Generac Power Systems 9344-1 User Manual

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Part No. 83874
OWNER’S
Manual
SERIES NP-80D
LIQUiD-COOLED RECREATIONAL VEHICLE
Model 9344-1
Revision 0(8/18/92)
CORPORATION
Printed in U.S.A.

GENERAL SAFETY RULES

THE MANUFACTURER SUGGESTS THAT THESE "RULES" FOR SAFE OPERATION BE COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHICLE. SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF THIS EQUIPMENT.
Study these SAFETY RULES carefully before operating or servicing applicable equipment. Become familiar with this Owner’s Manual 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. Stress safety to all operators and potential operators of this equip ment.
The manufacturer cannot possibly anticipate every pos sible circumstance that might involve a hazard. The warnings in this manual, therefore, are not all-inclusive.
If you use a procedure, work method or operating tech nique that Generac does not specifically recommend,
you must satisfy yourself that it is safe for you and others. You must also make sure the procedure, work method or operating technique that you chose, does not
render the generator to be unsafe.
For fire safety, the recreational vehicle generator must be properly installed and maintained. Instal
lation must comply with applicable codes and stan dards. Also, the generator must be installed to conform to the manufacturer’s detailed installation instructions. After installation, do nothing that might
render the generator in noncompliance with such codes, standards and instructions.
The recreational vehicle generator produces ex tremely dangerous electrical voltages and can cause dangerous, and possibly fatal, electrical shock. Avoid contact with bare wires, terminals, etc., while the unit is running. If you must work around an operating generator, stand on an insu lated, dry surface to reduce shock hazard.
Never work on this equipment or handle any elec trical device while standing in water, while barefoot, or while hands or feet are wet. Dangerous 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, if so equipped. DO NOT reconnect the bonding conduc tor to any generator part that might be removed or disassembled during routine maintenance. If the grounding conductor must be replaced, use only a flexible conductor that is of No. 8 AWG copper wire
minimum.
Inspect fuel system frequently for leaks or damage. Repair or replace any damaged or leaking compo nent 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.
In case of accident caused by electric shock, shut down the source of electrical power at once. If you cannot do this, free the victim from live conductor. AVOID DIRECT CONTACT WITH THE VICTIM. Use a dry board, dry rope, or other non-conducting tool to free the victim from live conductor. If victim is unconscious, apply CPR (cardio-puimonary re suscitation) and get medical help.
The generator engine gives off DEADLY carbon monoxide gas through its exhaust system. This dangerous gas, if breathed in sufficient concentra tions, can cause unconsciousness or even death. This exhaust system must have been properly in stalled, complying strictly with applicable codes and standards. After installing the unit, do nothing that might render the unit unsafe or in non-compliance with such codes and standards. The generator compartment must be completely vapor-seaied from vehicle interior. There must be no possibility of exhaust fumes entering the vehicle 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 operating conditions from leaking exhaust gases, leaking fuel, leaking oil or leaking coolant.
The generator compartment needs adequate venti lation to expel toxic fumes and diesel fuel vapors. Do not alter the installation in any way that might obstruct air and ventilation openings. Keep such openings clear and unobstructed.
Keep hands, feet, clothing away from drive belts, fans and other moving parts of this equipment. Never remove a drive belt or fan guards while the unit is operating.
Although diesel fuel is not as volatile as gasoline or LP gas (liquid propane), it is still dangerous. Com ply strictly with all laws and regulations regarding the handling of diesel fuel.
Inspect the generator periodically. Repair or re
place all damaged or defective parts immediately. Before performing any maintenance on the gener
ator set, disconnect its battery cables to prevent accidental starting. First disconnect the cable from the battery post indicated by a NEGATIVE, NEG or
(-)• Reconnect that cable last.
IDENTIFICATION RECORD
Please record the following information. Find this information on the Model/Seria! Number Plate and on the Generator Data Plate, affixed to your generator.
Model Number
Rated kW
Rated Hertz
Serial Number
Rated Volts
Rated RPM
1 -

READ THIS MANUAL THOROUGHLY

If you don’t understand any portion of this manual, contact Generac for a demonstration of actual starting, operating and servicing procedures.
Throughout this publication and on tags and decals affixed to the generator, DANGER and CAUTION blocks are used to alert you to special instructions about a particular operation that may be hazardous if per formed incorrectly or carelessly. Observe them care fully.
These safety warnings cannot eliminate the hazards they indicate. Complying strictly with the special in structions while servicing the unit plus "common sense" are major measures for preventing accidents.
The following definitions apply to DANGER, CAUTION and NOTE blocks found throughout the manual.
DANGER! AFTER THIS HEADING YOU CAN READ INSTRUCTIONS FOR HANDLING, IN STALLING OR SERVICING THAT, IF NOT COM PLIED WITH STRICTLY, MAY RESULT IN PER SONAL INJURY.
the generator. This prepares them if they need to oper ate the equipment in an emergency.
OPERATION AND MAINTENANCE
The operator is responsible for performing all safety checks: to be sure that all maintenance for safe opera tions is performed promptly; and to have the equipment checked by an Authorized Dealer periodically. Normal maintenance service and replacement of parts are the responsibility of the Owner/Operator and, as such, are not considered defects in materials or workmanship within the terms of the warranty. Individual operating ' habits and usage contribute to the need for maintenance service.
Proper maintenance and care of your recreational vehi cle generator keeps the number of problems to a minmum and keeps your operating expenses low. See your authorized Dealer/Distributor for service aids and accessories.
CAUTION! After this heading you can read instruc tions for handling, installing or servicing that, if not complied with strictly, may result in damage to equipment and/or property.
NOTE: After this heading you can read explanatory
statements that require special emphasis. The operator (driver) is responsible for proper and safe
use of the vehicle, equipment of the vehicle and the safety of all vehicle occupants. We strongly recom mend that the operator read this Owner’s Manual and thoroughly understand ail instructions before using this equipment. We strongly recommend instructing other occupants in the vehicle to properly start and operate
HOW TO OBTAIN SERVICE
When your recreational vehicle generator set requires servicing or repairs, simply contact an authorized Ser vice Station for assistance. Service technicians are factory-trained and are capable of handling all of your service needs.
When contacting an Authorized Service Facility of the factory about parts and service, always supply the com plete model number and serial number of your unit as given on its data plate.
The warranty of your generator is included in this Owner’s Manual as are listing for repair parts.
-2-
GENERATOR FEATURES
1. Engine Pre-heat Switch
2. Engine Start/Stop Switch
3. 10 amp DC Circuit Breaker
4. 35 amp AC Circuit Breaker
5. 30 amp Battery Chargingn Fuse
6. Generator AC Output Leads
7. Remote Leads
8. Hourmeter
9. Generator
10. Fuel Return Connection
11. Air Cleaner
12. Oil Drain Hose
13. Oii Filter
14. Oil Dipstick
15. Oil Filler Opening and Cap
16. Fuel Filter
17. 14 amp Fuse
-i-
G F r-J E n AT 1 ■ R_ Mì „ ? A R i/
GENti^.Al Jrt APPLÍCAbi'_r,'¡
These gr^nerators have been designer and rranuiac tured ior he purpose of suppi'/ing elcetn^ai f^ower for
recreational vehicle You chouLi not modify * *ne gen erator or L sp n f:' ally appiif atiuh oin- tfian fa wha' is was detiyiibC. 1 ^sie-e are inv ouesi- n.- pe"*-inii o to its application wri.>- or ''iH Tie r iciogc Do -a esc tne
unit until cl comnpifcni a'of'of'D r.ar “jv.sf*nv<t
DANGEn FOF FiRE 3ÄFE1 . i HL MUST HAVE SEEK' FROPERLf iNSlALLED IK COMPLIANCE W\lh AFPLrOAPLE TCCES AND | ST ^NDARD" TEE GENERATOR ALSO MOST hA/E SEEN iNSfAuLED IN STRiCT GOMPLin ANCE mdTh THE MANÖFACTPi^Efl S DFTAIlSO i INSTALLATION iWSTF.OCTlC NS FOLLGWiNG IN- j STAuI^fiTIOM. NOTHiYG MUST EE DONE ThA^ | M^GKT RENDER TNE JHll IN NON-OOMFLiANCe |
WiTh AuCh OD^ .S**ANr'^FOS A!4D Os-i
STRIjCJjf^liS.
