Generac Power Systems 0940-1 User Manual

Download

Manual No. A9I95

OWNER'S MANUAL

and Installation Instructions

IMPACT-34 plus with Inverter and IMPACT-36 plus with Inverter

AIR-COOLED

RECREATIONAL VEHICLE

GENERATORS

Model Nos. 0940-1, 0941-1

Revision 0 (09/24/98)

POWER SYSTEMS. INC.

Printed in U.S.A.

GENERAL SAFETY RULES

THE MANUFACTURER SUGGESTS THAT THESE "RULES” FOR SAFE OPERATION BE COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHICLE. SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF THIS EQUIPMENT.

study these SAFETY RULES carefully before operat ing or servicing applicable equipment. Become familiar with this Owner's Manual and with your generator. Safe, efficient and reliable operation can only be achieved if generator is 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.

WARNING:

The engine exhaust from this product

contains chemicais known to the State

of California to cause cancer, birth

^^^defects^rothenjeproductiv^iam

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 conformance 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 onto the vehicle, either by solid mounting to the vehicle frame or chassis or by means of an approved bonding conductor. DO NOT disconnect the bonding conductor, if so equipped. DO NOT reconnect the bonding con ductor to any generator part that might be removed or disassembled during routine mainte nance. If the grounding conductor must be

replaced, use only a flexible conductor that is of

No. 8 AWG copper wire minimum.

* •

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. Apply first aid and get medical help.

Inspect fuel system frequently for leaks or dam age. Repair or replace any oamaged or leaking component immediately. Never attempt to change, alter or modify the generator fuel system in any way that might affect safety or compliance with applicable codes and standards.

The generator engine gives off DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentra tions, can cause unconsciousness or even death.

This exhaust system must have been properly

installed, in strict compliance with applicable codes

and standards. Following installation, you must do

nothing that might render the system unsafe or in non-compliance with such codes and standards.

The generator compartment must be completely vapor sealed from vehicle interior. There must be

no possibility of exhaust fumes entering the vehi

cle interior. Never operate this equipment with a

leaking or defective exhaust system. Never use the generator or any of its parts as a

step. Stepping on the unit can stress and break parts and may result in dangerous, fuel leakage, oil leakage, etc.

Do not smoke around the generator. Wipe up any

fuel and oil spills immediately. Never leave oily or fuel soaked rags in the generator compartment or on the generator itself. Keep the area around the gener ator clean and free of debris.

Adequate ventilation is required to expel toxic fumes and fuel vapors from the generator com

partment. Do not alter the installation of this equip

ment in any manner that might obstruct air and ventilation openings. Such openings must be kept clear and unobstructed.

Keep hands, feet, clothing, etc., away from drive

belts, fans and other moving parts of this equip ment. Never remove any drive belt or fan guards while the unit is operating.

Inspect the generator periodically. Repair or replace

all damaged or defective parts immediately. These generators can be converted to use LP gas

(propane) as a fuel. Liquid Propane gas is highly EXPLOSIVE. The gas is heavier tnan air and

tends to settle in low areas where even the slight est spark can ignite the gas and cause an explo sion.

Before performing any maintenance on the gener

ator set, disconnect its battery cables to prevent

accidental start up. Disconnect the cable from the battery post indicated by a NEGATIVE, NEG or (-)

first. Reconnect that cable last.

TABLE OF CONTENTS

OPERATING INSTRUCTIONS

GENERAL SAFETY RULES...............................inside cover

IDENTIFICATION RECORD.............................................. 2-3

GENERATOR and INVERTER FEATURES

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

2-4

READ THIS MANUAL THOROUGHLY

Operation and Maintenance.................................................................. 5

How to Obtain Service........................................................................... 5

Service Dealer Location

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

GENERATOR FAMILIARIZATION

Generator Applicability.......................................................................... 6

Safety....................................................................................................... 6

OPERATING INSTRUCTIONS

Generator Control Panel........................................................................ 7

Automatic Choke.................................................................................... 7

Before Starting the Engine

Starting.................................................................................................... 8

Stopping the Generator......................................................................... 8

Applying Loads to Generator................................................................ 8

Attention Required After Submersion

Operation in High Grass or Brush........................................................ 8

Operating Precautions.........................................................................8-9

Effects of Moisture and Dirt.................................................................. 9

Don't Overload the Generator............................................................... 9

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

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

7-8

ENGINE PROTECTIVE DEVICES

Automatic Low Oil Pressure Shutdown.............................................. 9

High Temperature Shutdown................................................................ 9

Overspeed............................................................................................... 9

Low Voltage............................................................................................. 9

SPECIFICATIONS

Fuel Requirements............................................................................... 10

Engine Oil Requirements

Generator Specifications..................................................................... 10

Engine Specifications.......................................................................... 10

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

MAINTENANCE

Checking Engine Oil Level.................................................................. 11

Change Engine Oil............................................................................... 11

Change Oil Filter.................................................................................. 11

Engine Air Cleaner...........................................................................11-12

Clean Air Intake Screen Spark Arrestor Muffler

Engine Spark Plug.................................................................................12

Fuel Filter................................................................................................12

Inverter....................................................................................................12

Cleaning the Generator.........................................................................13

Battery................................................................................................:... 13

Service and Adjustments Throttle Linkage Adjustment

Adjusting the Carburetor................................................................. 14

Adjusting Valve Clearance

Major Service Manual

Exercising the Generator

Out of Service Protection.................................................................... 15

Return the Unit to Service after Storage

Service Dealer Location........................................................................15

....

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

.......

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

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

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

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

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

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

i................................................. 14

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

13-14

INSTALLATION INSTRUCTIONS

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

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

GENERAL INSTALLATION INFORMATION

Purpose and Scope...............................................................................17

Safety......................................................................................................17

Standards Booklets...............................................................................17

Equipment Description.........................................................................17

Engine Generator Operating Speed....................................................17

LOCATION AND SUPPORT

Generator Location

Generator Support.................................................................................18

Suspended Mounting............................................................................18

Generator Restraint...............................................................................19

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

GENERATOR COMPARTMENTS

Compartment Seams.............................................................................19

Compartment Size.................................................................................20

Compartment Construction..................................................................20

Sound Insulation Materials Compartment Floor Cutouts

Acoustics...............................................................................................21

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

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

20 21

COOLING AND VENTILATION AIR

Generator Air Flow................................................................................22

Cooling Air Inlet Openings...................................................................22

Compensating for Restrictions............................................................23

Inverter Location

Testing the Installation

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

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

GASOLINE FUEL SYSTEM

Fuel Tank...........................!....................................................................24

Generator Fuel Supply Line

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

PROPANE GAS FUEL SYSTEM

Parts Not Included in Fuel System......................................................25

Some Important Considerations..........................................................25

Va/tor Withdrawal..................................................................................25

Primary Regulator

Gaseous Carburetion............................................................................26

Fuel Supply Lines..................................................................................26

Excess Flow Valve................................................................................ 26

Leakage Tests........................................................................................26

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

EXHAUST SYSTEM

Mufflers and Spark Arrestors...............................................................27

Type of Exhaust System.......................................................................27

Exhaust System Safety.........................................................................27

12 12

ELECTRICAL CONNECTIONS

Wiring......................................................................................................28

Generator AC Connection System

Conduit....................................................................................................28

Isolating Different Power Sources Power Supply Cord

Ground Fault Circuit Interrupters......................................................29

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

Sensing Harnesses

BATTERY INSTALLATION

OPTIONAL ACCESSORIES

POST INSTALLATION TESTS INSTALLATION CHECK LIST MAJOR FEATURES AND DIMENSIONS

TROUBLESHOOTING

ELECTRICAL DATA........................................

REPAIR PARTS...............................

CALIFORNIA EMISSIONS WARRANTY

WARRANTY..................................................

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

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

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

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

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

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

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

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

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

........

................40 to 51

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

.........

....

35-36

... 38-39

,....52 -53

back page

28-30

29 ^

31 32 33

1 —

IDENTIFICATION RECORD

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

1. Model Number

3.kW Rating.

5. Phase

____

__________________

IMPACT-36 plus FEATURES

2.Serial Number_______________________

4. Rated Voltage.

6. Hertz

________

REFERENCE NUMBER IDENTIFICATION

1. Generator Air Intake Screen Air Cleaner

2. Air Intake Tube

Oil Dipstick and Filler Tube

5. Fuel Pump 12. Circuit Breaker Gasoline Carburetor

7. Fuel Primer Switch

8. Data Decal

9. 12 Volt Battery Connection

10. Engine Start/Stop Switch

11. Generator DC Output Leads

13.15 Amp Fuse

14. Hour Meter

2 —

IMPACT 36 plus

GASOLINE

IDENTIFICATION RECORD

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

1.Model Number

3.kW Rating.

5. Phase

____

__________________

2.Serial Number

4. Rated Voltage.

6. Hertz

________

IMPACT-34 plus FEATURES

_______________________

Generator Air Intake Screen

1. Air Cleaner

2. Air Intake Tube

4. LP Fuel Regulator Oil Dipstick and Filler Tube

5. LP Carburetor

7. LP Fuel Solenoid Fuel Primer Switch

Impact-34 plus

LP VAPOR

REFERENCE NUMBER IDENTIFICATION

9. Data Decal

10.12 Volt Battery Connection

11. Engine Start/Stop Switch

12. Generator DC Output Leads

13. Circuit Breaker

14.15 Amp Fuse

15. Hour Meter

— 3 —

INVERTER FEATURES

1. Inverter

2. 9 Pin Connection

3. Customer AC Output

PART No. A6187 INVERTER

REFERENCE NUMBER IDENTIFICATION

4. 2 Pin Connection

5. DC Input

6. Cooling Fan

— 4 -

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 and CAUTION blocks are used to alert you to special

instruction about a particular operation that may be hazardous if performed incorrectly or carelessly.

Observe them carefully. These safety warnings cannot eliminate the hazards

that they indicate. Strict compliance with the special

instructions while performing the service plus "com mon sense" are major measures to prevent acci

dents. The following definitions apply to DANGER WARN

ING, CAUTION and NOTE blocks found throughout

the manual.

DANGER: After this heading you can read han

dling, installing, operating or servicing instruc tions that, if not strictly complied with, will result in personal injury.

WARNING: After this heading you can read han dling, installing, operating or servicing instruc tions that, if not strictly complied with, may result

in personal injury.

CAUTION: After this heading you can read instruc tions for handling, installing, operating or servicing the generator that, if not strictly complied with, could result in damage to equipment and/or proper

ty.

NOTE: After this heading you can read explanatory statements that require special emphasis.

These symbols indicate the following:

Points out important safety information and, if not followed, could endanger personal safety and/or property of yourself and others.

Potential explosion hazard

Potential fire hazard

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 ihis 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 RV 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 RV 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 decal.

The warranty on your generator is included in this Owner's Manual, as well as listings for repair parts.

SERVICE DEALER LOCATION

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

ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER.

1-800-333-1322

— 5 —

GENERATOR FAMILIARIZATION

GENERATOR APPLIGVBILITY

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-1974 “Standard for Recreational Vehicles”, Part III, “Installation of Electrical Systems.” The generator also must have

been installed in strict compliance with the manu facturer’s detailed installation instructions. After installation, do nothing that might render the unit

in non-compliance with such codes, standards and

instructions.

This generator has been designed to work with an inverter (P/N A6187). The inverter changes the volt age from the generator from a DC to an AC voltage. This generator will not operate properly without the inverter box connected. All repairs of the inverter must be handled by an authorized service dealer (see

Page 12 in “Maintenance).

