses a storage battery must be properly ventilated. Do not allow smoking, open fiame, spards or any spark producing tools or equipment near the battery.

DANGER: Battery electrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, clothing, painted surfaces, etc. Wear protec tive goggles, protective clothing and gloves when handling a battery. If you spill the fluid, flush the affected area immediately with clear water.

__________________

CLEANING THE GENERATOR

Keep your generator set as clean and dry as possible. Dirt and moisture that are permitted to accumulate on electrical windings have an adverse affect on the insulation resistance of those windings.

Moisture that is allowed to remain in contact with windings will be retained in voids and cracks of the windings. Dirt makes the problem worse, since it tends to hold the moisture into contact with the wind ings. Salt, as from sea air, worsens the problem since it tends to absorb moisture from the air. The combina tion of salt and moisture makes a good electrical con ductor.

— 10 —

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.

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.

THROmE LINKAGE ADJUSTMENT

If needed, you can adjust the length of the linkage rod

between the electronic governor lever arm and the carburetor throttle lever arm. This adjustment helps to

establish the proper travel relationship between the two lever arms. If this adjustment is not properly set, the computer will NOT have control of the full range of

engine speed. If the rod adjustment is set too short, the computer will not have access to wide open throt tle or “full power” conditions. If the rod adjustment is

set too long, the computer will not have access to closed throttle or “no power” conditions.

Use the following procedure to assure the linkage rod

is properly adjusted:

1. Start the generator, then shut it down right away. As the engine coasts to a stop, observe from above the engine as the throttle lever on the carburetor rotates counter clockwise.

2. There should be a gap of 0.003 inch (0.08-0.5mm) between stop tab on throttle lever arm and the stop block on the carburetor die casting (Figure 8).

Figure 9 — Adjusting Throttle Linkage

4. Release spring clip so you can secure adjustment. This allows the carburetor and the electronic governor to be synchronized.

Figure 8 — Gap Between Stop Tab and Stop Bloc

CAUTION: Do not overbend the spring clip or the clip will lose its clamping force.

3. With pliers, lightly compress the spring clip on the carbu retor lever arm. This allows the linkage rod to slide freely through the clip. While the clip is compressed, rotate the throttle lever in the appropriate direction to increase or decrease the gap until there is 0.003 inch (0.08-0.5mm) clearance (Figure 9).

ADJUSTING THE CARBURETOR

The carburetor of your generator is preset at the factoiy. The carburetor should not be tampered with, as this will void the emission control system warranty. If your generator is used at altitudes in excess of 5000 feet, consult your Generac Authorized Service Facility

regarding high altitude jetting changes.

ADJUSTING VALVE CLEARANCE

After the first 50 hours of operation, you should adjust

the valve clearance in the engine. When adjusting valve clearance, the engine should

be at room temperature and the piston should be at

Top Dead Center (TDC) of its compression stroke

(both valves closed). Correct clearance Is 0.001-

0. 003 inch (0.03-0.07mm). Adjust valve clearance as follows:

1. Loosen the rocker arm jam nut. Use an alien wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge (Figure 10 on page 12).

—11 —

Figure 10 — 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 11).

Figure 11 — Tightening Jam Nut

Tighten Jam Nut to

65-85 inch-pounds

(7-10 N-m)

MAJOR SERVICE MANUAL

To obtain a service manual for your generator, order it from your dealer/distributor or contact the factory. Be sure to identify your unit’s MODEL NUMBER and SERIAL NUMBER.

EXERCISING THE GENERATOR

Generac recommends that you start and operate the

generator at least once every seven days. Let the unit

run for at least 30 minutes to “exercise” the engine.

OUT OF SERVICE PROTECTION

If you cannot exercise the generator every seven days and it is to be out of service longer than 30 days, prepare the generator for storage as follows:

• Start the engine and let it warm up.

• While the engine is 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 opening. Crank engine several times to distribute oil, then install and tighten spark plug.

• Remove the battery and store In a cool, dry room on a

wooden board. Never store the battery on any concrete or dirt floor.

• Clean and wipe the entire generator.

RETURN UNIT TO SERVICE

AFTER STORAGE

To return the unit to service after storage, proceed as follows:

• Check tag on engine for oil viscosity and classification.

Verify that the correct recommended oil is used in engine. If necessary, drain and refill with proper oil.

• Check battery. Fill all cells to the proper level with distilled

water. DO NOT USE TAP WATER IN THE BATTERY. Recharge battery to 100% state of charge, or, if defective, replace the battery.

• Turn OFF all electrical loads, then start the engine.

• Let engine warm up.

• Apply electrical loads to at least 50% of the unit’s rated

wattage capacity.

• When engine is thoroughly warmed up, shut it down. THE GENERATOR IS NOW READY FOR SERVICE.

SERVICE DEALER LOCATION

TO LOCATE THE NEAREST GENERAC SERVICING DEALER, PLEASE CALL OUR 800 NUMBER.

ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER.

1-800-333-1322

INSTALLATION SAFETY RULES

DANGER: FOR FIRE SAFETY, INSTALLATION OF A GENERATOR INTO A RECREATIONAL

VEHICLE MUST COMPLY STRICTLY WITH ARTICLE 551, NFPA 70; ANSI C1-1975; AND,

ANSI All9.2-1975/NFPA 501C “STANDARD FOR RECREATIONAL VEHICLES" (PART 3,

“INSTALLATION OF ELECTRICAL SYSTEMS"). IN ADDITION, THE MANUFACTURER'S

INSTRUCTIONS AND RECOMMENDATIONS MUST BE COMPLIED WITH.

NOTICE TO INSTALLER

The Installation Instructions have been published by

Generac Corporation to aid in the installation of the products described in this manual. Generac assumes

that installation personnel are familiar with the proce

dures for installing such products, or similar products that Generac manufactures. Generac also assumes that personnel have been trained in the recommend

ed installation procedures for these products and that

such training includes (a) use of common hand tools,

(b) use of special Generac tools, and (c) use of any tools and/or equipment from other suppliers.

We could not possibly know of and advise the recre ational vehicle trade of all conceivable methods, pro cedures or techniques by which to perform an installa tion. We could not know of the possible hazards that

might result from each installation method, procedure

or technique. We have not undertaken any such wide

evaluation. Therefore, people who use a method, pro

cedure or technique that Generac does not specifically

recommend must first completely satisfy themselves that their safety, the safety of the vehicle's occupants

and the products's safety is not endangered by the

method, procedure or tecnnique selected.

Information, illustrations, specifications, etc., con tained in this Installation Manual are based on the lat

est information available at the time of publication.

Every effort has been expended to be sure that such

data is both accurate and current. However, the man

ufacturer reserves the right to change, alter or other

wise improve this product at any time without prior

notice.

SAFETY RULES

Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE. Do not permit smoking, open flame, sparks or any source of heat in the vicinity while handling gasoline. Comply with all laws governing the storage and handling of gaso line.

Fuel lines must be properly installed, properly fastened and free of leaks. There must be no possibility of gasoline vapors entering vehicle interior.

You are required to install an approved, flexible, non-conductive fuel line between the generator fuel connection point and rigid fuel lines.

If the generator is converted to a liquid propane (LP) gas fuel system, install the unit so it com plies with all codes, standards and regulations pertaining to such systems. LP gas is highly explosive. The gas tends to settle in low areas where even the slightest spark can ignite it and cause an explosion. Do not allow gas vapors to enter the vehicle.

Engine exhaust gases contain DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause uncon-

sciousness or even death. Install the exhaust

system in strict compliance with applicable

codes, standards and regulations. There must be

no possibility for exhaust gases entering the vehi

cle interior and endangering people or animals. The generator set produces dangerously high

electrical voltage. Contact with bare wires, bare

terminals, etc., will result in extremely hazardous

and possibly lethal electrical shock. All applicable electrical codes, standards and

regulations must be strictly complied with in the installation and use of this equipment.

The generator must be properly grounded (bond

ed) to the vehicle chassis or frame. If the vehicle electrical circuits can be powered by

any other source of electricity (such as a “dockside” power receptacle), there must be no possibil ity of connecting the different power sources to the vehicle circuits at the same time. The “dockside" (utility) power source must be positively isolated

from the vehicle circuits whenever the generator is

operating. Failure to isolate the vehicle circuits

from the dockside power supply when the genera

tor is running may result in damage to the genera tor or serious injury or death to dockside (utility) power workers oue to backfeed of electrical ener

gyNever work on the equipment while standing in

water, while barefoot, or while hands or feet are wet. Dangerous electrical shock will result.

Jewelry conducts electricity, which can cause dangerous electrical shock. Remove all jewelry (such as rings, watches, or bracelets) before working on this equipment.

The generator requires an adequate flow of air

‘for cooling and ventilation. Without sufficient cool

ing air flow, the engine-generator quickly over heats, which causes serious damage to the gen erator, a fire or an explosion. Generator air inlet and outlet openings must be provided in strict compliance with the manufacturer's recommen dations.

Never work on this equipment while physically or mentally fatigued. Stay alert at all times.

Storage batteries give off EXPLOSIVE hydrogen gas while charging. The battery used for cranking and starting this generator should be installed in its own vented compartment. Provide adequate ventilation for the battery, to prevent explosive hydrogen gas from accumulating.

Never insert any tool or other object through

k openings in the generator interior, even if the unit

is not running. You might seriously injure yourself

or damage the equipment. Staying alert and using “common sense” are

major measures for preventing accidents.