______
_____ ______
_______
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ek Cl If '*'f ,ii< juifirg id'o ‘''C0v*,i:e/ - fVd !
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The owner/operaior should be sure the unit has been installed to allow adequate ventillation for cooling and exhaust air.
SAFETY
Before attempting to use the generator set, carefully read GENERAL SAFETY RULES inside the cover of this Manual. Comply stricly with these RULES to pre vent accidents and damage to aauipment and/or prop­e’~y. r-ne-r-c Ciijaesio that copy. g and posting GEN
ERAL S-FFT RL re n peteriO* hazard areas of the.
vapirie 'ire:, sarnty ^ ^ ope ators and potential
'perah • 1 fOO 'Vi.'nfrji
GENErATSiP A^C CONNECTION SYSTEM
"h' per b pjr (: ^ win a -mal stator AC power
vcs.dingc rn- i- ' c . UvV wind res supply electrical
• G ce" T curtemH-r u' ci' jc 'oacm by means of a dual d '/r I' ,i-mh{yfi /"if M Uc-e, .loweverOhe neutral c QiijMm-h
■“ht mtm h . '-ij'k*, s > that units power r/j/'* -0 -Of . ‘,,a! y aiurf i): c r you can rewire
'hs n ffu(Iir~ on / lO'v !’c k( !f ctrical loads. Be
jff r Un ^ nrki"f n ci'mjif breakers (C.B.
ji ~ lum . ) Alb ' -.1 I. -U> tj io' L 'olts
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j 1/ 0 0 i) <) ' G
T2 (WHITE)
-120 V,
-240 vC
T1 (RED)
Figure 1Connections for 120/240 Volts
Figure 2 Connections for 120 Volts Only
44
öCn
cm
J
T3 (BLACK)
4 -
OPERATION
GENERATOR CONTROL PANEL
See Figure 3 to identify the following components: Hourmeter: Provides continous indication of engine
operating time, in hours and tenths of hours. Use the hourmeter with the periodic maintenance schedule, to make sure that required periodic maintenance tasks are completed on a timely basis.
Engine-Stop/Start Switch: To crank the engine, hold switch at START position. Release the switch when the engine starts. To shut down an operating engine, set the switch to STOP.
10-Amp Circuit Breaker: Protects the DC control cir cuit against overload. If the circuit breaker has opened due to an overload, engine preheat and start functions cannot occur. The breaker is a "push to reset" type.
G E N E R A C
N P 8 0 D
R V GENERATOR
•MAr.'.iAL fOP COMh
E CC 0« ^ '
Preheat Switch: The diesel engine is equipped with glow plugs, one for each cylinder. When you press the preheat switch (Figure 3), the glow plugs heat the engine combustion chamber for quicker starts in cold weather. To preheat the combustion chamber for quicker starts in cold weather. Press the switch and between 15 and 30 seconds. Continue holding in the preheat switch while cranking the engine until it starts.
NOTE: Refer to THE GENERATOR A-C CONNEC TION SYSTEM on Page 4. Individual installations will differ. If an overload occurs, the dual breakers will open the hot stator leads (11 and 44). When the generator has been connected for 120 volts only, one of the dual circuit breakers will open stator AC output lead No. 11 (hot lead).
REMOTE START/STOP PANEL
A remote mounted Start/Stop Panel is available, which allows you to start and stop the generator engine con veniently from inside the vehicle.
You can also order a remote panel that includes meters and gauges for monitoring low oil pressure, high coolant temperature and low coolant level (Figure 5), in addition to a start/stop switch. The panel also includes an am meter, a voltmeter and an hourmeter.
Figure 3Generator Control Panel
Dual AC Circuit Breaker: Rated at 35 AC amps, the circuit breaker (Figure 4) protects the generator’s AC output circuit against overload and provides a method of turning OFF the generator’s 120/240 volts AC output to vehicle circuits.
Figure 4Dual 35-amp Circuit Breakers
1 mEM PREMEC WHTCH KM Sfl sec
L AFTEW SO sec Of WOHMr l»R£8S rcW »»ffTCH,
corrwue TO ewiTM mEHSJu mnc» *<hile cfWiWHO
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GEN.
RUN
LiJ
STOP START
PREHEAT
LJJ
30 SEC. MAX
GENERAC R.V. GENERATOR “
Figure 5Remote Start/Stop & Gauge Panel
BEFORE STARTUP
• Check Engine Crankcase Oil Level: Refer to
SPECIFICATIONS and MAINTENANCE sections for procedures and recommendations.
CAUTION! Any attempt to crank or start the engine before properly servicing it with recommended oil will result in an engine failure.
NOTE: Engine was factory serviced with a high quality
oil classified "For Service CD" or "For Service CC" and having a viscosity rating of SAE 30. The installer may have refilled the crankcase with an oil more suitable for ambient temperature ranges in your area.
® Check Coolant Level: Check coolant level prior to
initial use and at recommended intervals. Refer to SPECIFICATIONS and MAINTENANCE sections for procedures and recommendations.
® Check Fuel Supply: Make sure an adequate sup
ply of clean fuel is available to the engine. Many installations include a Fuel Shutoff Valve, which you must open before starting the engine.
NOTE: On some installations, the generator may have been provided with its own fuel tank. On other installa
tions, the generator may "share" with the vehicle’s fuel
tank. When the vehicle’s tank is shared, some installers may have installed a generator fuel pick up tube in the shared tank that is shorter than the vehicle’s pick up
tube. When a shorter generator fuel pickup tube is
installed in the tank, the generator will run out of gas
while sufficient fuel remains in the tank for vehicle
engine operation.
START THE GENERATOR
To start the generator from either the generator control
panel or from the optional Remote Panel, proceed as
follows:
1. Turn OFF electrical loads, using whatever means provided.
NOTE: If starting from the generator panel, turn OFF loads by setting the generator’s main circuit breaker to
OFF or OPEN. If starting from a Remote Panel, turn OFF loads using whatever means is provided in the vehicle (such as a main circuit breaker.)
2. Press the preheat switch (if engine is cold) for . between 15 and 30 seconds.
3. At the same time, hold the Engine-Start/Stop
Switch at START and press the preheat switch to crank engine. Release the switch when the engine starts.
4. Let the engine stabilize and warm up.
5. Turn ON electrical loads, using whatever means
provided.
SHUTTING DOWN THE GENERATOR
1. Turn OFF electrical loads, using whatever means provided.
2. Let the engine run at no-load for a few minutes to stabiize internal temperatures.
3. Set the Engine-Run/Stop Switch to STOP position.
-6
AUTOMATIC LOW OIL PRESSURE
SHUTDOWN
The engine is equipped with a normally-closed (N.C.)
oil pressure switch (Figure 6). Engine oil pressure holds the switch open during cranking and operation. Should oil pressure drop below about 15 psi, the switch contacts close and the engine automatically shuts down.
HIGH COOLANT TEMPERATURE
SHUTDOWN
This switch (Figure 7) is a normally open (N.O.) thermo
static device which is immersed in engine coolant. Should engine coolant temperature exceed about 230°F (110°C), the switch contacts close and the en gine shuts down.
ADDITIONAL INFORMATION
Figure 8Engine Controller Circuit Board
NOTE: After an overspeed shutdown, the engine may be cranked and re-started. However, if the engine overspeeds again, the engine shuts down again.
ENGINE GOVERNED SPEED
The generator is equipped with a 4-pole revolving field
(rotor) which must be driven at 1500 rpm to produce the
unit’s rated a-c frequency of 50 Hz. The diesel engine
governor was factory set to about 52 Hz. (1560) at
no-load. After installing it, the installation technician should check and adjust the governed speed. Setting the no-load frequency slightly high helps prevent exces sive frequency, rpm and voltage droop under heavy
electrical loading.