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 3400 watts (3.4 kW) for the Impact 34 plus, or 3600 watts (3.6 kW) for the Impact 36 plus. The maximum current at

120 volts is 28.3 amperes for the Impact 34 plus, or

30 amperes for the lmpact-36 plus.

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.

— 6 —

OPERATING INSTRUCTIONS

GENERATOR CONTROL PANEL

Mounted on the generator control panel (Figure 1) are the following features:

Figure 1 — Typical Control Panel

FUEL PRIMER

Before starting a cold engine (if it has not been start ed in more than two weeks), you must press this switch to bring fuel from the tank to the fuel carbure tor. This rocker type switch springs back into its origi nal 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 BREAKERS

Protects generator's AC output circuit against over load, i.e., prevents unit from exceeding wattage/amperage capacity.

HOUR METER

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

AUTOMATIC CHOKE (GASOUNE ONLY)

The engine is equipped with an automatic choke (not shown) that consists of two main components — choke solenoid and prechoke.

■ CHOKE SOLENOID (GASOLINE ONLY)

During engine cranking (start/stop switch at START), a solid state control circuit board signals the choke solenoid to actuate and cycle (choke on/choke off)

until engine starts. The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking. When the engine starts, the choke cycling stops.

■ PRECHOKE (GASOLINE ONLY)

The choke system also has a temperature sensitive

metal strip that adjusts the choke valve angle accord

ing to ambient temperatures (i.e., in cofd 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 OR 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 sen/iced 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 aasoline installations, the generator

engine may “share’^the vehicle’s gasoline fuel tank with the vehicle engine. Some installations may provide

separate 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.

_________________

— 7 —

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 throught 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. Symptoms of carbon monoxide poisoning are (a) inability to think coherently, (b) vomiting, (c) twitching muscles, (d) throbbing temples, (e) dizzi ness, (f) headache, (g) weakness and sleepiness. If you feel any of these symptoms, move into fresh air immediately. If symptoms persist, get medical help.

STARTING

IMPORTANT: Read the vehicle manufacturer’s instructions. The owner/operator should become familiar with the vehicle in which this generator is installed. Differences exist between vehicles. For example, some vehicles may use a transfer switch to isolate dockside power from the generator, while other vehicles may use an isolating receptacle. Some vehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads.

To crank and start the generator engine, proceed as follows:

1. Turn OFF electrical loads, using whatever means provid ed in your vehicle (such as a main line circuit breaker or transfer switch).

NOTE: If you start the engine with the start/stop

switch on the generator control panel, turn OFF loads by setting the panel’s main breaker to its “OFF” or “OPEN” position. Electrical load circuits may be turned ON after the generator has started, stabilized and warmed up.

NOTE: On gas units you only need to use the fuel

primer during the initial startup, after the unit has not been used for an extended period of time (two weeks) or the fuel line has been disconnected. The primer is

used to prime the fuel pump and carburetor.

2. To crank and start the engine, hold the start/stop switch at START. Release the switch when the engine starts.

CAUTION; If the engine does not start after it has been cranking for 15 seconds, release the start/stop switch and try again. Hoiding the switch for longer than 15 seconds may damage the starter motor.

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

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

NOTE: If you start a warm generator engine, you

may press the start switch only slightly to engage the

ignition system. However, you should press and hold the starter switch for a minimum of two (2) seconds to energize the field boost system. If you start the engine without energizing the field boost system, the generator produces no output.

STOPPING THE GENERATOR

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

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

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

APPLYING LOADS TO GENERATOR

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

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

• DO NOT overload the generator.

■ LEniNG ENGINE STABILIZE

The generator supplies correctly rated frequency and voltage only at the proper governed speed. Some electrical appliances may be extremely sensitive to voltage and frequency. Incorrect frequencies and/or voltages can damage those appliances.

If electrical loads are applied at reduced operating speeds, such loads imposed on the engine when suf ficient power is not available may shorten engine life. Never turn ON electrical loads until after the genera tor engine has started and stabilized ON-speed.

AHENTION REQUIRED AFTER

SUBMERSION

If the motor home generator has been submerged in water, it must NOT be started or operated. Following any submersion in water, have an authorized Generac Service Facility thoroughly clean and dry the generator.

OPERATION IN HIGH GRASS OR BRUSH

Never operate the generator while the vehicle is parked in high grass, weeds, brush or leaves. Such materials can ignite and burn from the heat of the exhaust system. The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down.

OPERATING PRECAUTIONS

Never operate the motor home generator set while the vehicle is parked over dry leaves, dry grass or any other combustible substance. The generator’s

exhaust system becomes extremely hot and can cause a fire if it is too close to combustible materials.

— 8 —

The generator’s exhaust system gives off DEADLY carbon monoxide gas. This dangerous gas, if breathed in sufficient concentrations, can cause unconsciousness and even death. Never operate the generator set with the vehicle inside any garage or other enclosed area. Never operate the generator if it has a leaky exhaust system. Close windows in the vicinity of the generator exhaust outlet and take any other steps to prevent exhaust gases from entering

rooms or areas occupied by people or animals.

EFFEQS OF MOISTURE AND DIRT

Keep the generator set as clean and dry as possible.

Protect unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and moisture to accumulate on 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 Pages 2-3).

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

To avoid overloading, add up the wattage of all con

nected electrical lighting, appliance, tool and motor loads. This total should not be greater than the gener ator’s rated wattage capacity.

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

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

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

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

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

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

This generator has a computer that monitors low oil pres sure, oil ternperature, engine speed, and low voltage out put. This section discusses those protective devices.

AUTOMATIC LOW OIL PRESSURE SHUTDOWN

The engine is equipped with an oil pressure sensor that shuts down the engine automatically when oil

pressure is too low. If the engine shuts down by itself and the fuel tank has enougn fuel, check the engine oil level.

■ INITIAL STARTUP______________________

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

■ SENSING LOW PRESSURE

If the system senses low oil pressure during opera tion, the engine shuts down. If you do restart the engine after a low oil pressure shutdown and have

not corrected the low oil level, the engine runs for about 10 seconds as described above then stops.

______________

HIGH TEMPERATURE SHUTDOWN

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

ENGINE PROTECTIVE DEVICES

OVERSPEED

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

WARNING: Do not attempt to physically adjust or control the engine speed. Equipment damage or

personal injury may result.

LOW VOLTAGE

The computer monitors the voltage output of the gener ator. If voltage sensors indicate that voltage has dropped below a preset level, the engine will automati cally shut down. Once the unit has shutdown, the com puter is automatically reset when you restart the engine.

NOTE: The computer allows for the low voltage out

put that occurs during startup. A time delay that allows the engine to start and warm up is pro grammed into 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.

— 9 —

SPECIFICATIONS

FUEL REQUIREMENTS

(GASOLINE UNITS)

These generators are equipped with gasoline fuel systems as standard equipment. Specific installa tions may provide either a separate fuel tank for the generator, or the generator may “share” the vehicle engine’s fuel tank.

NOTE; Installations using a “shared" fuel tank may

have a generator fuel pickup tube that is shorter than the vehicle engine’s pickup tube. Such an arrange ment causes the generator engine to “run out of gas” while adequate fuel for the vehicle remains in the tank.

To reduce lead and carbon deposits use high quality

UNLEADED gasoline with the generator. Leaded REGULAR grade gasoline is an acceptable substi tute.

NOTE: Using “Unleaded” gasoline contributes to

longer engine valve life by reducing lead and carbon deposits.

CAUTION: Generac does not recommend using any gasoline containing alcohol, it must not con tain more than 10 percent ethanol and it must be removed from the generator during storage. Do NOT use any gasoline containing methanol. If you use gasoline viiith alcohol, inspect more frequently for fuel leaks and other abnormalities.

FUEL REQUIREMENTS (LP UNITS)

These generators are equipped with a liquefied petro leum (LP) gas fuel system. LP gas is usually supplied as a liquid in pressure tanks.

These generators require a “vapor withdrawal” type fuel system. This type of gaseous fuel system uses the vapors forming above the liquid fuel in the storage tank. Air temperature around the storage tank must be high enough to sustain adequate fuel vaporization. In colder climates, you may need to use an indepen dent heat source to be sure the fuel sufficiently vapor izes in the storage tank.

LP gas may consist of propane, butane or a mixture of the two gases. Propane vaporizes at temperatures as low as -20°F (-29°C), but butane returns to its liq uid state when the temperature drops below about 32°F (0°C). For that reason, a higher ratio of propane is desired in the gas mixture when temperatures drop below freezing.

FUEL CONSUMPTION (IN GALLONS PER HOUR):

LOAD GASOLINE

HALF

FULL

0.13

0.20 0.52

0.40 1.05

0.37

ENGINE OIL REQUIREMENTS

The recommended oils include the following:

• During summer months: SAE 30. An acceptable substi tute is SAE 10W-30.

• During winter months: SAE 5W30. DO NOT USE SAE

10W-40.

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

GAS GENERATOR SPECIFIGVTIONS

Model

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

Rated Maximum Continuous

AC Power Output............................ 3600 watts (3.6 kW)

Rated Voltage.............................................. 120 volts AC

Rated Maximum Continuous Current at 120 volts

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

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

Maximum Battery

Charge Current..................................................,. 15 amps

Recommended Battery Cranking Current..

Gross Weight................................................................... 86 lbs

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

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

Impact-36 plus

30 AC amperes

400 amps

LP GENERATOR SPECIFICATIONS

Model.......................................................... Impact-34 plus

Rated Maximum Continuous

AC Power Output............................ 3400 watts (3.4 kW)

Rated Voltage........................................... 120 volts AC

Rated Maximum Continuous

Current at 120 volts............................. 28.3 AC amperes

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

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

Maximum Battery

Charge Current................................................................ 15 amps

Recommended Battery

Cranking Current........................................................... 400 amps

Gross Weight................................................................... 87 lbs

ENGINE SPECIFICATIONS

Type of Engine

Cooling Method................................................. Air-cooled

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

Type of Governor Air Cleaner Starter

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

Ignition System.................................................. Solid state

Recommended Spark Plugs Spark Plug Gap

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

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

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

12 volt DC electric

...........

Champion RC12YC

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

0.030 inch (0.8mm)

GN-220

Electronic

Paper element

10-

MAINTENANCE

This section includes information about sirtiple main tenance which includes the following tasks;

• Checking engine oil level.

• Changing engine oil.

• Changing oil filter.

• Air cleaner maintenance.

• Cleaning the air intake screen. Cleaning spark arrestor.

• Cleaning spark plug. Replacing fuel filter. Servicing inverter.

CHECKING ENGINE OIL LEVEL

Check engine crankcase oil level at least every eight hours of operation, or before each use (Figure 2).

• Be sure the generator is as level as possible.

• Remove oil dipstick and wipe dry with clean, lint-free cloth.

• Install and tighten oil dipstick, then remove again.

• Oil should be at dipstick FULL mark. If necessary, add the recommended oil to the FULL mark only. DO NOT

FILL ABOVE “FULL" MARK.

• Install and tighten oil dipstick cap before operating the engine.

Figure 2 — Oil Dipstick and Fill Tube

• Remove oil dipstick and fill crankcase with the recom mended oil (See Page 10). The engine crankcase can hold about 1 quart (950ml). DO NOT FILL ABOVE “FULL” MARK.

• Install and tighten dipstick cap before operating engine.

CHANGE OIL FILTER

Replace the engine oil filter after the first 8 hours of operation, every 50 operating hours thereafter.

• Turn oil filter counterclockwise to remove (Figure 3).

Figure 3 — Oil Drain Plug and Engine Oil Filter

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

• Run engine and check for leaks.