— 13 —

GENERAL INSTALLATION INFORMATION

PURPOSE AND SCOPE OF MANUAL

These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the pro duct's installation requirements. Give serious consid eration to all information and instructions in the Manual, both for safety and for continued reliable

operation of the equipment. Because of the different recreational vehicle models

and the variations between the models, it would be extremely difficult, if not impractical, to provide detailed instructions on every installation possibility. For that reason, instructions and illustrations in this manual are general in nature. Illustrations are not intended to serve as detailed installation blueprints.

The installation should comply strictly with all applica ble codes, standards and regulations pertaining to the installation and use of this product. If any portion of this manual appears to be in conflict with such codes, standards or regulations, the applicable codes, stan dards or regulations must take precedence over the manual.

SAFETY

Before handling, installing, operating or servicing this equipment, be sure to read carefully the “Notice to Installer” and “Safety Rules” at front of this manual. Comply with all SAFETY RULES to prevent death, personal injury or damage to equipment and/or prop erty. Stress safety to all installers, operators and ser

vice technicians who work on this equipment.

STANDARDS BOOKLETS

Installation, use and servicing of this equipment should comply strictly with published standards, as well as the manufacturer's recommendations. The fol lowing standards booklets (latest revision) are avail able from the sources indicated:

1. NFPA Standard 501C, “Standard for Recreational Vehicles”, available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

2. NFPA 70, “NFPA Handbook of the National Electric Code”, obtained from same address as Item 1.

3. ANSI CM 975 and ANSI 119.2-1975, available from the

American National Standards Institute, 1430 Broadway,

New York, NY 10018.

4. ANSI A119.2/NFPA 501C, available from the Recreational Vehicle Association, 1896 Preston White Drive, Reston, VA 22090.

5. California Administrative Code, Title 25, available from

the State of California, Documents Section, P.O. Box

1015, North Highlands, CA 95660.

6. CSA Electrical Bulletin 946, available from the Canadian

Standards Association, Housing and Constructions

Materials Section, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R3.

EQUIPMENT DESCRIPTION

Instructions and information in this section pertain to Generac air-cooled generators — more specifically, the installation of NP30 recreational vehicle genera tors. These generators are designed specifically for installing in recreational vehicles.

ENGINE GENERATOR

OPERATING SPEED

The generators are driven by single-cylinder engines. The engines drive revolving fields (rotors), high fre quency, permanent magnet alternators. The genera tors supply 120 volts AC at 60 Hertz. The generators revolving fields are driven at a variable speed depending on the instantaneous demand for power. Computers monitor that demand and adjust the engine speed to provide adequate power to the con nected loads.

GENERATOR AC CONNEaiON

SYSTEM

The generators are equipped with single voltage AC connection systems. The following facts pertain to such a connection system:

• On the units, the 120 volts, connections system is pro tected by a circuit breaker.

• The AC connection system on all air-cooled generators use a GROUNDED neutral.

• A separate green ground wire is connected to the recre ational vehicle's junction box.

—14 —

LOCATION AND SUPPORT

GENERATOR LOCATION

The most desirable location for the generator set is

between the vehicle's main frame members However,

this is seldom possible. Most units must be installed

on the side of the vehicle and are difficult to reinforce. Many recreational vehicles have been factory

equipped with an area for the generator set. Some vehicles may even have a generator compartment, provided by the vehicle manufacturer.

Plan the generator location based on the following:

• The generator set must be installed on a framework that is part of the recreational vehicle, as outlined in the para graph entitled “Generator Support."

• The location must provide an access opening that is large enough to permit generator removal (unless the genera tor is to be removed from underneath the supporting framework.

• The location must provide easy access to frequently ser viced components, such as filters, oil drain, spark plug and other common maintenance parts.

• The location must provide sufficient room to allow mini mum clearance of at least 1 inch (2” recommended) between all sides and 1 inch (2" recommended) on top of the generator. If sound insulation is to be used on com partment walls and ceiling, the minimum recommended applies to the space between the generator and such insulation,

• The location must provide adequate cooling and ventilat ing air flow for the generator without a great deal of work and expense.

GENERATOR SUPPORT

The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding. The metal framework on which the generator will rest and which

will restrain the generator set should consist of at least two horizontal beams. These beams should con sist of (a) 1-1/2 inch square, 11 gauge steel tubing OR (b) 1-1/2 inch, 11 gauge angle iron. A typical sup porting frame with horizontal support tubing, is shown in Figure 12.

The generator can be installed so that it sits on top of the horizontal support tubing, if the vehicle design permits. Another method is to suspend the generator below the horizontal support tubing by means of suit able, structurally sound metal framework. The follow ing general rules apply:

• Vehicle construction MUST be capable of supporting the weight of the generator.

• Whether the generator is mounted above the horizontal support tubing or suspended below the tubing, the sup porting frame used must be structurally sound.

• If the generator cannot be bolted directly to the support ing frame or support tubing, consider using additional tubing, angle brackets or other supports to give the sup porting frame sufficient strength.

SUSPENDED MOUNTING

If you are going to suspend the generator below the horizontal support tubing, the suspension method you use with the vehicle frame members must have the following: (a) be able to support the weight of the gen erator; and (b) provide sufficient restraint for the gen erator. One typical suspended mounting system is shown in Figure 13. The location of a suspended mounting system must be carefully planned, keeping the following general rules in mind:

• Protect the generator against road splash and debris.

Baffles or splash guards may be required to protect cer tain areas of the generator. To make sure the generator is adequately protected, road test the installation through mud, water and slush.

Figure 13 — Typical Suspended Mounting System

Figure 12 — Typical Horizontal Support Frame

permit adequate cooling and ventilating air flow to be supplied.

—15-

GENERATOR RESTRAINT

Use four 3/8"-16 hardened steel bolts (Grade 5) to fasten the generator to the supporting frame or the support tubing. These bolts must pass through (a) the generator mounting base, (b) the corripartment floor, if a compartment is used, and (c) the supporting framework (Figure 14). All bolts must be long enough so that when tight, at least 3 threads are visible past the retaining lock nuts. Refer to “COMPARTMENT” section for location of generator mounting holes.

GENERATOR COMPARTMENTS

Fig ure 14 — Typical Generator Restraint

COMPARTMENTS

The generator set may or may not be installed inside a compartment that is constructed specifically for housing a generator. This section applies to generator compartments when they are installed. The following general rules apply to compartments;

• The generator compartment should be either constructed of, or lined with, 26 gauge galvanized steel.

IMPORTANT; ALUMINUM IS NOT AN ACCEPT

ABLE ALTERNATIVE TO GALVANIZED STEEL,

DUE TO ALUMINUM'S LOW MELTING POINT.

• If the compartment is lined with galvanized steel, it may be constructed of any material. Generac recommends that the compartment be construct ed of 1/2-inch thick plywood, with the floor made of a double thickness of plywood for added strength.

• All seams, splices and joints of the compartment walls (unless vapor tight by design) should be caulked.

Figure 15 — Types of Lock Seams

IMPORTANT; CAULKING MUST BE DONE SO

THAT THE CAULKING MATERIAL WILL STAY IN

PLACE PERMANENTLY. PRESSING SUCH MATE RIALS AS PUTTY TAPE ONTO JOINTS AND SEAMS WILL NOT MEET THAT REQUIREMENT. A HIGH QUALITY SILICONE RUBBER SEALANT IS RECOMMENDED.

• Holes and openings through the compartment walls for passage of electrical conduit, conduc tors, etc, into vehicle living area must be sealed vapor-tight with silicone rubber base sealant.

• If you use flexible metal conduit, seal the conduit

at the end where it terminates inside the junction box. Flexible metal conduit is NOT vapor tight along its entire length.

• Seams and joints of the galvanized steel

(whether used as a liner or the compartment itself) must be lapped and mechanically secured.

Such seams may be manufactured, welded, bolt ed, riveted, or screwed. Manufactured lock seams are shown in Figure 15.

-ML IT

FOLD LOCKED STANDING

GOBDON SEAM

DOUBLE LOCK DOUBLE SEAM

HZI

STANDABO LAP JOINT

— 16 —

ACME LOCK

OFF SET

LOCK SEAM

COMPARTMENT SIZE

Plan the compartment size carefully. Provide a mini mum of at least 1 inch (2” recommended) of clearance between the generator and compartment walls and

1 inch (2” recommended) of clearance between the generator and the ceiling AFTER you have lined the compartment with metal, and AFTER you have

installed sound insulation (Figure 16).

NOTE: Refer to the “Dimensions and Features" draw

ing in the back of this manual.

Figure 16 — Provide Clearance Around Generato

PLYWOOD

COMPARTMENT

11NCH MINIMUM CLEARANCE ON ALL SIDES (Z" RECOMMENDED)

riTliVCl

1 INCH MINIMUM

TOP VIEW OF

GENERATOR

CLEARANCE ABOVE GENERATOR (2” RECOMMEND ED)

METAL UNING-

INSULATION

COMPARTMENT CONSTRUCTION

The generator compartment should be constructed of 1/2

inch thick plywood. Make the compartment floor a double

thickness of 1/2 inch plywood with the grain of the wood

at cross section for added strength (Figure 17).

Figure 17 — Typical Compartment Construction

• Vapor seal all compartment seams and joints, to prevent poisonous, flammable or explosive vapors from entering the vehicle interior. Refer to the sealant information as noted below.

NOTE: Silicone rubber base sealant is an acceptable caulking material. Pressing putty tape onto compart ment joints and seams is NOT acceptable.

• After the compartment has been metal lined and vapor sealed, line the compartment interior walls and ceiling with an approved, non-flammable sound insulating mater ial. See “Sound Insulating Materials.”

DANGER: Do not install sound insulation or any absorbent material on the compartment floor inte

rior. Such materials will become soaked with com bustible or explosive vapors and liquids and will become a fire hazard.