DANGER; DO NOT TAMPER WITH THE ENGINE GOVERNOR SETTINGS. EXCESSIVELY HIGH ENGINE SPEEDS ARE DANGEROUS AND IN CREASE THE RISK OF PERSONAL INJURY AND DAMAGE TO EQUIPMENT AND/OR PROPERTY. EXCESSIVELY LOW SPEEDS IMPOSE A HEAVY LOAD ON THE ENGINE WHEN ADEQUATE EN GINE POWER IS NOT AVAILABLE AND MAY SHORTEN ENGINE LIFE. THE GENERATOR SUP PLIES CORRECT RATED FREQUENCY AND VOLTAGE ONLY AT THE PROPER SPEED. SOME ELECTRICAL DEVICES MAY BE DAM AGED BY INCORRECT FREQUENCY AND/OR VOLTAGE. IF ENGINE SPEED APPEARS TO BE INCORRECT, CONTACT YOUR NEAREST AU THORIZED SERVICE FACILITY.
Figure 7High Coolant Temperature Switch
OVERSPEED SHUTDOWN
The generator control panel houses an Engine Control ler circuit board (Figure 8). That circuit board receives a-c frequency signals from generator stator leads 11 and 22. Should a-c frequency exceed about 72 Hz
(2160 rpm), circuit board action initiates an automatic shutdown after a few seconds.
25-HOUR BREAK-IN PERIOD
The first 25 hours of operation is the break-in period for
the generator. Properly breaking in the generator is
essential to reducing oil consumption and enhancing
engine performance. During the break-in period, ob
serve the following rules:
• For the first 25 hours, run the generator at varying electrical loads, to help set the enaine piston rings properly.
- 7
Following the initial 25-hour break-in period, avoid light electrical loads for the next 75 hours of opera tion. The unit should be loaded at 50% (or more) of its capacity during those 75 hours. Repeated light loads during break-in period may improperly seat the piston rings, resulting in blowby and high oil consumption.
Check oil level frequently during the break-in period. Add oil if needed. It is natural for the generator engine to consume much oil until the piston rings
have seated properly. When the 25-hour break-in period is done, complete
the tasks recommended under 25-HOUR CHECK
UP PERIOD.
25-HOUR CHECK-UP PERIOD
After the first 25 hours of operation have been com pleted, contact an Authorized Service Facility for the following maintenance. The Owner/Operator is respon sible for any changes.
Change engine crankcase oil and oil filter.
Check all fluid levels. Check all cooling system hoses and fittings for
damage, deterioration, looseness, etc. Check all
hose clamps for tightness and security.
Check engine for proper operation.
Inspect the diesel engine fuel system for leaks, tightness and security of fuei fittings and hoses.
Inspect drive belts for condition and proper tension.
Inspect the exhaust system for damage, deteriora tion, leaks, proper operation.
Inspect the electrical system.
Inspect the installation for safety violations, compli ance with codes and standards.
FREEZING TEMPERATURE OPERATION
The engine cooling system should have been properly filled with a 50-50 mixture of ethylene glycol base anti freeze and soft water. When adding coolant to the radiator or to the coolant recovery bottle, add only the recommended 50-50 mixture. Refer to SPECIFICA TIONS section. If the recommended 50-50 mixture is added to the system consistently, the unit adequately protects against freezing temperatures.
ATTENTION REQUIRED AFTER
SUBMERSION
If the generator has been submerged in water, it must NOT be started and operated. Following any submer sion in water, have an authorized Generac Service Facility thoroughly clean and dry the generator.
OPERATING PRECAUTIONS
Never operate the generator set while the vehicle is parked over dry leaves, dry grass or any other combus
tible substance. The generator’s exhaust sytem be comes extremely hot and can cause fire if it is too close to combustible materials.
The generator’s exhaust system gives off DEADLY
carbon monoxide gas. This dangerous gas, if breathed
in sufficient concentrations can cause unconsciousness
and even death. Never operate the generator set with the vehicle inside any garage or other enclosed area.
Never operate the generator with a leaking exhaust
system. Close windows in the vicinity of the generator
exhuast outlet and take any other steps that may be
necessary to prevent exhaust gases from entering
rooms or areas occupied by people or animals.
EFFECTS OF MOISTURE AND DIRT
Keep the generator set as clean and dry as possible.
Protect the unit against excessive dust, dirt, corrosive vapors, road splash, etc. Permitting dirt and moisture to accumulate on generator windings wii! have an ad verse affect on the insulation resistance of those wind
ings. When moisture is allowed to remain in contact with
windings, some of that moisture will be retained in voids and cracks in the insulation. This causes a reduced
insuiation resistance and will eventually cause prob
lems. Dirt will make the problem worse, since dirt tends to hold moisture in contact with the windings. Salt (as from sea air) will also worsen the problem since it tends to absorb moisture from the air. Salt and moistsure, when combined, form a good electrical conductor.
- 5
_________
SPECIFICATIONS
FUEL REQUIREMENTS
Recommended fuel is any high quality, automotive type diesel fuel conforming to JIS No. 2D diesel fuel. Keep the fuel clean.
RECOMMENDED FLUIDS
Engine Oil; Use a high quality detergent oil classified
"For Service CC or CD." Detergent oils keep the engine cleaner and reduce carbon deposits. Use oil having the following SAE viscosity rating, based on the ambient temperature range anticipated before the next oil change:
Temperature Oil Grade (recommended)
Above 100°F
40°-l00°F
Below 40°F
Coolant: Use a mixture of half low silicate, ethylene glycol base anti-freeze and half soft water. Coolant system capacities may vary, depending on the specific installation, length of system hoses, radiator use, etc. Use only soft water and low silicate anti-freeze. If desired, a high quality rust inhibitor may be added to the recommended coolant mixture. When adding coolant, always add the recommended 50-50 mixture.
CAUTION! Do not use any chromate base rust in hibitor with ethylene glycol base anti-freeze or chro mium hydroxide ("green slime") forms and causes overheating. You must chemically clean engines the have operated with a chromate base inhibitor before adding ethylene glycol base anti-freeze. Using any high silicate anti-freeze boosters or addi tives will also cause overheating. In addition, using any soluable oil inhibitor is not recommended for this equipment.
SAE10W-30 or SAE 30 j
SAE 5W-20 or 5W-30
SAE 40 !
GENERATOR SPECIFICATIONS
Series........................................NP-80D
Model Number Rated Maximum Continuous a-c Power Rated Volts Rated Maximum Continuous Load Current
At 120 Volts .............................62.5 amps
At 240 Volts.............................31.25 amps
Rated a-c Frequency
Phase........................................1-Phase
Power Factor Number of Rotor Poles
Rotor Speed at No-Load........... 1860 rpm
Engine Type
Displacement.............................58.2 inches (954cc)
Cooling Method Combustion Chamber Cylinders and Arrangement
Bore...........................................2.95 inches (75mm)
Stroke
.......................................
Compression Ratio....................23 to 1
No. of Main Bearings Break Mean
Effective Pressure....................
..........................
..................................
...............................
................
............................
.............
9344-1
7500 watts (7.5 kW) 120/240*
60 Hz. at 1800 rpm
1.0 4
ENGINE SPECIFICATIONS
..............................
............
............
...............
................ 5
4-cycie diesel
Water Cooled
Swirl Type
......