NOTE: Check oil level and fill to full mark after

checking for leaks. Filter will retain some oil.

NOTE: See “Engine Oil Requirements” on Page 10

for recommended oils.

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 3). Drain

oil completely into a suitable container.

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

—11 —

ENGINE AIR CLEANER

Paper Filter: Once every 25 operating hours or once

each year (whichever comes first), clean or replace the paper filter (Figure 4). Follow the steps on page

12.

Figure 4 — Engine Air Cleaner Assembly

• Remove air cleaner cover, then remove paper filter.

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

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

CLEAN AIR INTAKE SCREEN

Clean all foreign material from the air intake screen (Figure 5) at lease once every 100 hours of operation. Clean more often if necessary.

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

from this area.

Figure 5 — Clean Air Intake Screen

Figure 6 — Setting Gap on Spark Plug

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

FUEL FILTER

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

Figure 7 — Fuel Filter

SPARK ARRESTOR MUFFLER

The spark arrestor must be maintained in effective working order by the vehicle owner/operator.

In the State of California, the preceding is required by law (Section 4442 of the California Public Resources

Code). Other states may have similar laws. Federal

laws apply on federal lands. Inspect and clean the spark arrestor every 100 hours

of operation. To remove the spark arrestor, remove the exhaust

tubing connected to the muffler and then remove the screw that attaches the arrestor to the muffler.

Replace the cone-shaped spark arrestor if torn, perfo rated or otherwise damaged.

ENGINE SPARK PLUG

Clean 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.

— 12

All repairs of the inverter MUST be handled by an authorized service dealer (see Figure 8).

Figure 8 — Inverter Warning Label

WARNING H

HIGH VOLTAGE

UNIT TO BE SERVICED ONLY BY AN AUTHORIZED GENERAC SERVICE DEALER. ALLOW 2 MINUTES FOR UNIT TO POWER DOWN BEFORE OPENING TO REDUCE RISK OF INJURY OR ELECTROCUTION.

CLEANING THE GENERATOR

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

insulation resistance of those windings.

Moisture that is allowed to remain in contact with wind

ings will be retained in voids and cracks of the wind

ings. Dirt makes the problem worse, since it tends to hold the moisture into contact with the windings. Salt, as from sea air, worsens the problem since it tends to absorb moisture from the air. The combination of salt and moisture makes a good electrical conductor.

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

BATTERY

All lead-acid storage batteries will discharge when not

in use. Inspect the generator battery as follows:

■ ONCE WEEKLY_________________________

Inspect battery posts and cables for tightness, corro sion. Clean and/or tighten as necessary.

Also check battery fluid level, and, if necessary, fill with DISTILLED WATER ONLY. DO NOT USE TAP WATER IN BATTERY.

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 can form an explosive mixture around the battery for severai hours after charg ing. The siightest spark can ignite the 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, sparks or any spark producing tools or equipment near the battery.

SERVICE AND ADJUSTMENTS

■ ENGINE SPEED_________________________

Engine speed is completely computer-controlled. There is no adjustment for speed on the unit. The computer adjusts the engine speed using an electron ic governor throttle control. The computer monitors the demand for power and adjusts the engine speed accordingly. This allows the engine to produce only the power required, resulting in tuel 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 throtile manually or any other way.

THROTTLE LINKAGE ADJUSTMENT

If needed, you can adjust the length of the linkage rod between the electronic governor lever arm and the carburetor throttle lever arm. This adjustment helps to establish the proper travel relationship between the two lever arms. Ir this adjustment is not properly set, the computer will NOT have control of the full range of engine speed. If the rod adjustment is set too snort,

the computer will not have access to wide open throt tle or “full power” conditions. If the rod adjustment is

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

Use the following procedure to assure the linkage rod is properly adjusted:

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

2.There should be between stop tab on throttle lever arm and the stop block on the carburetor die casting (Figure 9).

Figure 9 — Gap Between Stop Tab

TOP VIEW OF

THROnUE

LEVER ARM

a gap of 0.003 inch (0.08-0.5mm)

tnrotti

and Stop Block

THROTTLE

'LEVER ARM

DANGER: Battery eiectrolyte fluid is an extremely caustic sulfuric acid solution that can cause severe burns. Do not permit fluid to contact eyes, skin, ciothing, painted surfaces, etc. Wear protec tive goggles, protective ciothing and gioves when handiing a battery. If you spill the fluid, flush the affected area Immediately with clear water.

DANGER; Do not use any jumper cables or boost er battery to crank and start the generator engine. If any battery has discharged, remove it from the vehicle for recharging.

-13 -

MAINTAIN A MINIMUM

6AP0F0.003‘

(0.0t-0.5MM)

CAUTION: Do not overbend the spring clip or the

clip will lose its clamping force.

CAUTION: Do not overbend the spring clip or the clip wiil 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 10).

1. Loosen the rocker arm jam nut. Use an alien wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge (Figure 11).

Figure 11 — Adjusting Valve Clearance

Figure 10 — Adjusting Throttie Linkage

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

Feeler

Guage

2. When valve clearance is correct, hold the pivot ball stud with the alien wrench and tighten the rocker arm jam nut with a crows foot. Tighten the jam nut to 65-85 inchpounds torque. After tightening the jam nut, recheck valve clearance to make sure it did not change (Figure 12).

Figure 12 — Tightening Jam Nut

ADJUSTING THE CARBURETOR

The carburetor of your generator is preset at the facto|7. The carburetor should not be tampered with, as this will void the emission control system warranty. If your generator is used at altitudes in excess of 5,000 feet, consult your Generac Authorized Service Facility regarding high altitude jetting changes.

ADJUSTING VALVE CLEARANCE

After the first 50 hours of operation, you should adjust the valve clearance in the engine.

When adjusting valve clearance, the engine should be at room temperature and the piston should be at Top Dead Center (TDC) of its compression stroke (both valves closed). Correct clearance is 0.001-

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

— 1 4 —

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 PROTEQION

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

• Start the engine and let it warm up.

• While the engine is still warm from running, drain the oil

completely. Refill crankcase with recommended oil. See “Specifications.”

• Attach a tag to the engine indicating the viscosity and

classification of the oil in the crankcase.

• Remove spark plug and add about 1/2 ounce (15ml) of

clean, fresh engine oil into spark plug threaded 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 earthen floor.

• Clean and wipe the entire generator.

RETURN UNIT TO SERVICE

AFTER STORAGE

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

• Check tag on engine for oil viscosity and classification. Verify that the correct recommended oil is used in engine. If necessary, drain and refill with proper oil.

• Check battery. Fill all cells to the proper level with distilled water. DO NOT USE TAP WATER IN THE BATTERY. Recharge battery to 100% state of charge, or, 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

15 —

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 RECOMMENDA TIONS 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 w/ith the proce dures for installing such products, or similar products that Generac manufactures. Generac also assumes that personnel have been trained in the recommended 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, proce dures 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 product's safety is not endangered by the method, procedure or technique selected.

Information, illustrations, specifications, etc., contained in this Installation Manual are based on the latest infor mation available at the time of publication. Every effort has been expended to be sure that such data is both accurate and current. However, the manufacturer reserves the right to change, alter or otherwise improve this product at any time without prior notice.

SAFETY RULES

A Gasoline is extremely FLAMMABLE and its vapors

^ are EXPLOSIVE. Do not permit smoking, open

flame, sparks or any source of heat in the vicinity while handling gasoline. Comply with all laws gov erning the storage and handling of gasoline.

Fuel lines must be properly installed, properly fas tened and free of leaks. There must be no possi bility 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.

A If the generator can be equipped with a liquid

propane (LP) gas fuel system, install the unit so it complies with all codes, standards and regulations pertaining to such systems. LP gas is highly explo sive. 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 unconscious ness 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 vehicle interior and endangering people or animals.

A The generator set produces dangerously high

^ electrical voltage. Contact with bare wires, bare

terminals, etc., will result in extremely hazardous and possibly lethal electrical shock.

• All applicable electrical codes, standards and reg ulations must be strictly complied with in the instal lation 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 possibility of

connecting the different power sources to the vehi cle circuits at the same time. The “dockside” (utility)

power source must be positively isolated from the

vehicle circuits whenever the generator is operat

ing. Failure to isolate the vehicle circuits from the

dockside power supply when the generator is run

ning may result in damage to the generator or seri

ous injury or death to dockside (utility) power work ers due to backfeed of electrical energy.

• Never work on the equipment while standing in water, while barefoot, or while hands or feet are wet. Dangerous electrical shock will result.

• Jewelry conducts electricity, which can cause dan gerous 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 cooling air flow, the engine-generator quickly overheats, which causes serious damage to the generator, a fire or an explosion. Generator air inlet and outlet openings must be provided in strict compliance with the manufacturer's recommendations.

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

A Storage batteries give off EXPLOSIVE hydrogen

^ gas while charging. The battery used for cranking

and starting this generator should be installed in its own vented compartment. Provide adequate ventilation for the battery, to prevent explosive hydrogen gas from accumulating.

• Never insert any tool or other object through open ings 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.

16 —

GENERAL INSTALLATION INFORMATION

PURPOSE AND SCOPE OF MANUAL

These Installation Instructions have been prepared

especially for the purpose of familiarizing installers and o\wners of the applicable equipment with the product's installation requirements. Give serious consideration 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, per sonal injury or damage to equipment and/or property. Stress safety to all installers, operators and service technicians who work on this equipment.

EQUIPMENT DESCRIPTION

Instructions and information in this section pertain to Generac Impact air-cooled generators — more specifi cally, the installation of Impact-34 plus and Impact-36 plus recreational vehicle generators. These generators are designed specifically for installing in recreational vehicles.

ENGINE GENERATOR

OPERATING SPEED

The generators are driven by gasoline-powered, sin gle-cylinder engines. The engines drive revolving fields

(rotors), high frequency, permanent magnet alterna tors. The generators supply 120 volts AC at 60 Hertz with DC inverter. The generators revolving fields are

driven at a variable speed depending on the demand for power. Computers monitor that demand and adjust the engine speed to provide adequate power to the

connected loads.

STANDARDS BOOKLETS

Installation, use and servicing of this equipment should comply strictly with published standards, as well as the manufacturer's recommendations. The following stan dards booklets (latest revision) are available 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, M9W1R3.

— 1 7

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 generator is to be removed from underneath the supporting framework.

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

• The location must provide sufficient room to allow mini mum clearance of at least 1 inch between all sides and 1-

1/2 inches on top of the generator. If sound insulation is to be used on compartment walls and ceiling, the minimum recommended applies to the space between the generator and such insulation.

• The location must provide adequate cooling and ventilating 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 frame work on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams. These beams should consist of (a) 1-1/2 inch square, 11 gauge steel tubing OR (b) 1-1/2 inch, 11 gauge angle iron. A typical supporting frame with horizontal support tubing, is shown in Figure 14.

The generator can be installed so that it sits on top of the horizontal support tubing, it the vehicle design per mits. Another method is to suspend the generator below the horizontal support tubing by means of suit able, structurally sound metal framework. The following 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 supporting frame or support tubing, consider using additional tubing, angle brackets or other supports to give the supporting frame sufficient strength.

Figure 14—Typical Horizontal Support Frame

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 fol lowing: (a) be able to support the weight of the genera tor; and (b) provide sufficient restraint for the genera tor. One typical suspended mounting system is shown in Figure 15. The location of a suspended mounting system must be carefully planned, keeping the follow ing general rules in mind:

• Protect the generator against road splash and debris. Baffles or splash guards may be required to protect certain areas of the generator. To make sure the generator is ade

quately protected, road test the installation through mud, water and slush.

