(B>
SEINI
Air-cooled Recreational
Vehicle Generator
OWNER'S MANUAL
CORPORATION
Model No. 9734-3 Series NP-66LPG
THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS. WHICH, IF NOT FOLLOWED. COULD ENDANGER THE
PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THE
u
Revision 1 (9/18/97)
MANUAL BEFORE ATTEMPTING TO OPERATE THIS UNIT,
Manual No. A4081
Printed in U.S.A.
Generac NP-66LPG Recreational Vehicle Generator
0
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 ser
vicing applicable equipment. Become familiar with this Owner's
Manual and with your generator. Safe, efficient and reiiable
operation can only be achieved if generator is properly installed,
operated and maintained. Many accidents are caused by fail
ing to follow simple and fundamental rules or precautions. The
manufacturer suggests that these GENERAL SAFETY RULES
be copied and posted in potential hazard areas of the recreational
vehicle. Safety should be stressed to all operators and poten
tial operators of equipment.
The manufacturer cannot possibly anticipate every circum
stance that might involve a hazard. The warnings in this Manual
and on tags and decals affixed to the unit are, therefore, not ailinclusive. It you use a procedure, work method or operating
technique Generac does not specifically recommend, you must
satisfy yourself that it is safe for you and others. You must also
make sure the procedure, work method or operating technique
that you chose does not render the generator to be unsafe.
WARNING:
The engine exhaust from this product
contains chemicais known to the State
of Caiifomia to cause cancer, birth
defects, or other reproductive harm.
For fire safety, the recreational vehicle generator must be properly
installed and maintained. Installation must always remain in com
pliance with applicable codes and standards. In addition, the
generator must be installed in conformance to the manufacturer's
detailed installation instructions. Following installation, nothing must
be done that might render the generator in noncompliance with such
codes, standards and instructions.
The RV generator produces extremely high and dangerous elec
trical 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 insulated, dry surface to reduce shock hazard.
Never work on this equipment or handle any electrical 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. DO NOT
disconnect the bonding conductor, if so equipped. DO NOT recon
nect the bonding conductor to any generator part that might be
removed or disassembled during routine maintenance. It the ground
ing conductor must be replaced, use only a flexible conductor that
Recreational Vehicle Generator
is of No. 8 AWG copper wire minimum.
® In case of accident caused by electric shock, shut down the source
of electrical power down at once. If this cannot be done, free victim
from live conductor. AVOID DIRECT CONTACT WITH THE VICTIM.
Use a dry board, dry rope, or other non-conducting implement to
free the victim from live conductor.
• Inspect fuel system frequently for leaks or damage. Repair or
replace any damaged or leaking component immediately. Never
attempt to change, alter or modify the generator fuel system in any
way that might affect safety or compliance with applicable codes
and standards.
• The generator engine gives off DEADLY carbon monoxide gas
through its exhaust system. This dangerous gas, if breathed in suf
ficient concentrations, can cause unconsciousness or even death.
This exhaust system must have been properly installed, in strict com
pliance with applicable codes and standards. Following installation,
you must do nothing that might render the system unsafe or in noncompliance with such codes and standards. The generator
compartment must be completely vapor sealed from vehicle inte
rior. 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,
fuel leakage, oil leakage, etc.
• Do not smoke around the generator. Wipe up any fuel, and oil
immediately Never leave oily or fuel soaked rags in the generator
compartment or on the generator itself. Keep the area around the
generator clean and free of debris.
• Adequate ventilation is required to expel toxic fumes and gasoline
vapors from the generator compartment. Do not alter the installa
tion of this equipment in any manner that might obstruct air and
ventilation openings. Such openings must be kept clear and unob
structed.
• Keep hands, feet, clothing, etc., away from drive belts, fans and other
moving parts of ttiis equipment. Never remove any drive belt or fan
guards while the unit is operating.
• Inspect the generator periodically. Repair or replace all damaged
or defective parts immediately.
• This generator uses LP gas (propane) as a fuel. Liquid Propane
gas is highly EXPLOSIVE. The gas is heavier than air and tends
to settle in low areas where even the slightest spark can ignite the
gas and cause an explosion.