3
2.83 inches (72mm)
97
. 9-

MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE
* Performed by Authorizied Service Facility
** Performed by Owner/Operator
A. After the first 25 Operating Hours*
1. Change Oil and Oil Filter.
2. Check engine coolant level.
3. Inspect cooling system.
4. Check engine operation.
5. Inspect drive belts.
6. Inspect exhaust system.
7. Inspect electrical system.
8. Inspect battery.
9. Check governed speed setting.
10. Check engine valve clearance.
11. Inspect air cleaner/flame arrestor.
12. Clean the generator.
B. Every 8 Hours of Operation**
1. Check coolant level in coolant recovery bottle.
2. Check fuel level.
3. Check engine oil level.
C. Once Each Week**
1. Inspect the generator set.
2. Inspect the generator battery.
_____________
_________
________
______
_____
_____
OVERLOAD PROTECTION FOR ENGINE
D-C ELECTRICAL SYSTEM
Engine cranking, start up and running are controlled by a solid state Engine Controller circuit board. Battery voltage is delivered to that circuit board via 10 amp circuit breaker and 14 amp in-line fuse. These overcurr ent protection devices will open if circuit is overloaded.
CAUTION! If a circuit breaker opens or a fuse ele ment melts, you should find the cause of the over
load before resetting the circuit breaker or replacing the fuse.
10 amp Circuit Breaker: If the circuit breaker opens
due to an overload, you cannot crank or start the engine. The circuit breaker is a "push-to-reset“ type. For emer
gency shutdown, pull the circuit breaker open. Also see
"Generator Control Panel" on Page 5.
_
14 Amp Fuse: If the fuse element melts open, you
cannot crank or start the engine. If you must replace the fuse, use only identical 14 amp fuse (Figure 9).
30 amp Fuse: The generator set battery is charged
during operation by a d-c alternator, driven by the en
gine. This 30 amp fuse protects the charging circuit
against overload. Should you need to replace the fuse,
use only an identical 30 amp fuse (Figure 10).
D. Every 100 hours or Once Each Month**
(whichever comes first)
1. Inspect cooling system.
2. Inspect exhaust system.
E. Every 6 months or Every 250 Operating Hours"
(whichever comes first)
1. Change engine oil and filter.
2. Check engine operation.
3. Inspect drive belts.
4. inspect electrical system.
5. Inspect and check battery.
6. Check engine governor setting.
7. Clean or replace fuel filters.
8. Inspect air cleaner/flame arrestor.
9. Clean the generator.
10. Check cooling system and coolant level.
11. Inspect exhaust system.
12. Inspect fuel system.
F. Once Annually or Every 500 Operating Hours"
(whichever comes first)
1. Check engine valve clearance.
2. Check engine compression and condition.
3. Check fuel injection timing.
4. Check/test fuel injection nozzles.
G. Once Every Two Years
____________________
________
STAR n.NG
C ! K C U i I
10 AMP
Figure 914 amp Fuse
batter'T'
CHARGING pre-heat
30 AMP 30 SEC. MAX
ENGINE
CON TROLlEFV
14 AM
ST/
1. Drain, flush and refill cooling system.
Figure 1030 amp Fuse for Battery Charge Circuit
-10-
CHECKING FLUID LEVELS
Check Engine Oil: Check the engine crankcase oil level at least every 8 hours that you operate the unit, or before every time you use it (Figure 11).
Make sure the generator is as level as possible. Remove oil dipstick and wipe dry with a clean,
lintfree cloth. Install oil dipstick, then remove again. Oil should be at dipstick FULL mark. Never operate
the generator with oil level below dipstick ADD mark. DO NOT FILL CRANKCASE ABOVE DIP STICK FULL MARK.
Battery Fluid: Check battery electrolyte fluid at least once weekly. Fluid should cover separators in all bat tery cells. If fluid level is low, add distilled water to cover tops of separators. DO NOT USE TAP WATER IN
BATTERY.
Engine Coolant: Check coolant level in coolant recov ery bottle.
Add the recommended coolant mixture as neces sary.
Periodically remove radiator pressure cap to make sure the coolant recovery system is functioning properly. Coolant should be at bottom of radiator filler neck. If coolant level is low, inspect gasket in radiator pressure cap. Replace cap, if necessary.
To have pressure cap tested, contact an authorized
Generac Service Facility. Inspect cooling system and coolant recovery system for leaks.
INSPECT GENERATOR SET
Once each week inspect the generator set. Look for
fuel, oil coolant leaks. Check for missing or loose nuts,
bolts and other fasteners. Check for damage. If unitis dirty, it may be cleaned with a damp cloth or soft brush. Inspect the exhaust system. NEVER operate the gen erator with a defective exhaust.
INSPECT COOLING SYSTEM
Inspect the entire cooling system once each month or every 100 operating hours, whichever occurs first. Check for leaks, condition of hoses, tightness of clamps.
CHANGING ENGINE OIL
Refer to PERIODIC MAINTENANCE SCHEDULE for engine oil and filter change frequencies. You should also change generator engine oil before placing the
vehicle into storage.
Drain the oil while engine is still warm from running, which means warm up the engine, shut it dov^n and drain immediately as follows (Figure 12 ):
1. Remove OIL DRAIN HOSE from its retaining dip.
2. Loosen and remove OIL DRAIN HOSE CAP. Drain oil completely into suitable container.
Figure 12Changing Engine Oil
-11 -
3. When all oil has drained, insiail and tighten OIL DRAIN HOSE CAP.
4. Turn OIL FILTER counterclockwise and remove. Dispose of old filter.
5. Apply a light coating of engine oil to seal of new oil filter, install FILTER and tighten bv hand only. DO NOT OVERTIGHTEN.
6. Remove OIL FILLER CAP. Add recommended oil (see SPECIFICATIONS). DO NOT OVERFILL ABOVE THE DIPSTICK "FULL" MARK. Crank case oil capacity is 3.7 U.S. quarts (3.5 liters).
CAUTION! After refilling the crankcase with oil,
always check oil level on dipstick. NEVER OPER
ATE ENGINE WITH OIL BELOW THE DIPSTICK "ADD" MARK.
7. Start engine and check for oil leaks.
COOLANT CHANGE
Every two years, the cooling system should be drained,
flushed and refilled by an Authorized Service Facilty.
See SPECIFICATIONS for cooling system recommen
dations.
MISCELLANEOUS MAINTENANCE
Cleaning the Generator: Keep your standby genera
tor as dean and as dry as possible. Dirt and moisture
that is allowed to accumulate on internal generator windings have an adverse effect on insulation resis tance.
Periodically clean generator exterior surfaces. A soft brush may be used to loosen caked on dirt. You can
use a vacuum system or dry, low pressure air to remove any accumulations of dirt, if the generator is housed
inside an all-weather enclosure, clean the enclosure with a soft, damp cloth or sponge and water.
Once each year have the generator cleaned and in spected by an Authorized Service Facility. That facility will use dry, low pressure air to clean internal windings.
Parts inside the control console should be cleaned and inspected at this time as well.
Finally, have the insulation resistance of stator and rotor windings checked. If insulation resistances are exces sively low, the generator may require drying.
Battery: All lead-acid storage batteries discharge when not in use. Refer to specific instructions and warnings that accompany your battery. If such information is not available, observe the following precautions when han dling a battery:
DO NOT use jumper cables and a booster battery to crank or start the generator engine.
DO NOT recharge a weak batter/ while it is installed in the generator. Remove battery from generator and recharge in a well-ventilated area, away from fuel vapors, sparks, heat or flames.
Battery electrolyte fluid is an extremely caustic sul furic solution that can cause severe burns. DO NOT permit fluid to contact eyes, skin, clothing, painted surfaces, wiring insulation, etc. If you spill any battery fluid, flush the affected area with clear water
immediately.
Always wear safety glasses, rubber apron and
gloves when handling a battery.
Batteries give off explosive hydrogen gas while charging. The gas can form an explosive mixture around the battery for several hours after charging. Any spark, heat or flames can ignite the gas'^and cause an explosion which can shatter the battery, causing blindness or other serious Injury.
PERIODIC REPLACEMENT PARTS
Part Name
Oil Filter
Radiator Cap
Air Cleaner Element
Fuel Filter
Generac Part No.
127-70939
46627 70941 69858
-12
TROUBLESHOOTING
PROBLEM
Engine won’t crank.
POSSIBLE CAUSES REMEDY
1. 10 amp circuit breaker tripped.
2. 14 amp fuse blown.