Figure 15 — Typical Suspended Mounting System

GENERATOR MOUNTING

HOLES F0R3/8°-16

BOUS (BOTH SIDES)

The installer must make certain that selected location will permit adequate cooling and ventilating air flow to be sup plied.

—1 8 —

GENERATOR RESTRAINT

Use four 3/8"-16 hardened steel bolts (Grade 5) to fas ten the generator to the supporting frame or the sup port tubing. These bolts must pass through (a) the generator mounting base, (b) the compartment floor, if a compartment is used, and (c) the supporting frame work (Figure 16). 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.

Figure 16 — Typical Generator Restraint

GENERATOR COMPARTMENTS

COMPARTMENTS

The generator set may or may not be installed inside a compartment that is constructed specifically for hous

ing a generator. This section applies to generator com partments when they are installed. The following gen

eral rules apply to compartments;

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

IMPORTANT: ALUMINUM IS NOT AN ACCEPTABLE 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 rec

ommends that the compartment be constructed 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 16 — Types of Lock Seams

IMPORTANT: CAULKING MUST BE DONE SO THAT THE CAULKING MATERIAL WILL STAY IN PLACE PERMANENTLY. PRESSING SUCH MATERIALS AS PUTTY TAPE ONTO JOINTS AND SEAMS WILL NOT MEET THAT REQUIREMENT. A HIGH QUALITY SILI CONE RUBBER SEALANT IS RECOMMENDED.

Holes and opening walls for passage etc, into vehicle living area must be sealed vaportight 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, bolted, riveted, or screwed. Manufactured lock seams are shown in Figure 16.

ssaqe of

s through the compartment electrical conduit, conductors.

JTLar

FOLD LOCKED STANDING

GORDON SEAM

DOUBLE LOCK DOUBLE SEAM

STANDARD LAP JOINT

— 19 —

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 compart ment with metal, and AFTER you have installed sound insulation (Figure 18).

NOTE: Refer to the “Major Features and Dimensions”

drawing in the back of this manual.

Figure 18 — Provide Clearance Around Generator

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 19).

Figure 19 — Typical Compartment Construction

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

• 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 previously.

NOTE: Silicone rubber base sealant is an acceptable

caulking material. Pressing putty tape onto compart ment joints and seams is NOT acceptable.

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

DANGER: Do not install sound insulation or any absorbent materiai on the compartment fioor interi

or. Such materials will become soaked with com

bustible or explosive vapors and iiquids 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 cush ions, fiberboard and other flammable materials. You may need to use approved non-flammable insulat ing materials in high temperature areas.

CROS8«8ECTION VIEW METAL LIHIHQ

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

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-flamma ble type. One excellent insulating material is a 1 inch

thick fiberglass having a 2-pound density. When fiber

glass 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 mate rial. For example, a sheet of lead or visco-elastic mate rial, along with a layer of other acoustical material, 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 20);

• Engine exhaust and cooling air outlets

• Generator cooling air inlet

• Four holes for passage of generator mounting bolts. See "Generator Restraint" on Page 19.

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 lev els. Such a compartment might be constructed as fol lows (Figure 21);

• 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.”

Figure 21 — Typical Noise Abatement Compartment

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

• Seal all compartment door edges to prevent noise leakage around the door perimeter.

• Line the compartment door interior (except for air oo(

ings) with suitable, fire proof sound insulation (such 1 -inch thick fiberglass with a 2-pound density).

len

Figure 20 — Compartment Floor Cutout

COOLING AND VENTILATING AIR

It is absolutely essential that an adequate flow of air for cooling, ventilating and engine combustion be supplied to the generator set. Without sufficient air flow, the engine-generator quickly overheats. Such overheating 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 interi or. 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 control panel (Figure 22). This air flow cools the engine-gener ator 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 22 — Air Flow Through Engine-Generator

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

Figure 23 — Air Inlet in Compartment Door

10 SQUARE INCHES (OPTIONAL OPENINGS)

40 SQUARE INCHES (MINIMUM OPENING)

IMPORTANT; IF YOU PLAN TO INSTALL THE GEN ERATOR IN A COMPARTMENT, BE SURE TO LEAVE AT LEAST ONE INCH (2” RECOMMENDED) OF CLEARANCE BETWEEN THE GENERATOR AND COMPARTMENT WALLS AND CEILING. INCLUDE 26 GAUGE GALVANIZED STEEL LINING AND SOUND INSULATION WHEN YOU MEASURE FOR THIS 1 INCH (2” RECOMMENDED) 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 open

ing (Figure 24).

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 23. The third opening should provide for a minimum of 40 square inches unrestricted and be located lower on the compartment door.

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 24 — Suspended Mount Inlet Door

be sure air is available to the top of the generator since air inlets are located at the top.

By providing an opening in the vehicle skirt and space

above the generator for cooling air flow (Figure 26 on Page

23). Recommended clearance above the top of the gener ator is at least 2 inches.

— 22 —

Figure 25 — Air Inlet Using Ductwork

Some materials may offer only a 60 percent ‘1ree 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 OPENING

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 mea sures 4 inches wide by 12-1/2 inches long provides the required air flow (4 x 12.5 = 50 square inches).

INVERTER LOCATION

The inverter should be located in a dry, well ventilated area in order for the inverter to work effectively. Approximately eight inches of space should be allowed at each end of the inverter for adequate ventilation.

The sensing harnesses supplied with the inverter have a maximum length of 12 feet. If the cables are longer than needed, coil the excess near the inverter unit. If a greater length is needed, contact Generac. DO NOT ATTEMPT TO SHORTEN OR LENGTHEN THE SUP

PLIED SENSING HARNESSES. The DC power wires

may be cut to the required length. Allow enough

length to make connection. Coil excess inside J-Box.

COMPENSATING FOR RESTRIQIONS

Such materials as screening, iouvers, or expanded

metal can restrict the free fiow of air. Compensate for this restriction by making the actuai air opening propor tionately larger.

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 INSTALLATION ESPECIALLY IF YOU BRING IN AIR FROM BELOW

THE GENERATOR SET.

GASOLINE FUEL SYSTEM

Installing a gasoline fuel system (Figure 27) for recre ational vehicle generator sets must comply with applic able codes, standards and regulations. The entire fuel system must be completely free of leaks. There must be no possibility of gasoline vapors entering the vehi

cle interior.

Figure 27 — Generator Fuel System

FUEL INLET

CARBURETOR

DANGER: Gasoline is highly flammable and its vapors are explosive. Comply with all codes, stan dards and regulations pertaining to gasoline fuel systems used in mobile generators. Properly install and maintain the fuel system and keep it entirely free of leaks. Gasoline vapors must not enter the vehicle interior.

FUEL PUMP

CAUTION: Do NOT tee the generator fuel supply line

into the vehicle engine fuei suppiy iine. If this is done, the generator wiil 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 suppiy iine, making it difficuit to start the vehicie engine.

GENERATOR FUEL SUPPLY LINE

RIGID FUEL LINES

Those lines used to supply fuel from a tank to the gen erator must comply with applicable codes, standards and regulations. The following generator rules apply to rigid fuel lines:

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

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

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

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

• Route fuel lines so if they leak, fuel does not drip onto any

electrical or exhaust system parts.

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

Factory installed generator fuel system components include (a) fuel filler, (b) 12-volt DC electric pump, (c) engine carburetor, and (d) interconnecting lines and fit tings. Connect a fuel supply line to the fuel filter inlet.

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

FUEL TANK

Either the generator must share the vehicle engine's fuel lank, or you must install a separate fuel tank for the generator set. All fuel tanks installed on the vehicle must be constructed, installed, restrained so it com plies with applicable codes, standards and regulations.

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.

— 2 4—

■ 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.

_____________________

PROPANE GAS FUEL SYSTEM

DANGER: LP (propane) gas is highly explosive. The gas is heavier than air and tends to settle in low areas, where even the slightest spark can ignite it and cause an explosion. Only competent, qualified persons should be allowed to install, test, adjust or service an LP gas fuel system. Install the optional fuel system in compliance with applicable codes, standards and regulations. After the installation, do nothing that might render the system

in non-compliance with applicable codes and standards.

PARIS NOT INCLUDED IN FUEL SYSTEM

The propane fuel system does NOT include such items

as (a) gas tank, (b) gas piping, (c) fittings, (d) valves, and (e) primary regulator, used to store the gaseous fuel and deliver it to the gaseous fuel solenoid (Figure

28). DANGER: Use only approved components in the gas

supply s^m. All components must be property

installed in accordance with applicable codes. Improper installation or use of unauthorized components may result in fire or an explosion. Follow approved methods to test the system for leaks. No leaka^ is permitted. Do not allow fuel vapros to enter the vehicle interior.

SOME IMPORTANT CONSIDERATIONS

When installing an LP gas system, consider seriously the following items:

• All fittings, lines, hoses and clamps must be tight and free

of leaks. Apply a pipe sealant to threads when assembling

threaded connections. This reduces the possibility of leak

age.

Test the entire fuel system for leaks, using approved test methods.

• Optimum gas pressure at the inlet to the gaseous fuel

solenoid valve and secondary regulator is 11 inches water column.

• The installer’s fuel supply connection point is at the

gaseous fuel solenoid valve. This is a 3/4 inch (female) connection. Provide a suitable 3/4 inch NPT (male) con nector to attach to the fuel supply line.

• Use a length of approved flexible fuel hose between

gaseous fuel solenoid valve and rigid gas piping. The flex ible line should be at least six (6) inches longer than nec essary.

VAPOR WITHDRAWAL

Liquid propane (LP) gas is stored in pressure tanks as a liquid. The gas systems used with these generators were designed only for “vapor withdrawal” type sys tems. Vapor withdrawal systems use the gas vapors that form above the liquid fuel in the tank. Do NOT attempt to use the kit along with any “liquid withdrawal” type system.

PRIMARY REGULATOR

Gas pressure delivered to the solenoid valve must be

properly regulated by means of a primary gas regula tor. Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank. The following

rules apply:

• For best results, the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column.

Do NOT exceed 14 inches water column.

• The installer must be sure the primary regulator is rated at

sufficient gas flow to operate the generator plus all other gas appliances in the circuit.

Figure 28 — Diagram of LP Gas System

25 —

NOTE: Recommended MINIMUM gas flow rate for all

air-cooled Impact-34 plus series generators is 67 cubic

feet per hour.

IMPORTANT: IF AN EXISTING PRIMARY GAS REG

ULATOR DOES NOT HAVE A SUFFICIENT FLOW CAPACITY FOR THE GENERATOR AND OTHER GAS APPLIANCES IN THE CIRCUIT, (a) INSTALL A

PRIMARY REGULATOR WITH ADEQUATE FLOW

RATE, OR (b) INSTALL A SEPARATE REGULATOR

RATED AT LEAST 67 CUBIC FEET PER HOUR. THE

INLET SIDE OF ANY PRIMARY REGULATOR THAT SUPPLIES THE GENERATOR MUST CONNECT DIRECTLY TO GAS TANK PRESSURE. DO NOT TEE THE GENERATOR LINE INTO A GAS CIRCUIT

FEEDING OTHER APPLIANCES.

GASEOUS CARBURETION

LP gas vapors should be supplied to the generator regulator inlet at about 11 inches water column (posi tive pressure). The engine piston draws air in during

the intake stroke (Figure 29). This air passes through

a carburetor venturi which creates a low pressure that is proportional to the quantity of air being pumped. The low pressure from the carburetor venturi acts on the regulator diaphragm, to pull the diaphragm toward the source of low pressure. A lever attached to the diaphragm opens a valve to permit gas flow through

the carburetor. The greater the air flow through the carburetor venturi,

the lower the pressure at the venturi throat, the greater the diaphragm movement and the greater the move

ment of the regulator valve. The more the regulator

valve opens, the greater the gas flow that is propor tional to air flow through the carburetor.

