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.
______
_____ ______
_______
_ J
Yolljiic ihi£ ue ' r:ur-titucupDyw'
fof s'Prraliiiy iOjE-^'j ^ ills Jncle chase r '
ek Cl If '*'f ,ii< juifirg id'o ‘''C0v*,i:e/ - fVd !
pr)we Y-• T aac .anr-a • >i com: "
a - uDr “f . fit r i IPO‘'Of' i"“, . ^ '"OCf fc
cl oo V' k'
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
i ounON. Oc TUI ove"ioacJ the q t n t tn h i ^ero^IriStakaA&rT!-.'j row|uite inai n eoc
die r'’uceo'o 0'a-itiii ov*-f|:cd'ng feoriciCic »'
• v'^i ' Of h ' .f 1. |, 1 ,-f
I '» c^fien f .!>' ' s<n "rh
•n. ’ ( .al '“ir III mi * -I-. *i mi s c ^ ‘ '
T ' i' m^- r fi- ,'0'j‘ "*** , I"» if"t 1 Of » 3<.»
“h
r- 5 im C» - »1 -jouc . Oí '
«' '-rk m- n Í ' il/ ^
I! ‘ - . p, C'Ok- Hi (.íuíí, ,f .Í ’ f
should not be areale
-, i Or t ’ / ,
if ;i,< !. i< L
i V
Ou >i2 iuun t n-c/ egufro si’t.o /«.m f
p.wef iOr Ä.i pa m. ' ut cml mn 'm * m.,* Ii ' :cm
Í viiursouua - tt
IhOTALL.O.OOrv
Ì hi T/ -I ' fdac -I " c i-t it -cr. fr!''''iio 'jinm
'Ui.ffm-p iimh-a u if t;r ni '“.ri. ./„!! j
mr- iPtc r-_cr-:5aur,, ,0 v'/v dice csct r^r-
.C'npiic J ,vkh O'COaDle C'^nec c'ar ,a'' L a d ~
u'Ci ' '-'C Dtrre'ntny ÍC- n'iaiia''i.jn
An k4‘'TMLi_AT‘Aju HANUA* wm- <ri!pD“ö *"c
^mcf-rarnr T*ri¿.| Mnuii emmne nertmOn'" c •“
orjcffcr"- and reLorT.mpnriai'crn c¡ I'^oaJina ..*m rt
rtic a r-creOicnni cehi'ie rollovxsnq .nomiia:r-r ,r
cjii„ a sneuid 'erma'-d tne incmliaron Oa .uri
Awner/Operaiors Or ihsi. .normakoo r-r-Cc''!'
- !• rCSO'^o. ÌO
JCP' Oidi m.ght Ibi.de^'--mon'r msem rcy; /^¡¡i im
m\ V iih -upOcLie c ano'* ca -^tn if-on¡ -
j 1/ 0 0 i) <) ' G
T2 (WHITE)
-120 V,
-240 vC
T1 (RED)
Figure 1 — Connections 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 3 — Generator 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 4 — Dual 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
UKTw. swrri.
GEN.
RUN
LiJ
STOPSTART
PREHEAT
LJJ
30 SEC. MAX
GENERAC R.V. GENERATOR “
Figure 5 — Remote 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 8 — Engine 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 7 — High 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:
TemperatureOil 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.
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 9 — 14 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 10 — 30 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 12 — Changing 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 CAUSESREMEDY
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
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 iEx 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.