• Openings in compartment walls for passage of electrical conduit, conductors, hoses, cables, etc., must be made vapor tight with suitable caulking material.

• Flexible conduit must be sealed internally at the end where it terminates inside a compartment's electrical

junction box.

NOTE: The preceding is required because flexible conduit, due to its unique construction, is not vaportight along its entire length.

DANGER: Do not install any flammable material directly above or around the compartment. Heat,

transferred through the compartment structure, may be sufficient to ignite, char or discolor seat cushions, fiberboard and other flammable materi als. You may need to use approved non-flammable insulating materials in high temperature areas.

Line the entire compartment interior with 26 gauge galva nized steel as described above.

Line the exterior (underside) of the compartment floor with 26 gauge galvanized steel.

— 17 —

SOUND INSULATING MATERIALS

Once installers have determined that compartments are properly constructed and metal lined, they can add acoustical material. This may include additional sealant or insulating material, to reflect noise away from the vehicle interior.

Sound insulating materials should be of a non-flam

mable type. One excellent insulating material is a 1

inch thick fiberglass having a 2-pound density. When fiberglass is used, its coated side should face toward the compartment interior.

Using a combination of sound insulating materials can often reduce noise more effectively than a single material. For example, a sheet of lead or visco-elastic material, along with a layer of other acoustical materi al, is more effective than when a single material is

used.

COMPARTMENT FLOOR CUTOUTS

You must provide openings in the generator compart ment for the following items (Figure 18):

• Engine exhaust and cooling air outlets

• Generator cooling air inlet

• Four holes for passage of generator mounting bolts. See “Generator Restraint” on Page 16.

DANGER: Fuel lines and exhaust piping must not penetrate into vehicle living area.

ACOUSTICS

If excessive noise levels should become a problem,

the installer may wish to consider the following:

• Using special sound insulating materials.

• Construction of a special noise abatement compartment.

IMPORTANT: ANY METHOD USED TO REDUCE NOISE MUST NOT ADVERSELY AFFECT THE FLOW OF COOLING AND VENTILATING AIR INTO OR OUT OF THE COMPARTMENT.

In addition to the effective use of sound insulating materials, construction of a special noise abatement

compartment might be considered to reduce noise

levels. Such a compartment might be constructed as

follows (Figure 19):

• Use 5/8-inch thick or 3/4-inch thick plywood in the com partment.

• Construct the compartment floor of a double thickness of 5/8-inch or 3/4-inch plywood.

Line the compartment interior walls and floor, as well as

the underside of the floor, with 26-gauge galvanized steel. Vapor seal all compartment seams and joints. Over the galvanized steel lining, install a selected combi

nation of acoustical materials as mentioned in “Sound Insulating Materials.”

DANGER: Do not install any insulation or other absorbent materials on the interior or underside of the compartment.

Seal all compartment door edges to prevent noise leak age around the door perimeter.

Line the compartment door interior (except for air open ings) with suitable, fire proof sound insulation (such as 1inch thick fiberglass with a 2-pound density).

Figure 19 — Typical Noise Abatement

(vrav4'Tutao

masuM

USDUIUi

Figure 18 — Compartment Floor Cutout

COOLING AND VENTILATING AIR

It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be sup plied to the generator set. Without sufficient air flow, the engine-generator quickly overheats. Such over heating can cause serious operating difficulties and may also cause fire and personal injury. The installer must make sure that sufficient air is available to the generator for cooling, ventilating and combustion. The installer must also provide for a path for exhausting the cooling air to the exterior of a compartment, if so equipped.

DANGER: Never use discharged cooling air for heating or permit such air to enter the vehicle inte rior. This air contains deadly carbon monoxide gas and other poisonous, flammable or explosive gases.

GENERATOR AIR FLOW

Engine operation drives cooling fans for the 2-stage cooling air system. A pressure fan draws cooling air into the top of generator and into the side of the con trol panel (Figure 20). This air flow cools the enginegenerator and electronic components. The second part of cooling system, a suction fan, draws air that is heated from a hot engine into a collector pan at the base of the unit. This heated air (although cooler than exhaust muffler) is directed across the muffler to cool

it. The heated air flow is then deflected out the bottom toward the ground.

Figure 20 — Air Flow Through Engine-Generator

NOTE: Screening, louvers, or expanded metal that

cover air openings restrict air flow that you must com

pensate for by making the actual air opening propor

tionately larger. See “Compensating for Restrictions.”

Figure 21 — Air Inlet in Compartment Door

10 SQUARE INCHES (OPTIONAL OPENINGS)

40 SQUARE INCHES UNRESTRICTED (MINIMUM OPENING)

For conventional compartment mounted units, the air inlet is generally provided in the compartment door.

IMPORTANT: IF YOU PLAN TO INSTALL THE GEN ERATOR IN A COMPARTMENT, BE SURE TO LEAVE AT LEAST ONE (V) INCH OF CLEARANCE BETWEEN THE GENERATOR AND COMPART MENT WALLS AND CEILING. INCLUDE 26 GAUGE GALVANIZED STEEL LINING AND SOUND INSULA TION WHEN YOU MEASURE FOR THIS 1 INCH CLEARANCE.

When the unit is installed on a suspended mounting system, one of several different methods of supplying air flow may be used as follows:

• Provide a door in the vehicle skirt having an air inlet opening (Figure 22).

COOLING AIR INLET OPENINGS

Ideally, you should provide three air inlet openings, whether the generator is housed in a conventional compartment or not. Two of the openings should be 10 square inches and located as shown in Figure 21. The third opening should provide for a minimum of 40 square inches unrestricted and be located lower on the compartment door.

Figure 22 — Suspended Mount; Inlet Door

19 —

Using ductwork (Figure 23). The installer must be sure air is available to the top of the generator since air inlets are located at the top.

Figure 23 — Air Inlet Using Ductwork

above the generator for cooling air flow (Figure 24). Recommended clearance above the top of the generator is at least 2 inches.

Figure 24 — Air Inlet in Vehicle Skirt

COMPENSATING FOR

RESTRiaiONS

Such materials as screening, louvers, or expanded metal can restrict the free flow of air. Compensate for

this restriction by making the actual air opening pro

portionately larger. Some materials may offer only a 60 percent “free air

inlet area." Other more efficient materials may provide up to a 90 percent free air inlet area. The percentage

of free air inlet opening is usually available from the

material supplier or manufacturer.

TO DETERMINE THE ACTUAL AIR INLET OPEN

ING SIZE REQUIRED, DIVIDE 40 SQUARE INCHES BY THE PERCENTAGE OF FREE AIR INLET AREA FOR THE MATERIAL YOU WILL USE.

For example: If you plan to use screening with an

80% free air inlet area, divide 40 by 0.8, which results

in 50 square inches. Minimum actual size of air inlet opening in this case is 50 square inches. An opening that measures 4 inches wide by 12-1/2 inches long

provides the required air flow (4 x 12.5 = 50 square

inches).

TESTING THE INSTALLATION

Generac recommends testing the installation to be sure adequate cooling air flow is available to the unit

before placing the unit into service. If the unit shows signs of overheating, you will need to enlarge the air openings. Never place a unit into service until absolutely certain that cooling and ventilation is ade quate.

IMPORTANT: YOU MUST TEST THE INSTALLA TION ESPECIALLY IF YOU BRING IN AIR FROM

BELOW THE GENERATOR SET.

— 20 —

GASOLINE FUEL SYSTEM

Installing a gasoline fuel system (Figure 25) for recre ational vehicle generator sets must comply with

applicable codes, standards and regulations. The entire fuel system must be completely free of leaks. There must be no possibility of gasoline vapors enter

ing the vehicle interior.

Figure 25 — Generator Fuel System

FUEL INLET

CARBURETOR

DANGER: Gasoline is highiy fiammable and its vapors are explosive. Compiy with aii codes, stan dards and regulations pertaining to gasoline fuel systems used in recreational vehicle generators.

Properly install and maintain the fuel system and

keep it entirely free of leaks. Gasoline vapors must

not enter the vehicle interior.

Factory installed generator fuel system components include (a) fuel filter, (b) 12-volt DC electric pump, (c) engine carburetor, and (d) interconnecting lines and

fittings. Connect a fuel supply line to the fuel filter

inlet. Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines.

FUEL PUMP

FUEL TANK

Either the generator must share the vehicle engine's

fuel tank, or you must install a separate fuel tank for

the generator set. All fuel tanks installed on the vehi cle must be constructed, installed, and restrained so it

complies with applicable codes, standards and regu

lations.

If the generator is to share the vehicle engine's tank,

separate fuel pickup tubes are required for the engine

and the generator. Generac recommends that you

make the fuel pickup tube 2 to 3 inches shorter than the vehicle engine's pickup tube. This prevents the generator from depleting the entire fuel supply during

prolonged generator operating periods.

CAUTION: Do NOT tee the generator fuel supply line into the vehicle engine fuel supply line. If this

is done, the generator will be starved of fuel when both engines are operating at the same time. Also, while the vehicle engine is not running, generator operation may drain the vehicle engine supply line,

making it difficult to start the vehicle engine.

GENERATOR FUEL SUPPLY LINE

RIGID FUEL LINES

Those lines used to supply fuel from a tank to the generator must comply with applicable codes, stan dards and regulations. The following general rules apply to rigid fuel lines:

• Rigid lines should be of annealed, seamless, drawn alu minum or steel.

• Lines and fittings must comply with SAE J512F, “Standard Automotive Fittings”, or with ANSI B126.26 (latest edition).

• Route the fuel line so that at least 2 inches of clearance is maintained between the line and any exhaust system parts.