• Before perfonning any maintenance on the generator set, discon
nect its battery cables to prevent accidental start up. Disconnect
the cable from the battery post indicated by a NEGATIVE, NEG or
(-) first. Reconnect that cable last.
u'l
Generac NP-66LPG Recreational Vehicle Generator
Please record the following information from the generator DATA PLATE or information decai.
1. Modei Number
3.kW Rating.
5. Phase
____________________
2. Serial Number
4. Rated Voltage.
6. Hertz
_________
_________________________
1. Generator Air Intake Screen
2. Engine Start/Stop Switch
3. Fuse
4. Circuit Breaker
5. Optional Remote Panel Receptacle
6. Generator AC Output Leads
7. Circuit Breaker
REFERENCE NUMBER IDENTIFICATION
8. 12 Volts Battery Connection ; i q ,
9. Fuel Primer Switch
10. Fuel Solenoid
11. Pressure Regulator
12. Oil Filter
13. Oil Drain Plug
14. Oil Dipstick and Filler Tube
Recreational Vehicle Generator
3
Generac NP-66LPG Recreational Vehicle Generator
GENERAL SAFETY RULES...........................2
IDENTIFICATION RECORD
GENERATOR FEATURES
..........................
............................
READ THIS MANUAL
Operation and Maintenance
How to Obtain Service........................................................................5
.............................................................
GENERATOR FAMILIARIZATION
Generator Applicability
Installation.............................................................................................6
Safety..................................................................................................... 6
Generator AC Connection System....................................................6
OPERATING INSTRUCTIONS
Generator Control Panel.....................................................................7
Optional Remote Start/Stop Panel
Before Starting the Engine.................................................................8
Starting.................................................................................................. 8
Stopping the Generator
Applying Loads to Generator
Don’t Overload the Generator
Additional Information...............................................................10-11
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..........................................................
7-11
SPECIFICATIONS
3
3
Fuel Requirements
Engine Oil Requirements
Generator Specifications
MAINTENANCE
5
6
Checking Engine Oil Level................................................................13
Change Engine Oil
Change oil filter..................................................................................13
Engine Air Cleaner............................................................................. 14
Spark Arrestor Muffler
Engine Spark Plugs............................................................................14
Miscellaneous Maintenance......................................................15-16
Out of Service Protection
Return the Unit to Service after Storage........................................16
TROUBLESHOOTING
7
REPAIR PARTS..................................18-27
...................
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13-16
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12
12
12
13
14
16
17
ELECTRICAL DATA.................................28
8
9
9
EMMISSIONS WARRANTY
BASIC 3-YEAR WARRANTY
................
...............
;....30-31
back page
Recreational Vehicle Generator
4
Generac NP-66LPG Recreational Vehicle Generator
If you doni understand any portion of this manual, contact Gen
erac for a demonstration of actual starting, operating and
servicing prwedures.
Throughout this publication and on tags and decals affixed to
the generator, DANGER and CAUTION blocks are used to alert
you to special instruction about a particular operation that may
be hazardous if performed incorrectly or carelessly. Observe
them carefully.
These safety warnings cannot eliminate the hazards that they
indicate. Strict compliance with the special instructions while
performing the service plus 'common sense” are major mea
sures to prevent accidents.
The following definitions apply to DANGER, CAUTION and
NOTE blocks found throughout the manual.
DANGER: AFTER THIS HEADING YOU CAN READ
HANDLING, INSTALLING, OPERATING OR SERVIC
ING INSTRUCTIONS THAT, IF NOT STRICTLY
COMPLIED WITH, MAY RESULT IN PERSONAL
INJURY.
CAUTION: After this heading you can read instruc
tions for handiing, instaliing, operating or servicing
the generator thaL if not strictiy complied with, may
resuit in damage to equipment and/or property.
NOTE: After this heading you can read explanatory statements
that require special emphasis.
These symbols indicate the following:
Points out important safety information and, if not fol
lowed, could endanger personal safety and/or property
of yourself and others.
Potential explosion hazard
The operator (driver) is responsible for proper and safe useof the vehicle, equipment on the vehicle, and the safety of all
vehicle occupants. We strongly recommend that the operator
read this Owner's Manual and thoroughly understand all
instructions before using this equipment. We also strongly rec
ommend instructing other occupants in the vehicle to properly
start and operate the generator. This prepares them if-they
need to operate the equipment in an emergency.