The following facts about the secondary regulator must

be emphasized:

• The regulator must be sensitive to venturi throat pressure changes throughout the operating range.

• The regulator must be properly adjusted so it will stop the flow of gas when the engine is not running (no air flow through the carburetor).

• The slightest air flow (and vacuum) in the venturi throat should move the regulator valve off its seat and permit gas to flow.

FUEL SUPPLY LINES

• Propane gas lines must be accessible, but protected against possible damage.

• Do NOT connect electrical wiring to any propane gas fuel line or run wiring alongside the lines.

• Route gas lines away from hot engine exhausts.

• Retain gas lines with metal clamps that do not have sharp

edges.

• Install an approved length of flexible hose between the

gaseous fuel solenoid valve and riaid fuel supply lines. The flexible line must be non-metallic, non-organic and

non-conductive. It must be approved tor use with LP gas.

EXCESS FLOW VALVE

Propane gas tanks should have an excess flow valve, according to NFPA 501C, Paragraph 3-4.4. This valve and the gas lines must be carefully sized so the valve will close when a fuel line is severed or broken. Consult the Natural-LP Gas Association for information and limitations of excess flow valves.

Manual shutoff valves on the supply tank and else where in the system must be fully open when operat ing the generator. The excess flow valve functions properly only if all valves are fully open.

LEAKAGE TESTS

Do not place the generator into service until you have properly tested the gas system for leaks. To test the system, you need a separate source of 12 volts DC to open the gaseous fuel solenoid valve.

The leak test must comply fully with NFPA, Paragraph

318. All connections, hoses, valves, regulators, fitting, and other fuel system parts must be tested under gas or air pressure of not less than 90 psi (620kPa). while using soap and water or equivalent solution to check for leaks. Other approved methods of testing for leaks may be used, if appropriate. DO NOT USE ANY FLAME TO TEST FOR LEAKS.

DANGER: Gaseous fuel lines between the tank and the secondary regulator are under a positive pres sure (about 11 inches water column). Gas pressure at the outlet side of the secondary regulator, howev er, is a negative pressure (about 1-inch water col

umn) and can draw flame inside a line or fitting and cause an explosion.

Figure 29 — Propane Gas Carburetion Diagram

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 deadiy 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) inabiiity to think coherently, (b) vomiting, (c) twitching muscles, (d) throbbing in tempies, (e) dizziness, (f) headache, (g) weakness and sieepiness. if any of these symptoms ar experienced, move into fresh air immediately. If symptoms per sist, get medical attention. Do not operate the gen erator untii 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, insu late 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 ujge 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 permanently sealed from the vehicle interior.

Exhaust piping must be large enough to prevent excessive back pressure on the generator engine.

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

Plan exhaust system installation carefully. Comply with all applicable codes, standards and regulations.

Figure 30 — Exhaust System

TYPE OF EXHAUST SYSTEM

The Impact-36 plus and Impact-34 plus generators have a configuration for a bottom out exhaust system and is equipped with such an exhaust muffler (Figure 30).

— 2 7 —

ELECTRICAL CONNECTIONS

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 regu lations. 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 flamma ble, explosive or poisonous gases into the vehicle.

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 handle at least 115% of the installed generator's rated maximum current.

• If neutral conductors are used, they must be the same size as other leg wires.

• Route power supply conductors from generator DC output leads +DC (Red) and -DC (Blue), the return (Black) and

the ground (Green) wire through approved flexible conduit, through the compartment floor and to the terminal block

located in the DC junction box on the inverter. Refer to

ANSI/RVIA standard EGS-1-1993 for conduit selection.

• If flexible metal conduit is used between the generator and

the compartment junction box, the conduit end that termi

nates at the compartment junction box must be vapor-

sealed. Flexible metal conduit is NOT vapor tight along its entire length.

• From the AC output junction box on the inverter, route the

three wires T1 (Black), T2 (White), and the Green ground wire through approved flexible conduit to either (a) double pole, double-throw transfer switch, or (b) approved isola tion receptacle. Connecting to a transfer switch or isolation

receptacle must prevent vehicle electrical circuits from

being connected 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 CONNEQION

SYSTEM

The Impact plus AC generator output is provided by the remote located inverter module. 120V AC is provid ed from the terminal block located inside one of the J boxes on the inverter unit (Figure 31). The unit is pro vided with a ground which is connected to the genera tor and should be connected to the chassis of the recreational vehicle.

Figure 31 — Inverter J Box for AC Output

Circuit breaker protection is provided on the generator and protects the unit against overload. Do not apply

loads which exceed the rated wattage capacity of the generator. Add the watts or amperes of all lighting, appliance, tool and motor loads that the generator will operate at one time. This total should be less than the units rated wattage/amperage capacity.

ISOLATING DIFFERENT

POWER SOURCES

Conductors from the junction box must terminate in a double pole, double throw transfer switch (Figure 33 on Page 30). An alternate method for isolating different power sources is by using an isolating receptacle (Figure 34 on Page 30). Whichever method you use, you must be certain that both power sources are NOT connected at the same time.

POWER SUPPLY CORD

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

— 2 8 —

Figure 32 — Generator to Inverter Connection

ftf

GROUND FAULT CIRCUIT

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 recommenda tions.

SENSING HARNESSES

Sensing harnesses have been provided with the generator

to connect to the inverter (Figure 32). The four (4)

DCpower wires (Red, Blue Black, and Green) may be cut

to the desired length to meet the installation (see Figure

32).

CAUTION: DO NOT in any way cut or shorten the two sensing harnesses. If the harnesses are too long, simply tie the excess up neatly with standard cable ties.

— 29 —

Figure 33 — Transfer Switch Isolation Method

Figure 34 — Installation with Isolation Receptacle

BATTERY INSTALLATION

RECOMMENDED BAHERY

Install a battery that meets the following requirements;

• Battery must be a 12 volt, automotive type storage battery.

• For prevailing ambient temperatures above 32°F (0°C), use a battery rated 70 amp-hours and capable of deliver ing 400 cold cranking amperes.

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

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 voltage drop between battery terminals and the gener ator 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 larger the cable size must be as shown in the chart below.

BAHERY CABLE CONNEaiONS

1. Connect the battery cable from the battery post or terminal indicated by a POSITIVE, POS or (+) to the large lug on

the starter contactor as indicated in Figure 35.

2. Connect the battery cable from the battery post indicated by a NEGATIVE, NEG or (—) to the frame ground connec tion (Figure 35).

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 genera tor base. Connect the negative cable to the frame ground of the chassis.

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

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.

CABLELENGTH

in Feet (meters)

Oto 10(0 to 3)

11 to 15 (3.4 to 4.5)

16 to 20 (4.5 to 6)

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

CABLE SIZE

2‘

000

Figure 35 — Connecting Battery Cables

POSmVE CUSTOMER CONNECTION

STARTER CONTACTOR

(13) TO PANEL

(16) TO STARTER

(SS) CONTROLLED 12 VOLTS DC

GROUND

WIRE

FRAME GROUND

31 —

OPTIONAL ACCESSORIES

A plug-in receptacle (Figure 36) is provided on the

generator set, near the DC power 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 36 — Remote Panel Plug-In Receptacle

REMOTE PANEL MODELS

Model 9042: This remote panel (Figure 37) 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 38). Use the hourmeter in conjunction with the periodic maintenance schedule for your generator.

Figure 38 — Model 9043 Remote Panel

o o

GENERAC R.V. GENERATOR

REMOTE PANEL CABLES

Interconnection cables are available from Generac for connecting the optional remote panels to the generator 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 37 — Model 9042 Remote Panel

R.V.

32 —

POST INSTALLATION TESTS

The air cooled Impact-36 plus generator set was facto

ry tested and adjusted using gasoline as fuel.The air

cooled Impact-34 plus generator set was factory tested

and adjusted using LP gas 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. Gas fuel lines must have been prop erly purged and leak tested in accordance with applicable fuel 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 have been properly tested for

leaks before operating the system in compliance with ANSI A119.2/NFPA 501C. No leakage is permit ted. You must be sure no gaseous fuel vapors enter the vehicle interior.

INITIAL START

When absolutely certain that the unit has been proper

ly installed and prepared for use, start the engine as

follows:

1. Turn off all electrical loads. Do this by setting the generator main circuit breaker to its “OFF or “OPEN” position.

2. Refer to the Owner’s Manual shipped with unit for cranking and starting instructions. The engine may require more cranking for initial starting since the fuel lines have to be primed (Use of the Primer Switch on gasoline units will shorten this time).

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 will 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 FACTO

RY BEFORE SHIPPING. NO ADDITIONAL ADJUST MENT SHOULD BE NECESSARY. ONLY QUALIFIED SERVICE TECHNICIANS WHO HAVE BEEN

TRAINED SHOULD PERFORM ADJUSTMENTS

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 COOL

ING.

— 33 —

INSTALLATION CHECK LIST

LOCATION AND SUPPORT

___

1. The generator is properly located.

___

2. The generator is properly supported.

___

3. The generator is properly restrained.

___

4. The inverter is mounted securely.

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

___

5. Inverter has adequate ventilation.

FUEL SYSTEM

___

1. Fuel tank complies with code.

___

2. Fuel system properly installed.

___

3. Fuel system checked for leaks.

EXHAUST SYSTEM

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

ELECTRICAL CONNECTIONS

___

1. Comply with code requirements.

___

2. Inverter 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 prop erly 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.

DATE OF INSTALLATION

NAME OF INSTALLER

SIGNATURE OF INSTALLER

— 34 —

co сл

"П

MAJOR FEATURES AND DIMENSIONS (CONTINUED)

o o

r k

S x3 i/i

ou a

tt S z

0. ~ u

a. <

^^rr-T-

U4-

in in

O rs

— 36 —

TROUBLESHOOTING

PROBLEM

Engine won't crank. 1.

Engine cranks but won't start. 1.

Engine starts hard, runs rough.

Engine starts, shuts down

when Start/Stop switch is

reieased. 3. Defective Low Oil Pressure System 3.

POSSIBLE CAUSES

15 amp fuse is biown. 1.

Loose corroded or defective 2. battery cables.

Defective engine Start/Stop switch.

4. Defective starter contactor.

5. Defective starter motor.

6. Low or defective Battery

Out of fuel. 1. Replenish fuel.

2. Fuel pump is defective (Gasoline), OR, fuel solenoid is defective (LP). Open Wire #14 from Eng. Control Bd.

Engine is flooded. 4. Waif 5-10 min. before trying.

5. Spark plug defective. 5. Clean, regap or replace plug.

Air cleaner plugged or damaged.

Defective spark plug. 2. Clean, regap or replace plug.

Engine oil is low.

Engine is overheated. 2.

Defective Control Board

5. Defective Computer Control Board. 5. Have board serviced/replaced.

REMEDY

Replace 15 amp fuse.

Tighten, clean or replace

as necessary.

3. Replace Start/Stop switch.

4. Replace contactor.

5. Replace starter motor.

6. Charge or replace battery.

2. Replace defective fuel pump or fuel solenoid.

Reconnect wire.

Clean or replace as needed.

Check oil; add as needed. Check adequate ventilation. Have serviced/replaced.

4. Have board serviced/replaced.

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

Start/Stop switch and Control

3. Open/disconnected wire #0 between

Start/Stop switch & Control Bd.

4. Defective Control Board 4.

No output from generator. 1.