• Do not attach electrical wiring to fuel lines. Route the wiring so it cannot come into contact with any fuel line.

• Route fuel lines so if they leak, fuel does not drip onto any electrical or exhaust system parts.

• Use non-ferrous metal straps without sharp edges to secure fuel lines.

FLEXIBLE FUEL LINE

Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines. This prevents breaking of the line caused by vibration,

shifting, settling or movement. The following rules

apply:

• The flexible hose must comply with SAE J30B, “Standard

for Fuel and Oil Hose”. It must be approved for use with

gasoline.

• The hose should be at least 6 inches longer than is need

ed to prevent the hose from rupturing if the generator shifts or settles.

21 —

EXHAUST SYSTEM

The generator exhaust system must be safely and properly installed. Only approved mufflers and other exhaust system parts must be used. A properly installed exhaust system must be vapor tight, quiet and completely safe.

CAUTION: Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping. This causes excessive back pressure on the generator engine. Also, water from one engine can damage the other engine.

DANGER: The generator engine gives off deadly carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient con centrations, can cause unconsciousness or even death. Symptoms of carbon monoxide poisoning are (a) inability to think coherency, (b) vomiting, (c) twitching muscles, (d) throbbing in temples, (e) dizziness, (f) headache, (g) weakness and sleepi ness. If any of these symptoms are experienced, move into fresh air immediately. If symptoms per sist, get medical attention. Do not operate the generator until its exhaust system has been inspected and repaired.

MUFFLERS AND SPARK ARRESTORS

Exhaust mufflers and spark arrestors that Generac supplies meet code and standard requirements, and are approved by the U.S. Forest Service. Use only mufflers and parts approved by Generac. Any person(s) installing an unapproved muffler, or an unap

proved exhaust system part, or modifying an exhaust system in any way that might cause a hazard, is liable for any damage, injury or warranty expense that might be caused by such unapproved installation or modifi cation.

Failure to provide and maintain a spark arrestor may be in violation of the law. If this generator is used on any forest covered, brush covered, or grass covered unimproved land, you must provide a spark arrestor. The vehicle owner or operator must maintain this device in good condition. In the State of California, the preceding is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal laws apply on federal lands.

EXHAUST SYSTEM SAFETY

Maintain a clearance of at least 3 inches (76mm)

between exhaust system parts and any combustible

material (such as wood, felt, cotton, organic fibers or other like material). If you cannot maintain the 3-inch clearance, locate, insulate or shield the exhaust part(s) so that the temperature of any combustible material is not raised more than 117°F (65“C) above the ambient air temperature.

Extend the exhaust system at least one inch (25mm) past

the outer edge of the vehicle. Do not terminate the

exhaust system under the vehicle.

Terminate the exhaust tailpipe such that exhaust gases

will not be drawn back into the generator compartment and recirculated.

If there is any possibility of the tailpipe or muffler being damaged, protect these damage prone areas by means of a protective device (such as a “skid bar”).

Install the generator exhaust system according to safe automotive practices.

Use enough exhaust system hangers to prevent any part of the system from being dislocated.

Use exhaust system parts recommended by Generac. Using unapproved exhaust mufflers and exhaust system

parts is the responsibility of the person(s) installing such unauthorized parts.

Do not terminate the exhaust system under any opening,

window or vent which can be opened or is not perma

nently sealed from the vehicle interior. Exhaust piping must be large enough to prevent exces

sive back pressure on the generator engine.

Never tee the generator engine exhaust pipe into the

vehicle engine exhaust piping. This causes excessive back pressure on the generator engine. Also, wafer from one engine can damage the other engine.

Plan exhaust system installation carefully. Comply with all

applicable codes, standards and regulations.

Figure 26 — Exhaust System

TYPE OF EXHAUST SYSTEM

The NP-30G generator has a configuration for a bot tom out exhaust system and is equipped with such an exhaust muffler (Figure 26).

— 22 —

EXHAUST MUFFLER

ELECTRICAL CONNECTIONS

Be sure to read “Generator AC Connection System” on Page 4.

The following general rules apply to electrical connec tions in a recreational vehicle:

• Qualified electricians who are familiar with applicable codes, standards and regulations should install electrical wiring.

• The wiring should comply with codes, standards and reg ulations. The National Electric Code (NFPA 70), as well as state and local codes, apply.

• Switches and circuit breakers should be of a type approved

for use in recreational vehicles and must be mounted and installed to prevent damage from road shock.

• Wiring must be of adequate size, with approved insulative

qualities, and properly supported. Conduit and wire openings into generator compartment

(if used) must be vapor-sealed, to prevent entry of flam mable, explosive or poisonous gases into the vehicle.

ELECTRICAL JUNQION BOX

Install an approved, square electrical junction box that

has a blank cover on the interior or exterior wall of the area you plan to install the generator (NOT on the generator). Route the generator's AC output leads

into this junction box through approved flexible con duit. This is the point of first termination for generator AC output leads.

WIRING

• Wiring should be of stranded copper to reduce chance

that vibration may cause breakage.

• Wire gauge size of wires should be large enough to han

dle at least 115% of the installed generator's rated maxi mum current.

• If neutral conductors are used, they must be the same

size as other leg wires.

• Route power supply conductors from generator AC output

leads T1 (black) and T2 (white) and the green ground wire through approved flexible conduit to the electrical junction box on the compartment wall.

• If flexible metal conduit is used between the generator

and the compartment junction box, the conduit end that terminates the compartment junction box, must be vaporsealed. Flexible metal conduit is NOT vapor tight along its entire length.

• From the junction box route power supply wires through

approved conduit to either (a) double-pole, double-throw transfer switch, or (b) approved isolation receptacle. Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being con nected to two different power supplies at the same time (such as generator and dockside power).

• Conductors must be rated 221 °F (105°C) or must be of a larger conductor size.

GENERATOR AC CONNECTIONS

Generator AC output leads T1 (black) and T2 (white) come out of the generator as shown in Figure 27. Lead T1 (black) is “hot.” Lead T2 (white) is the “neu

tral” lead and is internally connected to ground. The

green lead (0) connects to ground in the junction box of the recreational vehicle.

Figure 27 — Generator AC Output Leads

Line T1 (black) is protected against overload by the circuit breaker (CB1). Use line T1-T2 to operate 120 volts, 1-phase, 60 Hz, AC loads.

CAUTION: Do NOT connect electrical loads in

excess of any circuit breaker rating or you will develop problems with circuit breaker tripping, which causes a loss of AC output. Also, do NOT exceed the generator's rated wattage capacity. Add the watts or amperes of all lighting, appliance, tool and motor loads the generator will operate at one time. This total should be less than the unit's rated wattage/amperage capacity.

CONDUIT

Route the conductors between the generator and the junction box through approved, flexible conduit. The following general rules apply:

• Cut wiring to the required length and allow extra wire tor junction box connections.

• Carefully prepare conduit ends, to prevent sharp edges from cutting through wiring insulation.

• Route conduit so it does not interfere with generator

movement.

• If you use metallic conduit, vapor seal the end of the con

duit where it enters the junction box. Do this because flexible metallic conduit is not vapor proof along its entire length.

— 23 —

ISOLATING DIFFERENT

GROUND FAULT CIRCUIT

POWER SOURCES

Conductors from the junction box must terminate in a double pole, double throw transfer switch (Figure 28). An alternate method for isolating different power sources is by using an isolating receptacle (Figure 29 on Page 25). Whichever method you use, you must be certain that both power sources are NOT connect ed at the same time.

POWER SUPPLY CORD

The power supply cord must comply with all applica ble codes, standards and regulations. It must be large enough to handle the full amperage to which it will be subjected.

Figure 28 — Transfer Switch Isolation Method

INTERRUPTERS

The National Electric Code (NFPA 70, 551-7) requires that you install ground fault circuit interrupters

(GFCIs) on all external and some internal electrical receptacles. Contact your manufacturer or dealer for recommendations.

24 —

Figure 29 — Installation with Isolation Receptacle

RECOMMENDED BAHERY

Install a battery that meets the following require ments:

• Battery must be a 12 volt, automotive type storage bat tery.

• For prevailing ambient temperatures above 32°F (0°C), use a battery rated 70 amp-hours and capable of deliver ing 360 cold cranking amperes.

• For prevailing ambient temperatures below 32®F (0°C), use a battery rated 95 amp-hours and capable of deliver

ing 450 cold cranking amperes.

IMPORTANT: IF THE BATTERY IS TO BE USED TO POWER OTHER VEHICLE ACCESSORIES, AS WELL AS START THE GENERATOR, YOU MAY NEED A BATTERY WITH A LARGER CAPACITY.

BATTERY INSTALLATION

BAHERY CABLES

Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes starting problems. For best cold weather starting, the voitage drop between battery terminals and the gen erator connection point should not exceed 0.12 volts per 100 amperes of cranking current.

Select battery cables based on (a) cable length, and (b) prevailing ambient temperatures. Generally, the longer the cable and the colder the weather, the larg er the cable size must be as shown in the chart below.

CABLELENGTH in Feet (meters)

0 to 10(0 to 3) 2*

11 to 15 (3.4 to 4.5)

16 to 20 (4.5 to 6)

‘For warm weather, use No. 2 cable up to 20 feet.

25 —

CABLE SIZE

000

BATTERY CABLE CONNECTIONS

1. Connect the battery cable from the battery post or termi nal indicated by a POSITIVE, POS or (+) to the large lug on the starter contactor as indicated in Figure 31.

2. Connect the battery cable from the battery post indicated by a NEGATIVE, NEG or (-) to the frame ground connec tion (Figure 30).