OPERATION AND MAINTENANCE
it is the operator's responsibility to perform ail safety checkis;
to make sure that all maintenance for safe operation is per
formed 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. Indi
vidual operating habits and usage contribute to the need for
maintenance service.
Proper maintenance and care of your industrial mobile gen
erator assures a minimum number of problems and keeps your
operating expenses at a minimum. See your authorized
Dealer/Distributor for service aids and accessories.
HOW TO OBTAIN SERVICE
V\/hen your recreational vehicle generator set requires servicing
or repairs, simply contact an Authorized Service Facility for
assistance. Service technicians are factory-trained and are
capable of handling all of your service needs.
When contacting an Authorized Service Facility or the factory
about parts and service, always supply the complete model
number and serial number of your unit as given on its data
decal.
Potential fire hazard
Potential electrical shock hazard
A
The warranty on your generator is included in this Owner's
Manual, as well as listings for repair parts.
Recreational Vehicle Generator
Generac NP-66LPG Recreational Vehicle Generator
GENERATOR APPLICABILITY
These generators have been designed and manufactured for
supplying electrical power for recreational vehicles. You should
not modify the generator or use it for any application other than
for what it was designed. If there are questions pertaining to
its application, write or call the factory. Do not use the unit until
you have been advised by a competent authority.
DANGER: FOR FIRE SAFETY, THE GENERATOR
MUST HAVE BEEN PROPERLY INSTALLED IN
A
COMPLIANCE WITH (1) ANS1119.2-1975/NFPA
501C-1974 "STANDARD FOR RECREATIONAL
VEHICLES", PART III, "INSTALLATION OF ELEC
TRICAL SYSTEMS." THE GENERATOR ALSO
MUST HAVE BEEN INSTALLED IN STRICT COMPLI
ANCE WITH THE MANUFACTURER'S DETAILED
INSTALLATION INSTRUCTIONS. AFTER INSTALLA
TION, DO NOTHING THAT MIGHT RENDER THE
UNIT IN NON-COMPLIANCE WITH SUCH CODES,
STANDARDS AND INSTRUCTIONS.
You can use this generator to supply electrical power for oper
ating 120/240 volts, single phase, 60 Hertz, AC electrical
loads. These loads can require up to 6600 watts of (6.6 kW)
of power, but cannot exceed 55 AC amperes of current at 120
volts or exceed 27.5 AC amperes at 240 volts.
CAUTION: Do not overload the generator. Some
installations may require that electrical loads be
alternated to avoid overloading. Applying exces
sively high electrical loads may damage the
generator and may shorten its life. Add up the
rated watts of all electrical lighting, appliance, tool
and motor loads the generator will power at one
time. This total should not be greater than the
wattage capacity of the generator. If an electrical
device nameplate gives only volts and amps, multi
ply volts times amps to obtain watts (volts x amps
= watts). Some electric motors require more watts
of power (or amps of current) for starting than for
continuous operation.
installer complied with all applicable codes, standards and reg
ulations pertaining to installation.
Owners/Operators should make sure nothing is done during
installation that might render the unit unsafe or in noncompli
ance with applicable codes, standards and instructions. They
should be sure the unit has been installed to allow adequate
ventilation for cooling and exhaust air.
SAFETY
Before using the generator set, carefully read GENERAL
SAFETY RULES inside the cover. Comply with these RULES
to prevent accidents and damage to equipment and/or prop
erty. Generac suggests copying and posting the GENER/^L
SAFETY RULES in potential hazard areas of the recreational
vehicle. Safety should be stressed to all operators of this
equipment.
GENERATOR AC CONNECTION SYSTEM
This generator set is equipped with dual Stator a-c power
windings. These two stator windings supply electrical power
to customer electrical loads by means of a dual 2-wire con
nection system. Note, however, that neutral is grounded.
The generator may have been installed so that units power 120
volts AC loads (Figure 1); or you can wire them to connect both
120 and/or 240 volts AC electrical loads. Be sure to install
jumper wire between the circuit breakers when reconnecting
for 120/240 volts. Refer to the Installation Manual for more infor
mation.