3. Loose corroded or defective battery cables.
4. Defective engine Start/Stop switch.
5. Defective starter contactor.
6. Defective starter motor.
Engine cranks but won't start.
1. Vehicle fuel shutoff valve is closed.
2. Out of fuel.
3. Fuel solenoid (FS) is defectcive
4. Fuel pump (FP) is defective.
5. Open Wire #14 from Engine Control C.B.
6. Clogged fuel filter or fuel line.
7. Engine mechanical parts failure.
8. Spark plugs defective.
Engine starts hard, runs rough.
1. Flame arrestor (air cleaner) plugged or damaged.
2. Defective fuel pump.
3. Plugged fuel filter or fuel line.
4. Water in fuel.
Engine starts, shuts down when Start/Stop switch is released.
1. Engine oil level is low.
2. Engine is overheated.
3. Defective Low Oil Pressure Switch
4. Defective Coolant Temperature Switch
5. Defective Engine Controller circuit board.
1. Reset circuit breaker
2. Replace fuse.
3. Tighten dean or replace as necessary.
4. Replace Start/Stop switch.
5. Replace contactor.
6. Replace starter motor.
1. Open valve.
2. Replenish fuel tank.
3. Refplace solenoid.
4. Repair or replace fuel pump.
5. Reconnecfwire.
6. Replace if clogged.
7. Repair or replace parts.
8. Clean, regap or replace plugs.
1. Clean or replace as needed.
2. Replace or repair fuel pump.
3. Replace filter; unclog fuel line.
4. Drain tank and refill.
1. Check oil and add oil as needed,
2. Check cooling system for leaks.
3. Replace switch.
4. Replace switch
5. Replace circuit board.
Start/Stop Switch at STOP, engine continues to run
1. Defective Start/Stop switch.
2. Open/disconnected wire #18 between Start/Stop switch & Engine Controller C.B.
3. Open/disconnected wire #0 between Start/Stop switch & Engine Controller C.B.
4. Defective Engine Controller circuit board
No a-c output from generator.
1. Check 15-amp circuit breaker.
2. Check vehicle circuit breaker & fuses.
3. Transfer switch set to NORMAL position
4. Generator internal failure.
1. Replace switch.
2. Reconneci/close wire.
3. Reconnect/close wire.
4. Replace board.
1. Reset to ON or CLOSED.
2. Reset and replace, if necessary,
3. Set to GENERATOR position.
4. Take generator to Authorized Generac service facility.
- 13 -
- CIRCUÍ г BREAKER 30A.3SA
- CiRCUíT BREAKER (iOA)
- CiRCUir BREAKER (5A)
- RELAY 02v) ТРОТ
relay (12v) DPOT
- DIODE 600V, 6АЫР
- DiOOE 600V, 6AMP
“ DC alternator
FUSE И AMP SEE
FUSE 30A FUEL PUMP
FUEL SOlENOlD
GROUND HIGH WATER TEMP SWITCH HOURME TER
LOW OIL PRESSURE SWITCH
preheat contactor
RESISTOR 10 OHM, 5 WATT
STARIER
START contactor
PREHEAT SWITCH
SWITCH START/STOP
SENSE transformer
id
О P
Z2
00
OJ o> tvi
CO
2
z
о g
>
Q
33
>
T3
I
Ш
о
о
Q
m
z
m
WIRE POSITION 1 IS GROUND. WIRE POSITION 2 TO 1 WILL START UNIT. WIRE POSITION 6 TO 1 WILL LIGHT A RUN LAMP.
WIRE POSITION 3
TO 1 WILL STOP UNIT­WIRE POSITION 4
TO 5 WILL START PREHEAT.
>
О

ELECTRICAL SCHEMATIC — NP-80D GENERATOR

DCA-DC ALTERNATOR DP£ -EXCiTATiON WINDING
n -FUSE UAMP SFE F2 -FUSE 30A FS -FUEL SOLENOiD FP -FUEL PUMP HM -HOURMETER HWT-HiGH water temp switch
LOS-LOW Oil PRESSURE SWITCH
PHC -preheat contactor R2 -resistor 10 OHM. 5W s -starter SC -START contactor
Sw -PREHEAT S'WITCH SW] -SWITCH, START/STOP T1 -SENSE transformer
TP -thermal PROTECTOR
CONNECTION OPTIONS
- 15 -
EXPLODED VIEW — ENGINE COMMON PARTS
Drawing No. 81982
-16
_______
Drawing No. 81982
REPAIR PARTS LIST — ENGINE COMMON PARTS
ITEM
PART NO.QTY.
1 81932 2 3 4 5
6
35586 81946 81947 55934
22302 7 51755 8 9
10
72501
43107
81942
11 49813 12 13 14 15 16 17 18
19 20 21 22
23
24 72573
25 26 27 28 29 30
75674 81975 357-70939 42909 81936 70941 42574 60108 26208 25507 42568 81951
70928 51716 22152 81939 65852 71912
DESCRIPTION
1 1.0 Liter Diesel Engine 6 1 1 1
1 -3/4" Hose Clamp 32 69860-B Upper Radiator Hose Lower Radiator Hose
Hose Retainer 35 70936 4 M10 Lock Washer 2
Ml 0-1.5 X 16mm Capscrew37 2 Engine Support 4 1 6
1
1
1 1 1
M8-1.25 X 25mm Capscrew
Exhaust Manifold
M6-1.0 Hex Nut
Exhaust Outlet Gasket42
Flex Exhaust Outlet 43
Manifold Gasket
M8-1.25 X 30mm Capscrew
Air Intake Chamber 1 Air Filter
1
1/8" NPT-1/8-28 Adaptor 1 Oil Pressure Switch 1
1
1
1
M8 Shakeproof Washer50 Ml 0 Washer
M8-1.25 X 20mm Capscrew
Engine Wire Harness 1 Oil Drain Fitting
1
1
5
1
1 1
Hose Clamp M5-0.8 Hex Nut M5 Lock Washer Oil Drain Bracket 58 Oil Drain Hose Clip
M5-0.8 X 8mm Screw
ITEM
PART NO.
31 69811 33 74018
34
74070
36 71956
22129 38 72553 39 40 41
49813
26850
22158
42568
22097
44 24114 45 56739 46 47 48 49
75763
77745
40173
49340
74024
51 43146 52 45757 53 54
74069
74009
55 39253 56 57
72564
71910-A 1
45771 4
59
46233
60 50190
QTY. DESCRIPTION
1 Drain Cap 1 Oil Drain Hose 4 4
M12 Lock Washer
Ml2-1.25 X 40mm Capscrew 2 Vibrator Mount 2
Special Washer 12 M8 Lock Washer 2 4
M8-1.25 X 50mm Capscrew
M6-1.0 Hex Nut 2 M6 Shakeproof Washer 4 No. 10-32 Hex Nut 4
M6-1.0 X 20mm Capscrew 6 M6 Lock Washer 4
5/16"-18 Hex Nut 2 12 volts Solenoid 2 Red Vinyl Boot 2 Starter Cable
1
1
1
1
Hose Clamp
Elbow (barb to thread) Fuel Pump Assembly
M6-1.0 X 10mm Capscrew 1 M10-1.0 x 25mm Capscrew 2 2 6
1
M10-1.5 X 40mm Capscrew
M10-1.5 Hex Nut
M8-1.25 X 20mm Capscrew
Fuel Filter Bracket
Lifting Bracket
M8-1.25 Hex Nut
1
1
3/8-30-1/8 V-Beit
Special M8 Fiat Washer
-17-
EXPLODED VIEW — ENGINE BLOCK
Drawing No. 82961
18
Drawing No. 82961
EXPLODED VIEW — ENGINE BLOCK
ITEM
1 139-70939
2 12 13 14 15 16 17
18 19 20
21
22 23 24 25
28
29 30 31 32 33
PART NO. QTY.