NOTE: If the generator compartment is grounded to the vehicle chassis, you need not connect a NEGA TIVE battery cable to the frame ground on the gener

ator base. Connect the negative cable to the frame

ground of the chassis.

3. Connect cables so the connectors are clean and tight.

Figure 30 — Connecting Battery Cables

BAHERY COMPARTMENT

Install the generator battery in its own, vented com partment. Place the battery compartment away from any source of heat, sparks or flame.

Provide ventilation openings in the battery compart ment. The minimum size of openings should be 2 square inches at the top of the compartment. Mount the battery on a strong, rigid supporting structure, where leaks and spills of battery fluid will not cause damage.

— 26 —

OPTIONAL ACCESSORIES

A plug-in receptacle (Figure 31) is provided on the gen erator set, near the AC connection wires. Use this receptacle to connect an optional remote-mounted start/stop panel to the generator. Installation of such a

panel will permit you to start and stop the generator

engine from any convenient location inside the vehicle.

Figure 31 — Remote Panel Plug-in Receptacle

REMOTE PANEL MODELS

■ MODEL 9042

This remote panel (Figure 32) mounts a rocker type

start/stop switch and a “Generator Run” advisory lamp. The lamp will turn on to indicate the engine is running.

__________________________

MODEL 9043

This panel mounts a rocker type switch, a “Generator

Run” lamp and an hourmeter (Figure 33). Use the hourmeter in conjunction with the periodic mainte nance schedule for your generator.

Figure 33 — Model 9043 Remote Panel

o o

GENERAC R.V. GENERATOR

OB\L Q RUN

TOTAL HOURS

STOP BTART

REMOTE PANEL CABLES

Interconnection cables are available from Generac for connecting the optional remote panels to the genera tor receptacle.

• To order a 10-foot long, 4-wire cable, specify Model 9045.

• To order a 30-foot long, 4-wire cable, specify Model 9046.

Figure 32 — Model 9042 Remote Panel

R.V.

— 27

POST INSTALLATION TESTS

The air cooled generator set was factory tested and adjusted using gasoline as fuel. You should not be required to adjust the unit any further except under special circumstances.

WARNING; Do not make any unnecessary adjust ments. Factory settings are correct for most appli

cations. When making adjustments, however, be

careful to avoid overspeeding the engine.

BEFORE INITIAL START UP

Before starting, complete the following:

1. Check engine crankcase oil level and, if necessary, fill to dipstick FULL mark with the recommended oil. Do not fill above FULL mark.

2. Check the fuel supply. Fuel lines must have been proper ly purged and leak tested in accordance with applicable

fuel-gas codes. All fuel shutoff valves in the fuel supply lines must be open.

DANGER: If an LP (propane) gas fuel system has

been installed, it must mave been properly tested for leaks before operating the system in compli ance with ANSI A119.2/NFPA 501C. No leakage is

permitted. You must be sure no gaseous fuel vapors enter the vehicle interior.

INITIAL START

When absolutely certain that the unit has been prop erly installed and prepared for use, start the engine as

follows:

1. Turn off all electrical loads. Do this by setting the genera tor main circuit breaker to the “OFF’ or “OPEN” position.

2. Refer to the Owner's Manual shipped with unit for crank ing and starting instructions. The engine may require more cranking for initial starting since the fuel lines have to be primed.

3. Let the engine warm up for about five minutes to allow internal temperatures to stabilize.

4. Carefully inspect the engine-generator for fuel, oil and exhaust system leaks. Before proceeding to the next step, correct any leakage immediately.

5. When all tests and adjustments at no-load are completed, apply electrical loads and check for proper operation under load. See “Testing Under Load". Run the unit at least 30 minutes with loads applied.

6. Turn off all electrical loads by setting the generator main circuit breaker to “OFF” or “OPEN.”

7. Let the unit run at no-load for a few minutes to stabilize internal engine-generator temperatures. Then, shut down the engine.

IMPORTANT: THE GENERATOR SET WAS THOR OUGHLY TESTED AND ADJUSTED AT THE FAC TORY BEFORE SHIPPING. NO ADDITIONAL ADJUSTMENT SHOULD BE NECESSARY. ONLY QUALIFIED SERVICE TECHNICIANS WHO HAVE BEEN TRAINED SHOULD PERFORM ADJUST MENTS OUTLINED IN THIS MANUAL.

TESTING UNDER LOAD

Apply electrical loads equal to about 75-100% of the unit's rated wattage/amperage capacity.

Let the unit run at least 30 minutes with load applied. During this part of the test, check that the unit is not running excessively hot and that adequate cooling air flow is available. You must not allow the unit to over heat during prolonged operation.

NOTE: The generator engine is equipped with a high temperature switch. The switch has normally-open (N.O.) contacts. When the temperature is too high, switch contacts close, and engine shuts down auto matically.

IMPORTANT: GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOLING.

— 28 —

INSTALLATION CHECK LIST

LOCATION AND SUPPORT

___

1. The NP generator is properly located.

___

2. The generator is properly supported.

___

3. The generator is properly restrained.

COMPARTMENT

___

1. Compartment construction is proper.

___

2. Holes/openings are vapor-sealed.

___

3. Compartment size is correct.

___

4. Compartment is vapor-sealed.

___

5. Sound insulation is O.K.

___

6. Floor cutouts properly completed.

COOLING and VENTILATING AIR

___

1. Air flow is adequate.

___

2. Air inlet opening is correct.

___

3. Compensate for restrictions

4. Installation has been tested

GASOLINE FUEL SYSTEM

___

1. Fuel tank complies with code.

___

2. Fuel system properly installed.

___

3. Fuel system checked for leaks.

ELECTRICAL CONNECTIONS

___

1. Comply with code requirements.

___

2. Junction box properly installed.

___

3. Wiring meets all standards.

___

4. All connections are correct.

___

5. Conduit properly installed and sealed.

___

6. Generator properly bonded to vehicle.

BATTERY INSTALLATION

___

1. Recommended battery is installed.

___

2. Recommended cables are installed.

___

3. Cables are clean and tight.

___

4. Cables are properly connected.

___

5. Proper ventilation is provided.

POST INSTALLATION TESTS

.1. All tests properly completed.

OPTIONS AND ACCESSORIES

Check that remote start/stop panels (if used) are properly installed.

If an hourmeter kit is installed, check that job was done properly.

If any other options and accessories are installed,

check that they were installed properly.

EXHAUST SYSTEM

_1. Complies with code requirements. _2. Properly and safely installed.

DATE OF INSTALLATION

NAME OF INSTALLER

SIGNATURE OF INSTALLER

— 29 —

«M8 MOUmiNG FASTENERS

(TOTAL OF 4 REQUIRED) "

7MM(0^”)-

74MM (2.91”)

25MM(1.00”)

CLEAR-MINIMUM

204MN

400MM

THIS IS AN OPTIONAL AIR INLET OPENING IN THE COMPARTMENT FLOORTHE PREFERRED AIR INLET ISTO BE IN THE COMPARTMENT DOOR. (THE AIR INLET AaOWS OUTSIDE AIR INTO THE AIR FILTER AND PROVIDES GENERATOR COOUNG-A MINIMUM OF 106MM OR 40 SO. INCHES OF

OPENING MUST BE PROVIDED IN THE COMPARTMENT.)

38MM(1.S0”)

CLEAR-MINIMUM

(8.03”)

15.74”)

25MM(1.02’0

CLEAR-MINIMUM~

MINIMUM DISTANCE INSIDE ENCLOSURE

514MM (20.23")

MINIMUM DISTANCE INSIDE ENCLOSURE

^ 25MM(1.00")

aEAR-MINIMUM

88MM(3.50") -

CLEAR-MINIMUM

(/) >

z D

m z

£2

(/)

425 MM (16.73”)

197 MM (7.76")

-27MM(1.06")O.D. EXHAUST

OUTLET

EXHAUST

OUTLET

160 MM (6.301

TROUBLESHOOTING

PROBLEM POSSIBLE CAUSES JREMEDY

Engine won't crank.

Engine cranks but won't start. 1. Out of fuel. 1. Replenish fuel.

Engine starts hard, runs rough,

low fuli load power. 2. Defective spark plug. 2. Clean, regap or replace plug.

Engine starts, shuts down

when Start/Stop switch is

released.

15 amp fuse is blown 1. Replace 15 amp fuse

2. Loose corroded or defective 2. battery cables. as necessary. Defective engine Start/Stop switch.

4. Defective starter contactor. 4. Defective starter motor.

6. Low or defective battery. 6. Change or replace battery.

2. Fuel pump is defective. 2. Replace fuel pump. Open Wire #14 from Eng. Control Bd.

4. Engine is flooded. 4. Wait 5-10 min. before trying. Spark plug defective.

1. Air cleaner plugged or damaged 1. Clean or replace as needed.

Loose spark plug boot.

1. Engine oil is low. 1.

2. Engine is overheated.

3. Defective Low Oil Pressure System

4. Defective Engine Control Board 4. Have board serviced/replaced.

5. Defective Computer Control Board

Tighten, clean or replace

Replace Start/Stop switch.

3. Replace contactor. Replace starter motor.

Reconnect wire.

Clean, regap or replace plug.

3. Press boot on securely.

Check oil; add as needed. Check for adequate ventilation.

3. Have serviced/replaced.

Have board serviced/replaced.

Start/Stop switch at Stop, 1. Defective Start/Stop switch 1. Replace switch. engine continues to run. 2. Open/disconnected wire #18 between

Start/Stop switch and Engine Control Open/disconnected wire #0 between

3. Start/Stop switch & Engine Control Bd.

Defective Engine Control Board 4.

No AC output from generator.

Check circuit breaker. 1.