Figure 1 — Connections for 120 Volts Only
INSTALLATION
This Owner’s Manual has been prepared under the assump
tion that a competent, qualified technician installed the
generator into a recreational vehicle. We also assume the
Recreational Vehicle Generator
GROUNDED
NEUTRAL
6
Generac NP-66LPG Recreational Vehicle Generator
GENERATOR CONTROL PANEL
Mounted on the generator control panel (Figure 2) are the fol
lowing features;
Figure 2 — Generator Control Panel
_____ IFU8E
START ISA
STOP I fuel
' ' PRIMER
MAIN
BREAKER
■ MAIN BREAKER
Protects generators AC output circuit against overload and pro
vides a method of turning OFF the generators 120/240 volts
AC output to vehicle circuits. The NP-66LPG has one 20 amp
breaker and one 30 amp breaker.
NOTE: If the Series NP-66LPG has been reconnected for dual
voltage AC output (120/240 volts), you can install line break
ers having an amperage rating that is different than stated
above. The replacement line breakers consist of two separate
breakers with a connecting piece between the breaker handles
(so that both breakers will operate at the same time). If the unit
is reconnected for dual voltage, it is no longer RVIA listed.
______________________________
REMOTE START/STOP PANEL
A remote mounted Start/Stop Panel is available, which allows
you to start and stop the generator engine conveniently from
inside the vehicle.
Figure 3 — Optional Remote Panel (Model 9042)
FUEL PRIMER
Before starting a cold engine (it has not been started in more
than two weeks), you must press this switch to bring fuel
from the tank to the fuel regulator. This rocker type switch
springs back into its original position when you release it.
START/STOP SWITCH
To crank and start the engine, hold this »«itch at its START
position. Release the switch when the engine starts. To stop
an operating engine, press and hold the switch in its STOP
position until the engine shuts off. The switch center position
is the RUN position.
FUSE
Protects the engine DC control circuit against electrical over
load. If the fuse element has melted open due to overloading,
the engine cannot be cranked. If you must replace it, use only
an identical replacement fuse.
Recreational Vetilcle Generator
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R.V.
GENERATOR
7
Uj’KR.AriuN !
Generac NP-66LPG Recreational Vtehide Generator
BEFORE STARTING THE ENGINE
IMPORTANT: INSTRUCTIONS AND INFORMATION IN THIS
MANUAL ASSUME THE GENERATOR HAS BEEN PROP
ERLY INSTALLED, CONNECTED, SERVICED, TESTED AND
ADJUSTED BY A QUALIFIED INSTALLATION TECHNICIAN
OF INSTALLATION CONTRACTOR.
■ INSTALLATION
Generator installation must have been properly completed so
it complies with all applicable codes, standards and regula
tions and with the manufacturer's recommendations.
■ ENGINE LUBRICATION
Have engine crankcase properly serviced with recommended
oil before starting. Refer to “Maintenance” and “Specifica
tions' sections for oil servicing procedures and
recommendations.
CAUTION; Any attempt to crank or start the
engine before you have properly serviced it with
the recommended oii may result in engine faiiure.
FUEL SUPPLY
The engine must have adequate supply of proper fuel to oper
ate. Before starting, check that sufficient fuel is available.
_____________________________
______________________
DANGER; THE GENERATOR ENGINE GIVES OFF
DEADLY CARBON MONOXIDE GAS THROUGH ITS
EXHAUST SYSTEM. THIS DANGEROUS GAS, IF
BREATHED IN SUFRCIENT CONCENTRATIONS,
CAN CAUSE UNCONSaOUSNESS OR EVEN
DEATH. DO NOT OPERATE THE GENERATOR IF
ITS EXHAUST SYSTEM IS LEAKING OR HAS BEEN
DAMAGED. SYMPTOMS OF CARBON MONOXIDE
POISONING ARE (A) INABILITY TO THINK COHER
ENTLY, (B) VOMITING, (C) TVYITCHING MUSCLES,
(D) THROBBING TEMPLES, (E) DIZZINESS, (F)
HEADACHE, (G) WEAKNESS AND SLEEPINESS. IF
YOU FEEL ANY OF THESE SYMPTOMS, MOVE
INTO FRESH AIR IMMEDIATELY. IF SYMPTOMS
PERSIST, GET MEDICAL HELP.