140-70939 20 143-70939 144-70939 145-70939 1 146-70939 182-70939 183-70939 184-70939 185-70939 186-70939 1 145-70939 168-70939 1 187-70939 188-70939 189-70939 1 26073-A 1 244-70939 245-70939 246-70939 145-70939 122-70939 1
DESCRIPTION
1 1 DIPSTICK TUBE
2 0-RING
1
1
1
1
1
2 3
1
1 0-RlNG 1 1 2
OIL PAN BOLT
BOLT DIPSTICK ROCKER COVER GASKET ROCKER COVER GASKET ROCKER COVER OIL STOPPER SCREEN BOLT GASKET NUT CAP O-RING 1/4" PIPE PLUG
TUBING SUCTION FILTER BOLT GASKET
¡9-
EXPLODED VIEW — CRANKSHAFT, PISTON & FLYWHEEL
Drawing No. 75679
ITEM
1
2 194-70939
3
4 196-709391
5 6
7
PART NO. QTY.
143-70939 195-70939
226-70939 197-709391 Bearing Holder 200-709391
8. 201-70939 9 198-709396
10
11 202-709393
199-709396 Dowel Pin 21 203-70939AR 0.25mm U.S. Bearing
204-70939AR
12 205-709393
206-70939AR 0.25mm U.S. Bearing 207-70939
13
208-709392
14 204-709392
15
210-709391 Bolt
DESCRIPTION ITEM
1 Crankshaft Assembly 16 1 Crankshaft Gear
1
1 Spring Pin
1
Key 216-70939 Dowel Pin
Bearing Holder
17
18 217-709393 Piston Pin Bearing Holder 19 Bolt 20
Standard Bearing
22
23
0.50mm U.S. Bearing24 Standard Bearing
AR
0.50mm U.S. Bearing
28 Thrust Washer 30 Bolt
- 20-
PART NO.
QTY.
DESCRIPTION
214-709393 Standard Piston Assembly 215-70939
211-70939 212-70939 213-70939
218-70939 219-70939 220-709393 221-70939 222-70939 223-709396 224-70939 225-70939 230-70939 231-70939
AR AR
3
AR AR
6 Snap Ring 3 Connection Rod Assembly
6 6
AR AR
1
1 Nut
Piston Assembly - 0.5mm O.S
Piston Assembly - 1.0mm O.S Standard Piston Ring Set Piston Ring Set - 0.5mm O.S. Piston Ring Set - 1.0mm O.S.
Bushing Connecting Rod Bolt Nut, Connecting Rod Bolt Standard Bearing Bearing — 0.25mm U.S. Bearing —0.50mm U.S. Pulley
U.S. — UNDERSIZE O.S .— OVERSIZE
Drawing No. 75678
EXPLODED VIEW — CYLINDER HEAD
ITEM
1 2 3 4 149-70939 5 6 7
8 9
10 11 157-70939 12
13 14 161-70939 15 16 17 18 19 20 21 22
PART NO.
147-70939 148-70939 6 447-70939
150-70939 151-70939 152-70939 153-70939 154-70939 6 155-70939 156-70939
158-70939 159-70939 160-70939
162-70939 163-70939
164-70939 165-70939
60108
167-70939 168-70939 169-70939
QTY.
1 3
2 3 3 3 3
6
12
6 1 1 11
3
2
2
1
2
1
1
4
1
DESCRIPTION
Cylinder Head Assembly Expansion Plug Expansion Plug Expansion Plug intake Valve Exhaust Valve Valve Guide Seal (Exhaust) Valve Guide Seal (Intake) Spring Retainer Key Cap Cylinder Head Gasket, 1.2mm thick Cylinder Head Gasekt, 1.3mm thick Bolt Bolt Lifting Eye Bolt Tubing
Bolt Oil Switch Thermo-Switch
Gasket
Washer
21 -
EXPLODED VIEW — CAM SHAFT
Drawing No. 75677
ITEM PART NO.
1 232-70939 2 3 4 234-70939 5 6 7 237-70939 8 9
10 11 241-70939 12 242-70939 13
233-70939 1 Camshaft Gear 195-70939 1 Key
235-70939 3 Spacer 236-70939
238-70939 239-70939 240-70939
243-70939
QTY.
1
1
1 1 1 1 1 Bolt 1 1 1 Nut
DESCRIPTION
Camshaft Assembly
Gear Bail Bearing
Slider Plate Tachometer Shaft
Bolt Gasket
r2 -
Drawing No. 75676
EXPLODED VIEW — CYLINDER BLOCK
ITEM
1 2 3
PART NO. 100-70939
447-70939
101-70939 4 102-709392 5 103-70939 6 104-70939 7 105-70939 8 106-70939 9
10
11
107-70939 108-70939 109-70939
110-70939
111-70939
12 112-70939 13 14 15 16
113-70939
114-70939
115-70939
116-70939
QTY.
1 1 1
DESCRIPTION
Complete Cylinder Block Expansion Plug 18 Expansion Plug
Expansion Plug 2 1
Expansion Plug 21 121-709391
Expansion Plug 4 Plug 4 Plug
1 1 1 1 1 1 1 1 2 2
Idle Gear Shari Bushing Bushing — Standard
0.25mm U.S. Bushing28 128-70939
0.50mm U.S.Bushing Ball Bearing
Expansion Plug
Ball Bearing mm = millimeter
Dowel Pin U.S. = Undersize Dowel Pin
ITEM PART NO.
17
117-709392 Dowel Pin
QTY. DESCRIPTK
118-709392 Spring Pin 19 20 120-70939
22 131-70939 23 123-70939 24 25 125-70939 26
119-709392
1 1
1
124-709391 Drain Cock
1
126-709391 27 127-709396 Tappet
6
29
129-70939 30 130-70939
1
1
- 2i
Stud Stud Stud Snap Ring Oil Seat
Connector Oil Filter
Push Rod Relief Valve 0-ring
EXPLODED VIEW — OIL PUMP COMPONENTS
Drawing No. 75682^
■X
\
•) I.. \ ^.
I r-\ '
1 \ -7^
• ‘ 7 .x, (— f > V H ■ \\ u A' ^ v'' ^X
.. 'i ^ Xf ■,X'' A"-i' A//A^
y \v73 Aa
Xv^^ 1: AA«
; •’"K
i r
A
A. I
ITEM
1 250-70939 2 3 251-70939 4 253-70939 1 5 254-7093S 6
7 8 9
10 11 263-70939 12 264-70939 3
PART NO.
252-70939
255-70939 AR 531-70939 AR 0.15mm Shim 532-70939 AR 258-70939 AR 0.50mm Shim 259-70939 260-70939 261-70939 1 Snap Ring 262-70939
AR — AS REQUIRED
DESCRIPTION
1 1 1
1 Oil Pump Cover
1 1 Collar
1 Front Plate 1 Gasket
Idler Gear Assembly Spring
Thrust Washer
Rotor
0,1mm Shim
0.2mm Shim Spring
Bolt
7
8
#
24
__________
Drawing No. 75683
EXPLODED VIEW — ROCKER ARM ASSEMBLY
ITEM PART NO.
1 2 3 4 5 6 7 8
9 10 11 12
170-70939 1 171-70939 172-70939 3 174-70939 6 173-70939 6 175-70939 176-70939 177-70939 178-70939
179-70939 180-70939 181-70939
QTY.
3
3 1 2 2 1 3 3
DESCRIPTION
Rocker Arm Assembiy intake Rocker Arm Exhaust Rocker Arm Nut Stud Rocker Arm Bracket Rocker Arm Shaft Spring Screw Spring Pin Nut Stud
25 -
EXPLODED VIEW — FUEL SUPPLY
Drawing No. 75693
TO FUEL TANK
ITEM PART NO.