Check circuit breaker. 1. Reset to ON or CLOSED.

2. Check vehicle circuit breaker & fuses. 2.

3. Transfer sw. set to NORMAL position.

4. Generator internal failure. 4. Take generator to an

5. Inverter defective. 5.

— 37 —

Replace switch. Reconnect or close wire.

Reconnect or close wire.

Replace board.

Reset and replace if necessary.

3. Set to GENERATOR position.

Authorized Generac facility. Take generator to an

Authorized Generac facility.

ELECTRICAL DATA

Drawing No. A6412 (Sheet 1 of 2)

-13

--------il-------

i-nsy

14 CH

I-------66-

66 BATTERY CHARGE WINDING

CUSTOMER SUPPLIED

BATTERY

16-------------( SM

----

17 - V START

SVI

r- 10—t—^ STOP

rv—^

I ^ HTD

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

LOP —

-----

83 ■

O—

RCWTE

PANEL

CONNECTOR

r’

1 I I f

181417 0

CUSTOMER AC CDOCCTIW

REMOTE PANEL (OPTIDNAL)

— 38 —

Drawing No. A6412 (Sheet 2 of 2)

ELECTRICAL DATA

BCR - BATTERY CHARGE RECTI TIER I BRI - BRIDGE RECTIFIER I BRS > BRIDGE RECTIFIER I BR3 - BRIDGE RECTIFIER I BR4 - BRIDGE RECTIFIER I CBl - CIRCUIT BREAKER. lOA. 2-POLE CC - CHOKE COIL I CH - CHOKE HEATER FI - FUSE. ISA FP - FUEL PUMP DN GASOLINE

SHUT-DFF VALVE DN L/P INV - INVERTER BOX HM “ HOUR METER HTD - SWITCH. HIGH TEMPERATURE OIL

(CLOSES ON HIGH TEMPERATURE) *

IC - IGNITION COIL

LCCCND

INDUCTOR ASSEMBLY IGNITION MODULE IGNITION SENSOR LIGHT. RUN (OPTIONAL)

SWITCH. LOW OIL PRESSURE (CLOSES 04 LOW PRESSURE) STEPPER MOTOR THROTTLE CWTROL C:ONTRX CIRCUIT BOARD

PCBl -

I □)«, 50 WATTS

RI -

STARTER CONTACTOR

SC -

STARTER MOTOR

IS, :

SWITCH. START/STOP SWITCH. FUEL PUMP PRIME SPARK plug LUG. BARREL

TERMINAL. CONNECTOR 4 TAB

terminal block

— 39 —

EXPLODED VIEW — GASOLINE GENERATOR

Drawing No. A6414

— 40 —

_____________

Drawing No. A6414

REPAIR PARTS — GASOLINE GENERATOR

ITEM PART NO.

1 A2467 1

94583 83312 2

3 4

81810

70185 6 86730 7

89476 8

40976 9

99948

11 12 22097 9 14 15 16 89477 1 17 18 90192

20 90051 21 22 96459 23 86709 24 25 26 27 28 29 90021 30 31 32 A5892 33 91437 1 HUB, MAGNET HOUS. ASS’Y 85 59636 34 003-91297 1 35 36 37 86674 1 COVER, AIR BOX 38 78609 2 39 66449C 4 HEX HD. CAPSCR., M6-1 x 80 40 41 42 4a 86692 1 ADAPTOR, STATOR 100 77667 44 45 86735 46 47 48 49 91306 50 36544 1 PIN, COTTER 3/32“ x 1/2" LG 51 52 86736 1 53

86705

92059

86706

89478

19 90881A

78631

35586

86710

87993

49815

90536

94665

93859

86673

78601

49226

80934

A6420

74908 3 TAPTITE, M5-0.8X10

47488

22159

31879

89473

45756

QTY.

DESCRIPTION

ENGINE, LONG BLOCK 54 83512

1 FLYWHEEL, FAN 55 91526

WASHER, CONICAL 56 HEX NUT, Ml 6-1.5 57 42907 3 CAPSCR., M8-1.25x16 LG

1 FILTER, OIL

1 TUBE, EXHAUST OUTLET

GASKET, EXHAUST 61

CAPSCR., M8-1.25x20 LG

4 1 STARTER 63 1 PLATE, DIVIDER

LOCKWASHER, 1/4"-M6 65 1 STEPPER MOTOR 1 ROD, THROTTLE CONTROL

CLIP, ADJUSTMENT 68 1

SNAP, RETAINING 1 WASHER, CARBURETOR 1 ASSEMBLY, CARBURETOR

GASK., CARBySPACER/HEAD 72

GASKET, CARB./SKIRT

GASKET, CARByiNLET ADPT 74

1 1 ADAPTOR, CARB. INLET 75 2 HOSE CLAMP-BAND 1.50"

HOSE, CARB. INLET 77 90072

ELBOW, AIR CLEAN. OUT. 78

1 2 HEX HD. CAPSCR., M5-.8 x 16 79 87478

GASKET, AIR CLEAN. OUT. 80 96627

1 1 BRCKT, AIR CLEAN. SUPP. 81 90613 1 HOUSING, FAN-UPPER 82 59635 1 FAN, GENERATOR 83 002-91297 1 ASS'Y, MAGNET HOUSING

TEMP SWITCH WIRE 86 88905 1 BASE, AIR BOX 87 92800 1 WRAPPER, ENGINE TOP

ELEMENT, AIR FILTER 88 89062

BOLT, AIR CLEANER COV. 91 22447

LOCKWASHER, M5 1 RETAINING RING, STATOR 1 ASSEMBLY STATOR

1 COVER, CHOKE MOUNT 102 52617 1 4

SCREW, 4-40 X.188" 4 LOCKWASHER-#4 4 FLATWASHER-#4 1 . SOLENOID, CHOKE 106

1 ASS,Y, BI-METAL & HEATER 108 86726

LINKAGE, CHOKE CONT. 109 4

M6-1 X 10 TAPTITE

ITEM PART NO. QTY.

005-91297 1

22129

74906 39253

64 55822

66 67 82774 1 WOODRUFF KEY-4 X 19

70 86704 3

76 94637 1

101 86714 1 SCREEN, OIL PICK-UP

103 104 105 43182 2

107

22311 22237

22264 2 LOCKWASHER-M4 89050

59637 4 TAPTITE 3/8"-16 X .75“ LG 86697 1

71 86701 1 BRACK., ENGINE MOUNT FR

86702

73 38353 3

89263 90071 1 0-RING, 1.062" I.D.

86708

004-91297

23762

23484P 96 23897 5 #10-M5 FLAT WASHER 97

94090 99 86675A

94643

74027 2

A1627 1 AIR CLEANER DECAL

92079

66849

DESCRIPTION

1 TAPTITE M8-1.25X15LG 4

11 LOCKWASHER-M8

4 CAPSCR., M6-1 X20LG. 3 3 CAPSCR., 3/8"-16 X 1.25" LG 3 2 PHMS, M4- .7x8 LONG

2 MACH. SCR.-M6-1 X 90 LG

1 BRACK., ENGINE MOUNT RR

1 ASSEMBLY, OIL FILL CAP

1 0-RING .562" I.D. 1 CARBURETOR SPACER

1 BRACK, START. SIDE ENO MNT.

1 COVER, BREATHER CANAL 1 1 STARTER WIRE 1 TEMP SWITCH GR.D WIRE

1 HOSE, BREATHER 2 WASH., EXT. SHAKEPRF-#10 3 1 SNAP BUSHING

1 1 1 SWITCH, OIL PRESSURE

M5 - 0.8 X12 MM CAPSCREW

OIL PRESS. SWITCH WIRE

CAPSCR., M8-1.25x20 LG

LOCKWASHER-3/8"

ASS,Y IGNITION SENSOR

SPACER, ENGINE MOUNT

RUBBER MOUNTS

OIL FILL TUBE

1 GASK., OIL FILT. ADAPTOR

#8 X 3/8" PLASTITE SCREW

1 PLASTITE SCREW, #4 x .37 LG

EXTENSION SPRING

WASH., INT. SHAKEPRF, 25"

SWITCH-THERM., OIL TEMP. ADAPTOR, OIL FILTER

DRAIN PLUG, Ml 2 X 1.75“ LG GASKET, OIL DRAIN PLUG SCREW, M3 X 5“ LONG LOCKWASHER, M3

TAPTITE M6-1 X 25 LG SKIRT, BAFFLE

2 TAPTITE, M5-0.8X 16

— 41 —

Ш S

"О

со

О)

о m

со

I" "Ö

hl03

îi О

то UPPER

FAN HOUSINQ

Drawing No. A6413

REPAIR PARTS — LP GENERATOR

ITEM

1 A2467 1 ENGINE, LONG BLOCK 57 42907 3 CAPSCR., M8-1.25 X 16 LONG 2 94583 1 FLYWHEEL, FAN 58 22129 10 LOCKWASHER-M8 3 83312 2 4 81810 2 HEX NUT, Ml6-1.5 61 39253 5 70185 6 86730 7 89476 1 8 40976 4 CAPSCR., M8-1.25x20 LG. 9 99948 11

12 22097 14 15 16 89477 1 CLIP, ADJUSTMENT 17 18 19 20 21 78631 1 GASKET, CARBURETOR/SKIRT 22 96459 1 23 86709 1 ADAPTOR, CARB. INLET 77 90072 1 0-RING .562" I.D. 24 25 86710 26 87993 1 27 28 90536 1 GASKET, AIR CLEANER OUT. 82 59635 29 30 31 32 A5892 1 ASSEMBLY, MAGNET HOUSING 87 35 86673 36 78601 1 ELEMENT, AIR FILTER 37 86674 1 38 78609 2 BOLT, AIR CLEANER COVER 97 94090 1 SWITCH, THERMAL OIL TEMP. 39 66449C 40 41 80934 1 42 A6420 1 43 44 45 53 45756 3 54 55 ' 91526

PART NO. QTY. DESCRIPTION

WASHER, CONICAL

FILTER, OIL 62 22511 3 CAPSCR., 3/8"-16 X 1.25" LONG

1 TUBE, EXHAUST OUTLET

GASKET, EXHAUST

1 STARTER MOTOR

86705 92059 1

86706 89478 1 SNAP, RETAINING 71

90192 1 WASHER, CARBURETOR 72 86702 1 BRACKET, ENGINE MOUNT RR A2774A 90051 2

35586 2

49815 2 90021 1

94665 93859 1 FAN, GENERATOR

49226 6 LOCKWASHER, M5 100 77667 1

86692 1 ADAPTOR. STATOR 103 94643 1 GASKET, OIL DRAIN PLUG 74908 3 TAPTITE, M5-0.8X 10 57822 1 CLAMP, HOSE 105 43182 2

83512

PLATE, DIVIDER LOCKWASHER, 1/4"-M6 67

STEPPER MOTOR

1 ROD, THROTTLE CONTROL

CARBURETOR ASSEMBLY 73 GASKET, CARB./SPACER/HEAD 74

GASKET, CARB./INLET ADAPT. HOSE CLAMP-BAND 1.25"

HOSE, CARBURETOR INLET ELBOW, AIR CLEANER OUTLET HEX HD. CAPSCR., M5-.8 x 16

BRACKET, AIR CLEANER SUPP. 83

HOUSING, FAN-UPPER 85 59636

BASE, AIR BOX 88 89062 COVER, AIR BOX 96

4 HEX HD. CAPSCR., M6-1 x 80

RETAINING RING, STATOR 101

ASSEMBLY STATOR 102 52617 1 DRAIN PLUG, Ml2 X 1.75" LONG

M6-1 X 10 TAPTITE 106

TAPTITE M8-1.25 x 15 LONG

CAPSCR., M5-0.8XM12 108 86726 1 SKIRT, BAFFLE

ITEM PART NO.