STARTING 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
in your vehicle (such as a main lirte circuit breaker or trans
fer switch.
NOTE; If starting from the generator panel, turn OFF loads
by setting the generators 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).
■ COOLING AND VENTILATING AIR
Air inlet and outlet opening in the generator compartment must
be open and unobstructed for continued proper operation. With
out sufficient cooling and ventilating air flow, the
engine-generator quickly overheats, which causes it to quickly
shutdown. Overheating could also damage the unit or your
vehicle.
■ ENGINE EXHAUST CAS_______________________
Before starting the generator engine, you should be sure
there is no way for exhaust gases to enter the vehicle interior
and endangering people or animals. Close windows, doors and
other openings in the vehicle that, if open, might permit exhaust
gases to enter the vehicle.
Recreational Vehicle Generator
2. Hold the engine Start/Stop Switch at START to crank engine.
Release the switch when the engine starts.
3. Let the engine run at no-load for a few minutes to stabilize
and warm up.
4. Turn ON electrical loads, using whatever means provided
(such as a main circuit breaker or transfer switch).
STOPPING THE GENERATOR
1. Tum OFF all electrical loads, using whatever means pro
vided (such a main circuit breaker or transfer switch).
2. Place Start/Stop switch in its STOP position.
8
Generac NP-66LPG Recreational Vehicle Generator
APPLYING LOADS TO GENERATOR
When applying electrical loads to the generator, observe these
guidelines;
• Before applying electrical loads, let the generator stabilize
and warm up for a minute or two.
• DO NOT overload the generator.
■ LETTING THE ENGINE STABILIZE
The generator supplies correct rated frequency and voltage
only at the proper governed speed. Some electrical appli
ances may be extremely sensitive to voltage and frequency.
Incorrect frequencies and/or voltages can damage those appli
ances.
If electrical loads are applied at reduced operating speeds, such
loads imposed on the engine when sufficient power is not avail
able may shorten engine life. Never turn ON electrical loads
until after the generator engine has started and stabilized
ON-speed.
■ DO NOT OVERLOAD THE GENERATOR
You can read the rated wattage/amperage capacity of your
generator on the generator data plate (see “Identification
Record” on Page 1).
/^plying electrical loads in excess of the unit’s rated capac
ity will cause the engine-generator to automatically shutdown.
To avoid overloading, add up the wattage of all connected elec
trical lighting, appliance, tool and motor loads. This total should
not be greater than the generator’s rated wattage capacity.
• Most lighting, appliance, tool and motor loads indicate their
requir^ watts on their nameplate or data plate. For light
bulbs, simply note the wattage rating of the bulb.
• If a load does not show its rated wattage, multiply that load’s
rated VOLTS times AMPS to obtain WATTS.
• Induction type motors (such as those that run the vehicle’s
furnace fan, refrigerator, air conditioner, etc.) need about 21/2 times more watts of power for starting than for running
(for a few seconds during motor starting). Be sure to allow
for this when connecting electrical loads to the generator.
Rrst, figure the watts needed to start electric motors in the
system. To that figure, add the running wattages of other
items that will be operated by the generator.
• Do not apply heavy electrical loads for the first two or three
hours of operation.
WATTAGE REFERENCE GUIDE
RUNNING
WATTS
*Air Conditioner (12.000 Btu)..................................................1700
Battery Charger (20 amp)....................................................................... 500
Belt Sander (3")
Chain Saw
Circular Saw (6-12")...............................................................800 to 1000
Coffee Maker..........................................................................................1000
•Compressor (1 HP)...............................................................................2000
•Deep Freeze............................................................................................ 500
Disc Sander (9")......................................................................................1200
Electric Range (one element)...............................................................1500
Electric Skillet........................................................................................ 1250
•Furnace Fan (1/3 HP)...............
Hair Dryer............................................................................................ 1200
Hand Drill (1")......................................................................................... 1100
Hedge Trimmer........................................................................................450
Impact Wrench..:
......................................................................................