1 2
3 47290
661-70939 69858
4 52221 5
6
7
8 74808
9
40173
378-709392 379-709391
52233 2
10 39450
TO INJUCTION PUMP
TO FUEL FtiMP
QTY. DESCRIPTION ITEM PART NO. QTY. DESCRIPTION
1 1
Fuel Filter Support
Fuel Filter 1 3/8“ dia. X 12-1/2" Hose 1 5/16" dia. X 6-1/2" Hose
4 No. 5.5 Hose Clamp
Gasket 15
Banjo Fitting 1
Fuel Bleed Fitting
1/8" NPT Tee (brass)18 2
1/8" NPT X 3/16“ 90-degree
11
30096
12 68736 1 3/16" dia. X 1/2" Hose 13 68736 1 3/16" dia. X 7-3/4" Hose 14
74823
74819 1 Fuel Bleed Fitting 16 17
651-709395 Fuel Bleed Gasket
662-70939
663-709392 Banjo Type Fitting
2
1/8" NPT X 3/16" Barbed Straight Fitting
4
Clamp
2 Hollow Bolt
Barbed Fitting
- 26
Drawing No. 82962
EXPLODED VIEW — WATER PUMP
ITEM
1 2 266-70939 3 4 5 6 270-70939 7 271-70939 1 Bolt 8
9
10
11 275-70939 12 15
PART NO. QTY.
265-70939 267-70939
268-70939 269-70939 3 Gasket
272-70939
273-70939 274-70939
247-70939 284-70939
1 Water Pump Assembly 1 1 Thermostat 1
1 1 Gasket
1 1 Bolt 1
1
1
DESCRIPTION
Plug Spring Set Plate
Bolt Nut
Pulley Bolt
-27-
EXPLODED VIEW — INJECTOR PUMP
Drawing No. 75686
ITEM PART NO.
1
316-70939
2
317-70939 318-70939 319-70939 320-70939
3
298-70939
4
321-70939
5
322-70939
6
323-70939
7
324-70939 8 9
10 11 12 13
14
325-70939
326-70939
327-70939
328-70939
329-70939
330-70939
331-70939
QTY.
1
AR
AR AR AR
2 2 3 3
DESCRIPTION ITEM
Injector Pump Assembly15
0.2mm Shim
0.3mm Shim 17
0.5mm Shim
1.0mm Shim Nut Bolt Gasket Insert
3 Cap 3
Injector
1 Tubing
1 Tubing
1 Tubing
1 Tubing
1
1 Bolt
Clamp
PART NO. QTY.
298-70939 1
16
332-70939 3 333-70939 1
18
334-70939
19
335-70939
20 264-70939
21
336-70939 1
22
337-70939 2 Washer
23338-70939
24
339-70939
25
240-709391 26341-70939 27
342-70939 1 28343-70939 29344-70939
AR — AS REQUIRED
28
DESCRIPT
Nut Glow Plug Connector
1
1
2
Gasket Cover Bolt Sensor
2
1
Nut Bolt Lock Wire
1
Solenoid Washer
1
1
Washer Screw
EXPLODED VIEW — TIMING GEAR HOUSING AND GOVERNOR
iTEM PART MO.
1 285-70939 2 3
286-70939 287-70939
4 307-70939
5 6 7 310-70939 8 314-70939 9
10 11
12 297-70939
13
14 299-70939
15
16 301-70939
17 18 19
20
21
22
23 24
308-70939 309-70939
315-70939
180-70939
296-70939
298-70939 300-70939 540-70939
282-709395 Bolt 288-70939 274-70939 311-70939 304-70939 305-70939 306-70939
QTY.
1 1 1
1 Spring 1 Washer
2
1 Stop Lever
2 1 4
1 Governor Lever
1 4 1
1 0-Ring
1 3
1 4
5 Bolt
1 1
1 0-Ring
DESCRIPTION
Timing Gear Housing Spring Pin Gasket 27
Nut 30 Cover 32
Gasket Nut
Bolt Nut 37 Shaft
Snap Ring Bolt
Oil Seal Bolt
Arm Snap Ring
ITEM
25 289-70939 26
28
29 31 33
34 35 36
38 71944
39
40
41
42
43 537-70939
44 45
46 47
PART NO.
QTY.
290-70939 291-70939 136-70939 292-70939 313-70939 293-70939
294-70939
295-70939
291-709391 302-70939 271-70939 303-70939
660-70939
3 Boit
2 Bolt
1 Screw
1
534-709391 535-70939
1
536-70939 539-70939
1 1
188-709391
541-70939
538-70939
1 3
1 1 1
1 Washer
1 1 1 1 1
1
1
DESCRIPTION
Governor Lever Assembly Tension Lever Snap Ring
Cotter Pin
Spring
Spring Arm 0-Ring
Snap Ring
Bracket
0-Ring
0-Ring
Spacer
Gasket
Holder
0-Ring
Cap
Bolt
Nut
EXPLODED VIEW — RADIATOR
Drawing No. 83294
• INDICATES
UK'aTION of
WELD STUDS
ITEM PART NO. QTY.
1
2 3 80245
4
5 82603 6 83058 7 81977-A 2 FOAM PAD 8 9
10
83098 83057
81905
81947 81946
82605 11 22097 12 49813 13 66831 14 15
35586 45757 4
16 42568
17 56892 18 19
20 21 22 23
58442 2
46627
52250 5 ft. FOAM PAD - 3/4" X 1" WIDE
50832
81976
51787
1 ASSEMBLY, BASE
1 RADIATOR, CROSS FLOW 1 1
1 1
1 1 1 15 11 2 RIVET, POP 4
7 6 CRIMPTITE, No. 10-32 x 3/8"
1 1
1 6 CAPSCREW, HEX HEAD - M4-0.7 x 16mm
DESCRIPTION
BLOWER HOUSING FAN, ENGINE RING, FAN INLET
BRACKET, RADIATOR MOUNTING HOSE, LOWER RADIATOR
HOSE, UPPER RADIATOR PLATE, BLOWER HOUSING LOCK WASHER - M6 NUT, HEX-M6-1.0
CLAMP (WORM TYPE) CAPSCREW, HEX HEAD - M6-1.0 x 25mm CAPSCREW, HEX HEAD - M6-1.0 x 20mm
CRIMPTITE, 1/4--20X 1/2" CAP, RADIATOR
DRAIN COCK-V8 NPT HUB, FAN
24 22152 6 LOCK WASHER - M4 25 22473 26
29451
11 5 ft.
FLAT WASHER-M6 FOAM TAPE - 1/8" X 1/2"
-30-
_________________
Drawing No. 75685
EXPLODED VIEW — D-C ALTERNATOR
ITEM
1 2 3
4
5
6
8
9
10 11 12
PART NO.
QTY.
77909 74829 72545 74007 74069 51753 277-70939 345-70939 349-70939 346-70939 348-70939
DESCRIPTION
1
1
Adjusting Plate 13 349-70939 M8-1.25 X 30mm Bolt
ITEM PART NO. QTY. DESCRIPTION
14
352-70939 1 Lock Washer 15 353-70939 1 1
2
1 1 1 1 1
M10 Flat Washer Ml 0-1.5 X 40mm Capscrew M6-1.0 X 40mm Bolt 18 350-70939 Alternator Assembly 19 351-70939 Flywheel Bearing Plate Assembly Stator
16 354-70939 17
355-70939
20 137-709391 Lock Washer 21
280-709391 Washer
22 356-709391 23 74827 1 M8 Flat Washer 24
70005 2
-31 -
1 Bearing 1 1 1 2 1 1
Coupler Clamp
Screw Screw
Cap
Nut Collar
M6 Lock Washer
J2
_________________
Drawing No. 83699
REPAIR PARTS LIST — CONTROL BOX
ITEM PART NO.
1
2
3 4 5
6 7 22220
8 22155
9
10 11 12 81903 13 14 67680 15 16 17 18
19 20 21 22 74076 23 24 25 26 42568 27 26850 28 29 30 45770 31 32 33 34 35 36 37 39 40 41 42 55440 44 45 46 47 49813 48 49
23484-F 32300 81904 22668 55927 75207-B
25433 39271 48512
71938-A 83635
74969 36900 22155 23762 81902 81884-D
77604 75208 55920
22152 23897
*77744 74041 51718 43184 51715 80882 72566 70325 22097 51716
*82617 1 Panel Wire Harness *81951 82737
22188 22473
QTY.