Check vehicle circuit breaker & fuses.

3. Transfer sw. set to NORMAL position.

Generator internal failure 4. Take generator to an

2. Reconnect or close wire.

3. Reconnect or close wire.

Replace board.

Reset to ON or CLOSED.

Reset and replace if necessary.

3. Set to GENERATOR position.

Authorized Generac facility.

— 31

ELECTRICAL DATA

Drawing No. A2420

CUSTOMER SimJES

BATTERY

- 0

L_ 14 — 10

---------

1 1

-------

Fil!.

PANEL ta 5 Ч Ы

CQNNECTQR 5 e 0 S

----------------

I I ^ I

18M170

CUSTOMER AC CONNECTION

32 —

BATTERY CHARGE RECTI HER CIRCUIT BREAKER CHOKE cmL СОНР1ЯЕР CONTROL BOARD CHOKE HEATER ENGINE CONTROL BOARD FUSE. ISA FUEL PUMP ON GASOLINE

SHUT-OFF VALVE ON L/P GENISTOR HOUR iCTER SWITCH, HIGH TEMPERATURE OIL (CLOSES ON HIGH TEMPERATURO IGNITION COIL IGNITION HDDXE IGNITION SENSOR UGHT, RUN (OPTIONAU SWITCH, LOW OIL PRESSURE (OPENS ON HIGH PRESSURD STEPPER MOTOR THROTTLE CONTROL RESISTOR, 500 OHM, 50 WATTS 1 OHN, 50 WATTS STARTER CONTACTOR STARTER MOTOR SWITCH, START/STDP SWITCH, FUEL PUMP PRIME SPARK PLUG LUG, BARREL TERMINAL, CONNECTCF 4 TAB TIME DELAY HLTER

Drawing No. A2420

ELECTRICAL DATA

33-

EXPLODED VIEW — LONG BLOCK

Drawing No. A6202 Rev. B

— 34 —

REPAIR PARTS — LONG BLOCK

Drawing No. A6202 Rev. B

ITEM PART NO. QTY. DESCRIPTION

1 76380 2 76389 3 4 5 77176 1 6 88057 1 7

8 21860 10 89923 11 89213L 1 13 14 90604 1 17 78699B 3 18 19 89096

21 A8822 1 22 78691 23 A5772 24 25 74908 26 78606 28 89230 6 HHFC, M8-1.25x35 LONG 30 A1720 2 RETAINER, VALVE SPRING 31 32 88590 1 DOWEL PIN. DIA. 12x18 LONG 33 83152 34 36 21705B 1 ASSEMBLY. CYLINDER HEAD W/GUIDES & SEATS 37 90082 1 VALVE, EXHAUST 38 39 88396A 2 40 83235 2 TAPPET 42 96362 1 GASKET, ROCKER COVER 43 77161 44 77160 2 ROCKER ARM 45 76307 2 NUT. ROCKER ARM 46 88403 1 PLATE, PUSH ROD GUIDE 47 48 88413B 1 COVER, ROCKER 49 50 90388 2 BOLT, TAPTITE M6 X 12 LONG 51 52 92977 1 ASSEMBLY SUMP, OIL 53 54 58 72347 1 SPARKPLUG, CHAMPION RC12YC 59 99922 1

88411

72657

76390

81695 2

A2477 1

A5776

88401 2 SPRING, VALVE

76381 2 BOLT, CONNECTING ROD

90081

77168 5

78629 2

83153 1

84186 2 WASHER, WEAR VALVE SPRING

88156

1 ASSEMBLY. CONNECTING ROD & CAP 1 PISTON PIN 1 2

2 RETAINER, PISTON PIN 1 ASSEMBLY, CRANKSHAFT AND GEAR 1 SEPARATOR, OIL BREATHER

1 RETAINER. OIL PRESSURE SPRING 1 SPRING, OIL PRESSURE 1 BALL, OIL PRESSURE 1 TAPTITE, M5-0.8 X 10 4 SCREW & LOCK WASHER, M6-1 x 12 LONG

1 VALVE, INTAKE

2 STUD, BALL PIVOT

1 SEAL VALVE INTAKE

SET, PISTON RING (STD. SIZE) PIPE PLUG 1/4 NPT COVER, BREATHER PISTON, 75 DIA.

ASSEMBLY, CRANKCASE

SEAL. OILCRANKSHAFT

CUP, BREATHER BAFFLE

SLEEVE. DOWEL DIA. 12

ASSEMBLY, CAMSHAFT

GASKET, CRANK CASE FLANGE

GASKET, CYLINDER HEAD

GEROTOR, INNER

PUSH ROD

HEADBOLT, M8 x 52MM

GASKET, BREATHER

GEROTOR, OUTER

WASHER, WAVE

35 —

—Ч

СЛ

m X

“0 n

О m о

m Z m

Drawing No. A5971 Rev. A

REPAIR PARTS — GENERATOR

TEM PART NO. QTY. DESCRIPTION ITEM

A2467 ‘ ■ 1

1 2 94583

83312 2 WASHER, CONICAL 56

1 aVWHEEL, FAN 55 52618 5

ENGINE, LONG BLOCK

4 81810 2 HEX NUT.M16-1.5

5 70185

6 86730 7

89476

8 40976

9 99948 11 86705 12 22097 8 LOCKWASHER, 1/4-M6 66 89050 14 92059 15 86706

16 89477

89478

18 90192

90881A 1 ASSEMBLY, CARBURETOR

20 90051 2 21

25 86710 26 87993 1 ELBOW, AIR CLEANER OUTLET 79 87478 27 49815 2 HEX HD. CAPSCR., M5-.8 X 16MM 80 28 29 90021 1 BRACKET, AIR CLEANER SUPPORT 81 30 94665 1 HOUSING, FAN-UPPER 82

32 A5892 1 ASSEMBLY, MAGNET HOUSING .84 004-91297 1 TEMP. SWITCH GROUND WIRE

78631

96459 86709 1 ADAPTOR, CARBURETOR INLET 76

35586

90536 1 GASKET, AIR CLEANER OUTLET MOUNT

31 93859

1 FILTER, OIL 58 22129 10 1 TUBE, EXHAUST OUTLET 59 74906 1 GASKET, EXHAUST 61 39253

4 SOCKET HD. CAPSCR., 62 22511 3

M8-1.25X20MM 63 22237 3 LOCKWASHER-3/8 1 1 PLATE, DIVIDER 65

1 STEPPER MOTOR SPEED CONT. 1 ROD, THROTTLE CONTROL 66 1 CLIP, ADJUSTMENT 69 1 SNAP, RETAINING 70 1

1 1 GASKET, CARB7INLET/ADAPTOR 75

2 1 HOSE, CARBURETOR INLET

STARTER, EATON/GENERAC

WASHER, CARBURETOR

GASKET, CARB7SPACER/HEAD

GASKET, CARBURETOR/SKIRT 74

HOSE CLAMP-BAND 1.50”

FAN, GENERATOR 83 002-91297 1

57 42907

64 55822 2 PHMS, M4-.7 X 8MM

67 82774 1

71 86701

72 86702 1 BRACKET, ENG. MOUNT REAR 73 38353 3

77 90072 1 0-RING .562” I.D.

78 86708 1 CARBURETOR SPACER

PART NO. QTY. DESCRIPTION

83512

005-91297 1 OIL PRESSURE SWITCH WIRE

. TAPTITE M8-1.25X 15 LONG

M50.8 X 12MM CAPSCREW

3 HEX HD. CAPSCR., M8-1.25 X 16MM

LOCKWASHER-M8

4 M6-1 X20MM TAPTITE 3 HEX HD. CAPSCR., M8-1.25 X 20MM

HEX HD. CAPSCR., 3/8-16 X 1.25”

22264

59367 4 86697 1 86704

89263 90071 1 94637

96627 1

90613 59635

2 LOCKWASHER-M4 2

3 1

1 ASSEMBLY, OIL FILLCAP\

1 OIL FILL TUBE

1 1 #8X3/8PLASTITESCREW

PPHM SCREW-M6-1 X 90MM WOODRUFF KEY-4MM X 19MM TAPTITE 3/8”-16 X .75'LONG ASSEMBLY IGNITION SENSOR

SPACER, ENGINE MOUNT

BRACKET, ENG. MOUNT FRONT

RUBBER MOUNTS

0-RING, 1.062" I.D.

GASKET, OIL FILTER ADAPTOR

BRACKET, STARTER SIDE ENGINE

COVER, BREATHER CANAL

STARTER WIRE

33 91437 1 HUB, MAGNET HOUSING ASSY. 85 59636 1 PLASTITE SCREW, #4 X .37"

34 35 86673 36 37 86674 1 COVER, AIR BOX 38 78609 2 BOLT, AIR CLEANER COVER 91 39 66449C 40 49226 4 LOCKWASHER, M5 96 23897 41 42 43 86692 1 ADAPTOR, STATOR 100 77667 1

45 86735 46 47488 47 48 31879 4 49 91306 50 36544 1 PIN, COTTER 3/32” X 1/2” 107 A8617 51 89473 1 ASSEMBLY. BI-METAL & HEATER 52 86736 1 LINKAGE, CHOKE CONTROL 53 45756 3

003-91297 1 TEMP. SWITCH WIRE 86 88905 1 EXTENSION SPRING

78601

1 ELEMENT, AIR FILTER

80934 1 A5898

74908 3 TAPTITE, M5-.08 X 10MM 101

1 STATOR ASSEMBLY

1 COVER, CHOKE MOUNT

22159

BASE, AIR BOX 87 92800 1

88 89062 1 HOSE, BREATHER 90 23762 2 WASHER, EXT. SHAKEPROOF-#10

22447

HEX HD. CAPSCR., M6-1 X 80MM 94 23484P 1

RETAINING RING, STATOR

SCREW,4-40X,188" LOCKWASHER-NO. 4 104 FLATWASHER-NO. 4 105 43182 2 LOCKWASHER, M3 SOLENOID, CHOKE

97 99 86675A 1

102 52617 1 DRAIN PLUG, M12-1.75 X 20MM 103 94643

106 90387 1

94090 1 SWITCH-THERMAL, OIL TEMP.