63 64 55822 65 66

68 69 70

75 76

78 79 80 81

104 74027

107

74906

22237 3 LOCKWASHER-3/8" 22264 2 LOCKWASHER-M4

&..050 2 PHILUPS PAN HD. MACH. SCREW82774 1 WOODRUFF KEY-4 X 19

59637 4 TAPTITE 3/8"-16 X .75 LONG 86697 1 86704 86701 1 BRACKET, ENGINE MOUNT FR

38353 3 89263 90071 1 O-RING, 1.062" I.D. 94637 1 OIL FILL TUBE

86708 1 87478 96627 1 BRACKET, START SIDE ENG MNT. 90613 1 COVER, BREATHER CANAL

002-91297 1 STARTER WIRE 88905 1 EXTENSION SPRING

92800 22447

23897 86675A 1 ADAPTOR, OIL FILTER 86714 1 SCREEN, OIL PICK-UP

A1643 92079

QTY, DESCRIPTION

CAPSCR., M6-1 X20LG. TAPTITE

CAPSCR., M8-1.25 x 20 LONG

2 PHMS, M4-0.7 X 8 LONG

M6-1 X 90 LONG

ASSEMBLY IGNITION SENSOR SPACER, ENGINE MOUNT

RUBBER MOUNTS

1 ASSEMBLY, OIL FILL CAP

CARBURETOR SPACER

1 GASKET, OIL FILTER ADAPTOR

1 NO. 8 X 3/8" PLASTITE SCREW

1 PLASTITE SCREW, #4 x .37 LG

WRAPPER, ENGINE TOP

1 HOSE, BREATHER 3 WASH., INT. SHAKEPROOF, 25" 5 #10-M5 FLAT WASHER

4 PSI OIL PRESSURE SWITCH

2 SCREW, M3 X 5“ LONG

LOCK WASHER-M3

A/C DECAL

TAPTITE, M6-1 X 25 LONG

— 43 —

EXPLODED VIEW — ENGINE LONG BLOCK

Drawing No. A6202

DATE; AUG.10, 1998

— 44-

REPAIR PARTS — ENGINE LONG BLOCK

Drawing

ITEM

1 2 76389 3 88411 1 SET, PISTON RING (STD. SIZE) 4 72657 5 77176 6 7 8 83379A 1 ASSEMBLY, CRANKSHAFT AND GEAR

10 89923

11 89213L 1

17 78699B 3 SLEEVE, DOWEL 0 12

18 A2477

19 89096 21 21704 1 GASKET, CYLINDER HEAD 22 78691 23 A5772 24 A5776 1 BALL, OIL PRESSURE 25 78692 1 BOLT, THREAD FORMING-M5 26 78606 28 89230 6 HHFC, M8-1.25 X 35 LONG 30 86293 2 RETAINER, VALVE SPRING 31 88401 2 SPRING, VALVE 32 88590 1 DOWEL PIN, a 12x18 LONG

33 83152 1 GEROTOR, INNER 34 76381 2 36 37 38 90081 39 40 83235 2 TAPPET 42 96362 1 43 77161 2 STUD, BALL PIVOT 44 45 76307 2 NUT, ROCKER ARM 46 47 48' 88413B 1 COVER, ROCKER 49 78629 2 50 90388 2 51 83153 1 52 92977 1 ASSEMBLY-SUMP, OIL 53 84186 2 WASHER, WEAR-VALVE SPRING 54 58 72347 1 59

No. A6202

PART NO.

76380 1 ASSEMBLY, CONNECTING ROD & CAP

88057 76390 2 RETAINER, PISTON PIN

81695 2 90604

21705B 1 ASSEMBLY, CYLINDER HEAD W/GUIDES & SEATS 90082 1 VALVE, EXHAUST

88396A

77160 2 ROCKER ARM

88403 77168 5

88156 1 SEAL VALVE-INTAKE

99922 1 WASHER, WAVE

QTY.

1 PISTON PIN

2 1 1

1 SEPARATOR, OIL BREATHER

1 CUP, BREATHER BAFFLE

1 ASSEMBLY, CAMSHAFT 1 GASKET, CRANK CASE FLANGE

1 RETAINER, OIL PRESSURE SPRING 1

4 SCREW & LOCK WASHER, M6-1 x 12 LONG

1 VALVE, INTAKE 2 PUSH ROD

1 PLATE, PUSH ROD GUIDE

DESCRIPTION

PIPE PLUG-1/4 NPT COVER, BREATHER PISTON, 75 DIA.

ASSEMBLY, CRANKCASE

SEAL, OIL-CRANKSHAFT

SPRING, OIL PRESSURE

BOLT, CONNECTING ROD

GASKET, ROCKER COVER

HEADBOLT, M8 x 52MM

GASKET, BREATHER BOLT, TAPTITE-M6 X 12 LONG GEROTOR, OUTER

SPARKPLUG, CHAMPION RC12YC

DATE: AUG.10, 1998

— 45—-

EXPLODED VIEW — CONTROL PANEL

Drawing No. A9192

o: <

_j o

X CO

I-

0 X

CO CO

O'*

=«:

— 46 —

Drawing No. A9192

REPAIR PARTS — CONTROL PANEL

ITEM PART NO.

91526 2 20093 3 A9180 4 36937 1 #10-32 X1" PHILUPS HD. SCR. 43 5

22158 6

74908 8 7 23484M

8 20107

10 A8592 13 14 16 18 19 23897 20

22 87798 23 92113 24 22676 25 26 A6422 27 28 30 A6436

32 A6060 33 34 43182 35 36

49226

75476

51715

22985

A9174 1

30809

32300

65795

22264

96874 4

43181

89744 1 RESISTOR, POWER 1 OHM

A6423A 2 BUS BAR, OUTER

QTY. DESCRIPTION

7 M5-0.8X 12MM PHILLIPS 1 BOX, CONTROL TOP 38 1 BOX, CONTROL PANEL

1 #10-32 HEX NUT

TAPTITE M5- .8 X 10MM 1 1 1

10 M4-0.7X 16MM 50 25105

2 4 M4 FLAT WASHER 51 9

1 RUBBER GROMMET 1 SWITCH, SPDT ROCKER 58 A6423C 1 BUS BAR, CENTER 1 1 1 1 1

1 4 PHMS M3-.05X10 4 LOCK WASHER-M3

SNAP BUSHING 90° CONNECTOR CIRCUITBREAKER,10A. 48 LOCK WASHER-M5

M4-0.7 HEX NUT

M5 FLAT WASHER 52 51718 CONTROL PANEL, FRONT

SWITCH, SPSTMOM ROCKER FUSE, 15A. AGC 60 23762 FUSE HOLDER EXTRUSION, CONTROLLER 62 RECTIFIER, ВАТТ. CHARGE 63 LOCK WASHER-M4 PANEL DECAL DIODE, DUAL 30A 66 ASSEMBLY. PCS CCG

ITEM PART NO.

37 45756 4

86722 1

41 7521OA 1 TERMINAL BLOCK

A6423B

44 025-91297

A6470

45 46 47

49 A9183 1

53 57

59 29333A 1 BLACK TIE WRAP, 7" LG

64 65

67 68 69

91' 69A

23484D 82121A

84867

77604 1 36933

A6187 A6429 1 WIRE HARN., 7 CONDUCTOR A6430 1 WIRE HARN., 2 CONDUCTOR

A6464 A6516 A6700 1

A6499A

33472 51714

QTY. DESCRIPTION

TAPTITE M6-1.0X10MM

BRACKET, HEAT SINK-PCB

BUS BAR, INNER

GROUND WIRE

DC POWER HARNESS

1 1 REMOTE PANEL HARNESS 1 SNAP BUSHING

CLAMP, CONT. PAN. HARN.

“HARNESS, CONT. PANEL

4 #6-32 X1/4“ PHILUPS RND HD.

MACH. SCREW

RUBBER U-CHANNEL

M4-0.7 X 10MM CAPSCREW

HOUR METER

PPHMS 10-32 X 3/8“ LG

4 SHAKEPROOF EXT. #10 1 INVERTER ASSEMBLY

WIRE HARN.-HEATSINK- PCBI **HARNESS-PCBI TO PANL.

“HARNESS-HEATSINK TO TERM. BLOCK

1 TERM. BLOCK, 4 POSITION

POP RIVET

2 2 M3-.05 NUT

— 47 —

EXPLODED VIEW — LP ENGINE SHEET METAL

Drawing No. A9193

— 48 —

__________

Drawing No. A9193

REPAIR PARTS — LP ENGINE SHEET METAL

ITEM PART NO. QTY. DESCRIPTION ITEM PART NO. QTY. 1 86705 1 PLATE, DIVIDER

2 56893 11 CRIMPTITE 10-24x1/2“ 3 4 A3666 1 5 74908 30 TAPTITE, M5- .8x10 LONG 50 6 A3667 7 22129 12 M8 LOCK WASHER 53 8

10 75494 2 SELF DRILL. SCREW

11 12 89680 1 SPARK ARRESTER 17 89471 1 18 86731A 1

19 86715 20 86726 21 22 23 86719 24 20519 25 26 27 29 22127 5 HEX NUT, 1/4"-20 30 31 86729 32 90518 33 89048 34 90537 1 RETAINER, SEAL 35 22145 4 FLAT WASHER-M8 73 36 75211 1 REGULATOR 37 38 23484D 1 SNAP BUSHING 75 39 40 22471 2 #8-32 HEX NUT 41 22264 2 #8 LOCK WASHER 77 51716 2 M5-0.8 HEX NUT 42

43 23897 4 FLAT WASHER #10/M5 80 44 22447

86718 3.5FT.SEAL RUBBER EXTRUSION

BOX, WRAPPER

MOUNTING RAILS 51

39414 4 M8-1.25X35MM CAPSCR.

#10-16X5/8"

A3638

86671 1 COVER, ROCKER COVER 61 86727 1 SKIRT, SPARK PLUG SIDE

90141A 1 GROUND STRAP 86724 1 PLATE, BASE COVER 43790

22097

40173

23762 2 EXT. SHAKEPROOF-#10 76 91526 2

79246 2 CAPSCR., M6-1.0X 16LG- 78 49226 2 LOCK WASHER, M5

1 WRAPPER, END PANEL

DEFLECTOR, AIR OUT 58 ASSEMBLY, MUFFLER

HOUSING, LOWER FAN

1 SKIRT, CARB. BAFFLE 60 A5606

1 PAN, BELLY 62 66443B 1 FRAME

1 90 « BARB. FITG. 3/8“ x 3/8" NPT 66

LOCK WASHER-1/4"/M6 68

9 1 CONTACTOR, STARTER 69 1 BOOT, CONTACTOR 70 1 SEAL, OIL FILTER HOLE

1 HOSE CLAMP

W/LOCK WASHER 79

WASHER, INTERNAL SHAKE

PROOF, 1/4“/M6

45 74260-103 47 47290 1 HOSE-3/8 I.D. X 11-1/2" LONG 48 92000 49

55 57 22145 2

63 64 45771 8 HEX NUT-M8 65

71 89047 2 SPACER, IGNITION COIL

72 86711 1 MODULE, IGNITION

74 49721 2

25425 2 26490 1 94670 2 91297-007 1 STARTER CONTACTOR

89045

A2666

A4603 1 BRACKET L/P 22507

A3764

20668 2 EARTHING STRAP

38353 3

56892 1 CRIMPTITE #10-24X3/8 79119 A7213 2 TAG, BOLT REMOVAL A5767 1 A9172 1 BRACKET, IGNITION SYSTEM

89049

49813 4 M6-1.0 HEX NUT

84867

56892 1 CRIMPTITE #10-24 X 3/8"

DESCRIPTION

1 GROUND STRAP, UNIT

1 BRACKET, MUFF. HANGER

STREET ELB. 45 « 3/4“ NPT PIPE NIPPLE 3/4“ X 2" “U“ BOLT W/SADDLE & 2-NUTS

GROUND WIRE

1 SEAL, WASHER EXHAUST

PIPE

1 FUEL SOLENOID 12VDC

5/16“ FLAT WASHER

2 CAPSCR., HEX HD.-

1/4”-20x1/2”LG

1 LP HOOK-UP FITTING

CUSTOMER MOUNTING

BRACKET

4 VIBRATION MOUNT

VIBRATION MOUNT

1/4”-20 TAPTITE

HHCS M5-0.8 X 6MM

1 ASSY., IGNITION COIL

M6-1.0X35MM HEX HD. CAPSCREW

M5-0.8X12MM PHILLIPS PAN HD. MACH. SCREW

2.5'" RUBBER “U" CHANNEL

49 —

EXPLODED ViEW — GASOLINE ENGINE SHEET METAL

Drawing No. A9194

— 50 —

REPAIR PARTS — GASOLINE ENGINE SHEET METAL

Drawing No. A9194

ITEM PART NO.