2 SB-1000-12 Snap Bushing 1 1 1 30-amp AGC Fuse 1 14-amp SFE Fuse 1 10-amp DC Circuit Breaker 1 No. 6 X 7/8" long Round Head Machine Screw 1 No. 6 Lock Washer 1 No. 6-No. 14 AWG Solderless Lug 1 1 1 Control Box 1 DC Regulator 1 AC Regulator Assembly 1 1 35-amp Circuit Breaker
4 No. 6-32 X 1/4" Phillips Pan Head Machine Screw
4 No. 6 Lock Washer 1 No. 10 External Lock Washer 1 1 Control Pane! Decal
2 1 1 1
2
2
10
8
8 1 1 M5-0.8 X 20mm Phillips Pan Head Machine Screw
2
2
2
4 No. 6 X 5/8" Self-tapping Screw
4 Spacer Nut 1 Engine Controller Assembly
6
2
2
1 Engine Wire Harness
4
4 1 8
DESCRIPTION
30-amp AGC Fuse Hoider 14-amp SFE Fues Holder
3/4" Greenlee, 90-degree Conduit Clamp 5-amp Circuit Breaker
AC Transformer
Control Panel M3-0.5 X 10mm Pan Head Machine Screw
Hour Meter Start/Stop Switch Preheat Switch M6-1.0 X 20mm Hex Head Capscrew M6 External Lock Washer M5 Lock Washer M5 Flat Washer M5-0.8 X 10mm Hex Head Capscrew Customer Leads
M4-0.7 X 10mm Pan Head Machine Screw M4 Lock Washer M4-0.7 Hex Nut
M6 Lock Washer M5 Hex Nut M5-0.8 X 25mm Hex Head Capscrew
Vibration Dampener
M6-1.0 Nut No. 6 Hex Nut M6 Flat Washer
NOT SHOWN
jj
EXPLODED VIEW — GENERATOR
Drawing No. 81983
Qs CM
0^
34
CM
\ ,
\
/
^ / \
/
\
!
\/
CO
\
1
i-
o
F5
Drawing No. 31983
REPAIR PARTS LIST — GENERATOR
ITEfyi
1 24488 2 24911 3 4 5 6 7 8 9
10
11
12 13 14 15 16 17 18
19 20 21 22 23
24 25 26
27
28
29
30
31
32
33
34 BM45761
35
36
37
38
39
40
41
42
PART NO.
BN45761 81931 47248 81956 81955 45770 22152 81974 74066 22302 81952 81900 81192 42911
81901
82737 22145
59450 75763 70954 81929 39253
70936
71956 22129 72553 45771 A-24044-A 23877-D 25105 82626
52858 81991 22097 22127 22237
42909 29107
25155
QTY.
4 4 4 1 1 45M Ball Bearing 1 1
10 6 4 4 4 1
1 Ring Fan
1 4 1 4 4 2 1 1 1 4 2 2 8 2 8 4 2 4 1 4
4 1 1 1
4
2
1 1
DESCRIPTION
No. 8 X 5/8“ Taptite Screw No. 8 X 3/8" Taptite Screw M8-1.25 X 160mm Stud 15" RV Rear Bearing Carrier
15" RV, 2.5L ASM Rotor 15" RV, 2.5L ASM Stator M5-0.8 X 10mm Hex Head Capscrew No. 10 Lock Washer M8 X 20mm Hex Flange Bolt M10-1.25 X 30mm Hex Screw M10 Lock Washer
15" RV, 15M Flex Plate 15" ISM Flywheel Mach.
M10-1.5 X 30mm Hex Head Capscrew Air Ring Baffle Vibration Mount 5/16-M8 Fiat Washer 5/16-18 X 1-1/4" Hex Head Capscrew
Battery Cable Boot Starter Motor 15", ISM 1L Engine Adaptor M8-1.25 X 20mm Hex Head Capscrew
Vibration Isolator 5/16-M8 Flat Washer 5/16-M8 Lock Washer
M8-1.25 X 60mm Hex Head Screw M8-1.25 Hex Nut Brush Brush Holder No. 6-32 X 1/4" SIMS Brush Cover M8-1.25 X 30mm Stud M8-1.25 Hex Nut Flange Red Wire Assembly 1/4" Lock Washer
1/4-20 Hex Nut
M10 Lock Washer M8-1.25 X 30mm Hex Head Capscrew
Rubber Grommet
Clamp
-35
NOTES
36
ELECTRICAL FORMULAS
TO FIND
KILOWATTS (kW)
KVA
AMPERES
WATTS
NO. OF ROTOR
POLES
FREQUENCY
RPM
KNOWN VALUES
Volts, Current, Power Factor
Volts, Current
kW, Volts, Power Factor
Volts, Amps, Power Factor
Frequency, RPM
RPM, No. of Rotor Poles
Frequency, No. of Rotor Poles
1-PHASE
ExI
1000
ExT !
E X T X 1.71 X PF
1000
E.xIa L73
1000 ; 1000
kWxlOOO
kWx 1000
E i Ex 1.73 xPF
Volts X Amps
E X I X 1.73 X PF
.
2 X 60 X Frequency
RPM
RPM X Poles
2x60 i
2 X 60 X Frequency
Rotor Poles :
2 X 6flxFie,quency
RPM X Poles
2x60
2 X 60 X Frequency
Rotor Poles
3-PHASE
RPM
kW (required for
Motor)
RESISTANCE
VOLTS
AMPERES
E = VOLTS
Motor Horsepower, Efficiency
Volts, Amperes
Ohm, Amperes
Ohms, Volts
I = AMPERES
HP X 0.746 :
Efficiency
E :
I
IxR
1 ^
1 R
HP X 0.746
Efficiency
E
I
IxR
E
R
1
R = RESISTANCE (OHMS) PF = POWER FACTOR
GENERAC’S 3-YEAR LIMITED WARRANTY
FOR NP SERIES RECREATIONAL VEHICLE GENERATORS
Generac warrants to the original purchaser that its generators will be free from defects in materials or workmanship for the period set forth below from date of original purchase. During said warranty period, Generac will, at its option, repair or replace any part which, upon examination by Generac or Generac Authorized Distributors and/or Dealers, is found to be defective under normal use and service.
3-YEAR WARRANTY SCHEDULE
1. All NP Series generators used in a recreational vehicle shall be warranted from date of purchase for a period of three (3) years or 2000 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 2000 hours.
2. The drive train, belt and pulleys on NP series air-cooled generators shall be warranted against failure due to defective materials or normal usage for the life of the generator. For the original owner, this drive train warranty shall include parts and labor plus a $50.00 payment upon return of the failed belt or pulley by the original owner. For succeeding owners, this power train warranty shall cover belt or pulley parts only.
3. Rental units, demonstrators or commercial applications, such as construction or utility, are warranted for one year or 2000 hours, whichever comes first.
All warranty expense allowances are subject to the conditions defined in the published POLICIES AND PROCEDURES" manual.
THIS WARRANTY DOES NOT COVER;
Costs of maintenance, installation and startup. Failures due to normal wear, accident, misuse, abuse, negligence or improper installation. Products which are modified or altered in a manner not authorized by the manufacturer in
writing. Incidental, consequential or indirect damages caused by defects in materials or workman
ship, or any delay in repair or replacement of defective parts. Failure due to misapplication. Telephone, telegraph, teletype or other communications expenses. Living or travel expenses of persons performing service. All transportation/travel expenses. Rental equipment used while warranty repairs are being performed. Overtime labor. Starting batteries, fuses, light bulbs and engine fluids.
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. SPECIF
ICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do no allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. GENERAC'S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PARTS AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE
A RESULT OF GENERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of
incidental or consquential damages, so the above limitation may not apply to you. Buyeragrees to make no claims against generac based on negligence.
‘GENERAC
This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.
GENERAC CORPORATION, P.O. Box 8, Hwy 59 and Hillside Road, Waukesha, Wl 53187
Telephone (414) 544-4811 FAX (414) 544-4851
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