86714

C1085 2

3 WASHER, INT. SHAKEPROOF, .25"

6 #10-M5 FUT WASHER

WRAPPER, ENGINE TOP

SNAP BUSHING

ADAPTOR, OIL FILTER SWITCH, OIL PRESSURE SCREEN, OIL PICK-UP

GASKET, OIL DRAIN PLUG

PPHMS, M3-0.5 X 8MM

AIR CLEANER DECAL

4 HEX HD. TAPTITE M6-1 X 25MM

108 86726 1 SKIRT, BAFaE 109

M6-1 XIOMM TAPTITE 110 A9257 1

56893

1 CRIMPTITE, 10-24X1/2“

SHIM, STARTER

— 37 —

EXPLODED VIEW — SHEET METAL

Drawing No. A9405 Rev. *

— 38

Drawing No. A9405 Rev. *

REPAIR PARTS — SHEET METAL

ITEM PART NO. QTY.

1 2 3 86718 4 5 74908 33 6 20150

7 8

10 49226 2 12 13 94670 17 18 86731A

19 86715 20 86726 21 22 86727 23 86719 24 25 26 86724 27 90475 28 28740 29 30 31 86729

32 90518 33 89048 34 90537

35 22145 4 36 30340 1 37

39 23762 2

40 22471 2

86705 49813

A3666

22129 39414 4 HEX HD. CAPSCR.,

89680

89471 1 DEFLECTOR, AIR OUT

86671

20519 90141A 1

22127 3 22097

48031C 5 23484D 1 SNAP BUSHING 74

22264 2

1 PLATE, DIVIDER 2 M61.0 HEX NUT 1 SEAL RUBBER EXTRUSION 44 22447 1 \WRAPPER, BOX

1 1 UBOLT, W/SADDLE & NUTS

1 ASSEMBLY, MUFFLER 1 1 1 1 SPARK PLUG SIDE 1 PAN,BELLY 1 FRAME

1 PLATE, BASE COVER 1 PUMP, FUEL 1

7 1 CONTACTOR, STARTER 1 BOOT, CONTACTOR 1 SEAL, OIL FILTER HOLE 1 RETAINER, SEAL

DESCRIPTION

TAPTITE, M50.8X 10MM CUSTOMER MOUNTING BARBED FITTING RAILS LOCK WASHERM8 HANGER

M8 1.25 X 35MM LOCK WASHER M5 (4" LONG) SPARK ARRESTOR

HOUSING, LOWER FAN SKIRT, CARB. BAFFLE COVER, ROCKER 57 23897

GROUND STRAP

BARBED 90 1/8" X 1/4"

HEX NUT, 1/420

LOCKWASHER1/4"M6

FLAT WASHERM8 1/4" FUEL LINE 4" LONG 1/4" HOSE CLAMP

EXTERNAL SHAKEPROOF #8 HEX NUT #8 LOCK WASHER

ITEM

42 79246

48 92000

49 30340 50

53 00791297

54 89045 55 20149 56 91526

59 A3638 60 22159

62 A5767

63 A9196 64 65 89049B 66 A9172 67 68 69 49226

70 51716

71 84867

72 73 56892 1 CRIMPTITE 1024x3/8

PART N0. QTY.

3 WASHER, INTERNAL

39450

82580D

86311 1 FUEL FILTER

56893

89047

91526 86711 1

49813

49721

1 1/8'x3/16"NPT90 DEG.

1 BRACKET, MUFFLER

1 1

1 SEAL, WASHER EXH. PIPE 1 CUSTOMER MNTG. RAIL 2 M5 0.8 X 12 MM CAPSCREW 4 M5 FLATWASHER 1 WRAPPER, END PANEL 2 #10 LOCK WASHER

11 CRIMPTITE, 1024x 1/2"

1 HEX HD. CAPSCR.,

1 2 SPACER, IGNITION COIL 1 COIL, IGNITION 1 BRACKET, IGNITION SYS. 2

2 LOCK WASHER, M5 2 M50.8 HEX NUT

.25FT.

2 M61.0x35MMHEXHD.

DESCRIPTION HEX HD. CAPSCR., M6 1.0 X 16MM W/LOCKWASHER

SHAKEPROOF, 1/4"M6

1/4" FUEL LINE (8" LONG) 3/16" CARBURETOR LINE

STARTER CONTACTOR GROUND WIRE

M50.8 X 6MM COVER, IGNITION SYSTEM

M50.8X 12MM PPHMS MODULE, IGNITION

RUBBER UCHANNEL M61.0HEX NUT

CAPSCR.

39 —

■a

I“

> <o

(7) ЛЗ

Z H

I“

Z m

)

Drawing No. A9406 Rev. *

REPAIR PARTS — CONTROL PANEL

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY.

1 91526 8 M50.8 X 12MM PHILLIPS PAN

20093 20092 1 BOX, CONTROL PANEL

3 4 36937 2

5 75476 5

6 74908 8 TAPTITE M5.8X10LONG 7 23484M 1

20107 1

92234 1 RV CONTROL BOARD

9 10 90145 13 49226 10 14 18 19 23897 8 M5 FLAT WASHER

20 20091 21 22

23 92113 1 SWITCH, SPSTMOM

24 25 32300 1 FUSE HOLDER 26 80939

28 22264 16 LOCK WASHER M4 29 30 20105B 31 86275 32 A3369 1 ASSEMBLY, PCB CCG 33

51715 22985

30809 87798

A9611

65795

22158

43181

HD. MACH. SCR.

1 BOX, CONTROL TOP

#1032x 1" PHILLIPS PAN HD. MACH. SCR.

PHILLIPS PAN HD. MACH. SCR., M4x 16

SNAP BUSHING 90 DEG. CONNECTOR

1 CIRCUIT BREAKER, 30A.

LOCK WASHER M5

2 HEX NUT M4

M4 FLAT WASHER

1 CONTROL PANEL, FRONT 1 RUBBER GROMMET 51 84867 4

1 SWITCH, SPOT ROCKER 52

ROCKER 53

1 FUSE, 7.5A. AGC 54

EXTRUSION, CONTROLLER 56

RECTIFIER, ВАТТ. CHARGE

2 #1032 HEX NUT

PANEL DECAL 60 23762 2 SHAKEPROOF LOCK

GENISTOR, TRIAC MODULE

4 TAPTITE, M30.5 X 10MM PAN

HD. MACH. SCR.

34 43182 35 36 83491 37 38 41 42 91281 1 43 86738A 1 44 00191297 1 45 91282A 1 46 91269A 1 47 23484D 1 48 82121A 2

49 20106

50 25105 2 #632 X 1/4" PHILLIPS ROUND

55 22159 2 #4 LOCKWASHER

57 58 59 A1491 1 CONN. 1/2"

62 29333A 1

89744 1

45756 86722 75210A

51718

77604 1 34028 2 #440 X 3/8’ LG. ROUND HD

27771 36933 2 PPHMS 1032x3/8" LONG 21532 1 CONDUIT, 1/2"

1 4 1 1

4 M40.7X10MMHEX HEAD

2 #440 HEX NUT

DESCRIPTION

LOCK WASHERM3 RESISTOR, POWER 1 OHM

RESISTOR, POWER 500 OHM TAPTITE M61 X 10 LONG BRACKET, HEAT SINKPCB TERMINAL BLOCK

12 PIN CONNECTOR ASSY. TRIAC MODULE HARNESS GROUND WIRE CUSTOMER WIRE HARNESS REMOTE PANEL HARNESS SNAP BUSHING CLAMP, CONTROL PANEL

HARNESS HARNESS, CONTROL PANEL

(NOT SHOWNFOR CLARITY)

HD. MACH. SCREW

RUBBER UCHANNEL

CAPSCREW

HOUR METER

WASHER, EXT. TOOTH #10

BLACK TIE WRAP, 7" LG

— 41 —

NOTES

— 42

NOTES

— 43 —

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board (“CARB“) and Generac Corporation are pleased to explain the Emission Control System Warranty on your new recreational vehicle equipment engine. In California, new utility and lawn and garden equipment engines must be designed, built and equipped to meet the State's stringent anti-smog standards. Generac Corporation will warrant the emission control system on your recreational vehicle equipment for the periods of time listed below provided there has been no abuse, neglect, unapproved modification, or improper maintenance of your recreational vehicle equip ment engine.

Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Also included may be the compression release system and other emission-related assemblies.

Where a warrantable condition exists, Generac Corporation will repair your recreational vehicle equipment engine at no cost to you for diagnosis, parts and labor.

MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:

Emissions control systems on 1995 and later model year utility and lawn and garden equipment engines are warranted for two years as hereinafter noted. If, during such warranty period, any emission-related part on your engine is defective in materials or workmanship, the part will be repaired or replaced by Generac Corporation.

OWNER'S WARRANTY RESPONSIBILITIES:

As the recreational vehicle equipment engine owner, you are responsible for the performance of the required maintenance listed in your owners manual. Generac Corporation recommends that you retain all receipts covering maintenance on your recreational vehicle equipment engine, but Generac Corporation will not deny warranty solely due to the lack of receipts or for your failure to provide written evidence of the performance of all scheduled maintenance.