1 86705 1 2 3 4 5 74908 6 A3667 7 8 39414 4

12 13 94670 1 17 89471 1 18 86731A 1 19 86715 1 20

21 86671 1 22 86727 1 23 24 25 90141A 1 26 27 28 28740 1 29 22127

30 22097 7

31 32 33 34 90537 1 35 36 30340 1 37 38 23484D 1 39 23762 2 40 22471 41 ' 22264 42

49813 2 86718 3.5 ft. A3666 1

22129 12

89680

86726

86719

20519

86724 90475

86729 90518 1 89048

22145 4

48031C

79246 2

22447

QTY.

31 2

1 1

2 2

DESCRIPTION

PLATE. DIVIDER M6-1.0HEX NUT SEAL RUBBER EXTRUSION WRAPPER. BOX TAPTITE. M5- .8 X10 LONG MOUNTING RAILS M8 LOCK WASHER M8-1.25X35MM CAPSCR. SPARK ARRESTOR U-BOLT. W/SADDLE & NUTS DEFLECTOR. AIR OUT ASSEMBLY. MUFFLER HOUSING. LOWER FAN SKIRT. CARB. BAFFLE COVER. ROCKER COVER SKIRT. SPARK PLUG SIDE PAN.BELLY FRAME GROUND STRAP PLATE. BASE COVER PUMP. FUEL BARBED 90 1/8" X 1/4" HEX NUT. 1/4”-20 LOCKWASHER-1/47M6 CONTACTOR. STARTER BOOT. CONTACTOR SEAL. OIL FILTER HOLE RETAINER. SEAL M8 FLAT WASHER 1/4” FUEL LINE-4“ LONG

1/4* HOSE CLAMP SNAP BUSHING EXTERNAL SHAKEPROOF #8 HEX NUT #8 LOCK WASHER CAPSCR.. M6-1.0 X16 LONG

W/LOCKWASHER WASHER. INTERNAL

SHAKEPROOF. 1/4“/M6

TEM PART NO. QTY. DESCRIPTION

45 103-74260 47 39450 1

48 92000 1 BRACKET. MUFFLER

49 30340 50 82580D 1

51 86311 1 53 007-91297 1

57 59 60

62 66443B 4 63 20668 64 45771 65 67 68 69 70 A9172 1 71 89047 72 86711 1 73 74 49721

75 49813 4 M6-1.0 HEX NUT 76

77 78 49226 79 80 56892 1

89045

A3638 56893 A5767

A3764

38353 3 VIBRATION MOUNT 79119 2 TAPTITE 1/4”-20 A7213 2 TAG. REMOVE BOLT 23897

89049B

91526 2 M5-0.8X12MM PHILLIPS

51716 2

84867

1 11 1

2 EARTHING STRAP 8 HEX NUT-M8

2 SPACER. IGNITION COIL

1 ASSY.. IGNITION COIL 2 M6-1.0X35MM HEX

2 LOCK WASHER. M5

2.5 FT.

GROUND STRAP. UNIT

1/8”x3/16”NPT90 DEG.

BARBED FITTING

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

(4" LONG) FUEL FILTER STARTER CONTACTOR

GROUND WIRE SEAL. WASHER EXHAUST

PIPE PANEL. WRAPPER BOX

CRIMPTITE. #10-24x1/2“

HEX HD. CAPSCR.. M5-0.8 X 6 LONG

CUSTOMER MOUNTING BRACKET

VIBRATION MOUNT

FLAT WASHER #10/M5 BRACKET. IGNITION SYS.

MODULE. IGNITION

HD. CAPSCREW -

PAN HD. MACH. SCREW M5-0.8 HEX NUT

RUBBER “U” CHANNEL CRIMPTITE #10-24X3/8”

— 51

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT ^

mUR 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 deny

you warranty coverage if your recreational vehicle equipment engine or a part thereof has failed due to abuse, neglert^

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.0.B0X8 FX: (414) 473-6505

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.

— 52 —

EMISSION CONTROL SYSTEM WARRANTY

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

[[.Applicability: This warranty shall apply to 1995 and later model year utility and lawn and garden equipment engines. The

ECS Warranty Period (“ECS Warranty Period“) shall begin on the date the new engine or equipment is delivered to its origi nal, end-use purchaser and shall continue for 24 consecutive months thereafter.

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

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

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

2. Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, will cause a warrant ed emissions - related part to fail to be identical in all material respects to the part as described in the engine manufac turer's application for certification.

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

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

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

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

2. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the Owner's Manual shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or

replace as necessary“ shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS

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

3. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner's Manual shall be warranted for the period of time prior to first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac Corporation according to Subsection (4)

below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the remainder

of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.

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

to the owner at a Generac Corporation Authorized Service Outlet.

.The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS

Warranty is in fact defective, provided that such diagnostic work is performed at a Generac Corporation Authorized Service Outlet.

6. Generac Corporation shall be liable for damages to other original engine components or approved modifications proxi-

mately caused by a failure under warranty of any emission-related part covered by the ECS Warranty.

7. Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to

meet the expected demand for such emission-related parts.

8. Any Generac Corporation authorized and approved emission-related replacement part may be used in the performance of any ECS warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac Corporation ECS warranty obligations.

9. Unapproved add-on modified parts may not be used to modify or repair a Generac Corporation engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac Corporation shall not be liable hereunder for failures of any warranted parts of a Generac Corporation engine caused by the use of such an unapproved add-on or modified part.

EMISSION RELATED PARTS 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

— 53 —

Generac’s Three-Year Limited Warranty For Recreationai Vehicle Generators

Generac warrants to the original owner and subsequent purchasers from the date of purchase by the original owner, that its generators will be free from defects in materials or workmanship for the period as set forth below. During said warranty period, Generac will, at its option, repair or rep^”^ any part which, upon examination by Generac or a Generac Authorized Distributor and/or Dealer thereof, is found to be defective from normal and service.

This warranty is only effective, upon Generac’s receipt from the original owner, a completed Warranty Registration Card, prior to the expiration of the warranty period. This card is the only valid registration identification and must be presented at time of requesting Warranty service. Claims will not

be accepted without presentation of this Registration Card.

THREE YEAR WARRANTY SCHEDULE

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

2. The drive belt and pulleys (If so equipped) on air-cooled generator used In recreational vehicles shall be warranted against failure due to defec tive materials or normal usage for the life of the generator. For the original owner, this drive belt and pulley warranty shall include parts and

labor plus $50.00 payment upon return of the failed belt or pulley by the original owner. For succeeding owners, this drive belt warranty shall

cover belt or pulley parts only.

3. Rental units, demonstrators, prime power, or commercial applications, such as construction or utility, are warranted for (1) one year or 2,000 hours, whichever comes first.

4. This transferable warranty Is In effect for all Recreational Vehicle Generators purchased after Jan. 1,1998.

THIS WARRANTY DOES NOT COVER:

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

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

Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of defective parts.

Failure due to misapplication.

Telephone, telegraph, teletype or other communication expense.

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, the GN-Series engines need periodic parts service and replacement to perform 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 disclaimed is limited to

the time period (one year) as specified in the express warranty. Liability for consequential, incidental or special damages under any and all war

ranties is excluded to the extent permitted by law. Some states do not allow limitations on how 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 1-800-526-2871. Warranty service 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 presented.

RO. Box 8

Generac Corporation

Waukesha, Wl 53187 Telephone: (414) 473-5514Fax: (414) 472-6505

Generac Power Systems 0940-1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

and Installation Instructions

IMPACT-36 plus FEATURES

IDENTIFICATION RECORD

IMPACT-34 plus FEATURES

READ THIS MANUAL THOROUGHLY

OPERATION AND MAINTENANCE

HOW TO OBTAIN SERVICE

SERVICE DEALER LOCATION

1-800-333-1322

GENERATOR FAMILIARIZATION

GENERATOR APPLIGVBILITY

SAFETY

GENERATOR CONTROL PANEL

AUTOMATIC CHOKE (GASOUNE ONLY)

BEFORE STARTING THE ENGINE

STARTING

STOPPING THE GENERATOR

APPLYING LOADS TO GENERATOR

OPERATION IN HIGH GRASS OR BRUSH

OPERATING PRECAUTIONS

EFFEQS OF MOISTURE AND DIRT

ENGINE PROTECTIVE DEVICES

OVERSPEED

LOW VOLTAGE

SPECIFICATIONS

CHECKING ENGINE OIL LEVEL

CHANGE OIL FILTER

CHANGE ENGINE OIL

ENGINE AIR CLEANER

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

SPARK ARRESTOR MUFFLER

ENGINE SPARK PLUG

CLEANING THE GENERATOR

BATTERY

SERVICE AND ADJUSTMENTS

THROTTLE LINKAGE ADJUSTMENT

ADJUSTING THE CARBURETOR

ADJUSTING VALVE CLEARANCE

MAJOR SERVICE MANUAL

EXERCISING THE GENERATOR

OUT OF SERVICE PROTEQION

SERVICE DEALER LOCATION

1-800-333-1322

INSTALLATION SAFETY RULES

NOTICE TO INSTALLER

SAFETY RULES

GENERAL INSTALLATION INFORMATION

PURPOSE AND SCOPE OF MANUAL

SAFETY

EQUIPMENT DESCRIPTION

STANDARDS BOOKLETS

LOCATION AND SUPPORT

GENERATOR LOCATION

GENERATOR SUPPORT

SUSPENDED MOUNTING

GENERATOR RESTRAINT

GENERATOR COMPARTMENTS

COMPARTMENTS

COMPARTMENT SIZE

COMPARTMENT CONSTRUCTION

SOUND INSULATING MATERIALS

COMPARTMENT FLOOR CUTOUTS

ACOUSTICS

COOLING AND VENTILATING AIR

GENERATOR AIR FLOW

COOLING AIR INLET OPENINGS

INVERTER LOCATION

TESTING THE INSTALLATION

GASOLINE FUEL SYSTEM

GENERATOR FUEL SUPPLY LINE

FUEL TANK

PROPANE GAS FUEL SYSTEM

PARIS NOT INCLUDED IN FUEL SYSTEM

SOME IMPORTANT CONSIDERATIONS

VAPOR WITHDRAWAL