As the recreational vehicle equipment engine owner, you should, however, be aware that Generac Corporation may dgm you warranty coverage if your recreational vehicle equipment engine or a part thereof has failed due to abuse, neg' '

improper maintenance or unapproved modifications.

You are responsible for presenting your recreational vehicle equipment 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) 473-5514

P.O. BOX 8 FAX: (414) 473-3626

WAUKESHA, Wl 53187

IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System

Warranty (“ECS Warranty”) which is provided to you by Generac Corporation pursuant to California law. See also the Generac Corporation Limited Warranties for Generac Corporation which is enclosed herewith on a separate sheet and also is provided to you by Generac Corporation. The ECS Warranty applies only to the emission control system of your new engine. To the extent that there is any conflict in terms between the ECS Warranty and the Generac Corporation Warranty, the ECS Warranty shall apply except in any circumstances in which the Generac Corporation Warranty may provide a longer warran ty period. Both the ECS Warranty and the Generac Corporation Warranty describe important rights and obligations with respect to your new engine.

Warranty service can only be performed by a Generac Corporation Authorized Service Outlet. At the time of requesting warranty service, evidence must be presented of the date of the sale to the original purchaser. The purchaser shall pay any charges for making service calls and/or for transporting the products to and from the place where the inspection and/or war ranty work is performed. The purchaser shall be responsible for any damage or loss incurred in connection with the trans portation of any engine or any part(s) thereof submitted for inspection and/or warranty work.

EMISSION CONTROL SYSTEM WARRANTY

Emission Control System Warranty (“ECS Warranty") for 1995 and Later Model Year Utility and Lawn and Garden Equipment Engines:

I^^Aplicability: This warranty shall apply to 1995 and later model year utility and lawn and garden equipment engines. The

^KS Warranty Period (“ECS Warranty Period") shall begin on the date the new engine or equipment is delivered to its origi-

' "’^h'al, end-use purchaser and shall continue for 24 consecutive months thereafter.

B. General Emissions Warranty Coverage: Generac Corporation warrants to the original, end-use purchaser of the new engine

or equipment and to each subsequent purchaser that each of its utility and lawn and garden equipment engines is:

1. Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pur suant to its authority, and

2. Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, will cause a warrant

ed emissions - related part to fail to be identical in all material respects to the part as described in the engine manufac

turer's application for certification.

C. The ECS Warranty only pertains to emissions-related parts on your engine, as follows:

1. Any warranted, emissions-related parts which are not scheduled for replacement as required maintenance in the Owner's

Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be repaired or replaced by Generac Corporation according to Subsection (4) below. Any such part repaired or replaced under

the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period.

2. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the Owner's Manual

shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of "repair or replace as necessary" shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS

Warranty shall be warranted for any remainder of the ECS Warranty Period.

3. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner's Manual

shall be warranted for the period of time prior to first scheduled replacement point for that part. If the part fails prior to

the first scheduled replacement, the part shall be repaired or replaced by Generac Corporation according to Subsection (4)

below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.

_4. Repair or Replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge

kto the owner at a Generac Corporation Authorized Service Outlet.

FThe 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 INCLUDE THE FOLLOWING;

1. Carburetor assembly and its internal components. a. Fuel filter

b. Carburetor gaskets

c. Fuel pump (if so equipped)

2. Air cleaner assembly a. Air filter element b. Intake pipe/manifold

3. Ignition system including: a. Spark plug

b. Ignition module

4. Catalytic muffler (if so equipped) a. Muffler gasket (if so equipped) b. Exhaust manifold (if so equipped)

5. Crankcase breather assembly and its components,

a. Breather connection tube

GENERAC’S THREE - YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE NP GENERATORS

Generac warrants to the original purchaser that its generators will be free from defects in materials or work manship for the period set forth below from date of original purchase. During said warranty period, Generac will, at its option, repair or replace any part which, upon examination by Generac or Generac Authorized Distributors and/or Dealers, is found to be defective under normal use and service.

THREE ■ YEAR WARRANTY SCHEDULE

1. All NP series generators used in a recreational vehicle shall be warranted for a period of three (3) years or 2,000 hours of operation, whichever occurs first. All parts, labor, removal and reinstallation shall be covered for the first two years. Parts and labor on selected generator and engine parts shall be covered during the third year or 2,000 hours, whichever occurs first. These selected parts are limited to: the main Rotor andStator, Computer Control Board (if applicable) with regard to the generator; the Cylinder Block, Cylinder Head, Crankshaft, Piston, Valve, Valve Lifter, and Manifolds with regard to the engine.

2. The drive train belt and pulleys on NP air-cooled generators (if applicable) used in recreational vehicles shall be warranted against failure due to defective materials or normal usage for the life of the generator. For the original owner, this drive train warranty shall include parts and labor plus $50.00 payment upon return of the failed belt or pulley by the original owner. For succeeding owner, this power train warranty shall cover belt or

pulley parts only.

3. Rental units, demonstrators, prime power, or'commercial applications, such as construction or utility, are war

ranted for (1) one year or 2,000 hours, whichever comes first.

THIS WARRANTY DOES NOT COVER:

Costs of maintenance, installation and startup. Failures due to (a) normal wear and tear from GN engine, or (b) accident, misuse, abuse, negligence or

improper installation. Products which are modified or altered in a manner not authorized by Generac in writing.

Any accidental, consequential or indirect damages caused by defects in materials or workmanship, or any

delay in repair or replacement of defective parts.

Failure due to misapplication.

Telephone, telegraph, teletype or other communication expenses.

Living or travel expenses of persons performing service. Any and all transportation/travel expenses.

Rental equipment used while warranty repairs are being performed. Overtime labor. Starting batteries, fuses, light bulbs, and engine fluids.

**NORMAL WEAR: As with all mechanical devices, engines need periodic parts service and replacement to per

form well. This warranty will not cover repair when normal use has exhausted the life of a part or an engine.

THERE IS NO OTHER EXPRESS WARRANTY. GENERAC HEREBY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES,

INCLUDING BUT NOT LIMITED TO THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE TO

THE EXTENT PERMITTED BY LAW. THE DURATION OF ANY IMPLIED WARRANTIES WHICH CANNOT BE DIS

CLAIMED IS LIMITED TO THE TIME PERIOD AS SPECIFIED IN THE EXPRESS WARRANTY. LIABILITY FOR CONSE QUENTIAL, INCIDENTAL, OR SPECIAL DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED. Some states

do not allow limitations on low long an implied warranty lasts, or the exclusion or limitation of incidental or

consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights, which vary from state to state.

For service, see your nearest GENERAC authorized warranty service facility or call 1-800-333-1322. Warranty ser

vice can be performed only by a GENERAC authorized service facility. This warranty will not apply to service at any other facility. At the time of requesting warranty service, evidence of original purchase date must be pre sented.

GENERAC CORPORATION® P.O. BOX 8 Waukesha, Wl 53187

TELEPHONE: (414)473-5514 FAX: (414)473-3626

Generac Power Systems 0661-5 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL SAFETY RULES

IDENTIFICATION RECORD AND GENERATOR FEATURES

TABLE OF CONTENTS

OPERATION AND MAINTENANCE

HOW TO OBTAIN SERVICE

SERVICE DEALER LOCATION

1-800-333-1322

GENERATOR FAMILIARIZATION

GENERATOR APPLICABILITY

SAFETY

GENERATOR CONTROL PANEL

AUTOMATIC CHOKE

BEFORE STARTING THE ENGINE

EFFEaS OF MOISTURE AND DIRT

OVERSPEED

LOW VOLTAGE

SPECIFICATIONS

FUEL REQUIREMENTS

ENGINE OIL REQUIREMENTS

GENERATOR SPECIFICATIONS

ENGINE SPECIFICATIONS

CHECKING ENGINE OIL LEVEL

CHANGE ENGINE OIL

ENGINE AIR CLEANER

ENGINE SPARK PLUG

FUEL FILTER

CLEANING THE GENERATOR

THROmE LINKAGE ADJUSTMENT

ADJUSTING THE CARBURETOR

ADJUSTING VALVE CLEARANCE

EXERCISING THE GENERATOR

OUT OF SERVICE PROTECTION

SERVICE DEALER LOCATION

1-800-333-1322

INSTALLATION SAFETY RULES

NOTICE TO INSTALLER

SAFETY RULES

GENERAL INSTALLATION INFORMATION

PURPOSE AND SCOPE OF MANUAL

SAFETY

STANDARDS BOOKLETS

EQUIPMENT DESCRIPTION

SUSPENDED MOUNTING

GENERATOR RESTRAINT

GENERATOR COMPARTMENTS

COMPARTMENTS

COMPARTMENT SIZE

COMPARTMENT CONSTRUCTION

SOUND INSULATING MATERIALS

COMPARTMENT FLOOR CUTOUTS

ACOUSTICS

GENERATOR AIR FLOW

COOLING AIR INLET OPENINGS

TESTING THE INSTALLATION

FUEL TANK

EXHAUST SYSTEM

ELECTRICAL JUNQION BOX

WIRING

GENERATOR AC CONNECTIONS

CONDUIT

POWER SUPPLY CORD

RECOMMENDED BAHERY

BATTERY INSTALLATION

BAHERY CABLES

BATTERY CABLE CONNECTIONS

BAHERY COMPARTMENT

REMOTE PANEL MODELS

REMOTE PANEL CABLES

POST INSTALLATION TESTS

BEFORE INITIAL START UP

INITIAL START

TESTING UNDER LOAD

INSTALLATION CHECK LIST

TROUBLESHOOTING

ELECTRICAL DATA

ELECTRICAL DATA