..............................................................................................
...........................................................
......................................................................................
Recreational Vehicle Generator
1000
1200
1200
500
RUNNING
WATTS
Lawn Mower...........................................................................................1200
Light Bulb...................................................................................................100
Microwave Oven..................................................................................... 700
•Milk Cooler............................................................................................ 1100
Oil Burner on Furnace..............................................................................300
Oil Fired Space Heater (140,000 Btu).....................................................400
•Paint Sprayer, Airless (1/3 HP)...............................................................600
Radio.............................................................................................50 to 200
•Refrigerator.........................................................................................v. 600
Slow Cooker
•Submersible Pump (1-1/2 HP)
•Submersible Pump (1 HP)
Table Savy (10”).................
Television
• Allow 2-1/2 times the listed watts for starting these
devices.
............................................................................................ 200
.........................................................
......;........................
.................................................
............................................................................
1750 to 2000
1750 to 2000
..2800
.2000
Generac NP-66LPG Recreational Vehicle Generator
ADDITIONAL INFORMATION
This section discusses some of the engine protective devices,
overload protection and breaking in a new generator.
■ AUTOMATIC LOW OIL PRESSURE
SHUTDOWN________________________________
The engine is equipped with a normally-open (N.O.) oil
pressure switch (Figure 4). Engine oil pressure holds the
switch open during cranking and operation. Should oil pres
sure drop below about 8-10 PSI, the switch contacts close
and the engine automatically shuts down.
Figure 4 — Switches for Engine
Safety Shutdown
Figure 5 — Field Boost Circuit
A solid state voltage regulator (Figure 6) controls the gener
ator’s AC output voltage. This regulator supplies an excitation
current to the rotor. By regulating the rotor’s excitation current,
the strength of its magnetic field is regulated and, in turn, the
voltage delivered to connected electrical loads is controlled.
When the AC frequency is 50 Hz, voltage is regulated at 120
volts (voltage-to-frequency ratio is 2-to-1).
■ HIGH TEMPERATURE SHUTDOWN
An oil temperature switch (Figure 4) with normally-open (N.O.)
contacts is mounted near the oil filter. If oil temperature were
to exceed about 284®F (140°C), the switch contacts close
and the engine shuts down.
■ FIELD BOOST
The Controller Circuit Board houses a field boost diode and
resistor which are not part of the automatic choke circuit.
These two components are part of a “field boosf circuit (Rgure
5). During engine cranking only, a positive DC (battery) volt
age is delivered through the diode, resistor, brushes and slip
rings, and the generator rotor. Application of this voltage to
the rotor “flashes the field” whenever it is started. Hashing of
the field each time the generator starts makes sure that a suf
ficiently strong magnetic field is available to produce “pick up”
voltage in the stator windings.
_______________________________
Figure 6 — Solid State Voltage Regulator
The voltage regulator also incorporates a “voltage surge pro
tection circuit.” This circuit prevents troublesome surges in the
generator AC output voltage. Voltage surge is a common
cause of damage to electronic equipment.
Recreational Vehicle Generator
10
Generac NP-66LPG Recreational Vehicle Generator
■ 25-HOUR BREAK IN PERIOD
The first 25 hours of operation are for “breaking in” the new
generator. Correctly breaking in the generator is essential to
minimize fuel consumption and provide maximum engine per
formance. During this 25-hour break in period, comply with the
following;
• Run the unit at varying electrical loads, to help seat engine
piston rings properly.
• For the 75 hours of operation after the “break in’ period, avoid
light electrical loads. Load the generator at 50% (or more)
of its rated wattage capacity. Repeated light loads during the
break in period can cause improper seating of engine piston
rings, which could cause blowby and high oil consumption.
• During the break in period, check engine oil level frequently.
It is normal for oil consumption to be high during the break
ing in period.
• After the 25-hour break-in period, complete the tasks rec
ommended under “25-hour Check Up.”
__________________
125-HOUR CHECK UP
After the 25-hour break-in period, contact an authorized ser
vice facility for the following maintenance. The vehicle owner
is responsible for any charges:
• Change engine crankcase oil and oil filter.
• Check all fluid levels.
• Inspect cooling and ventilation openings on the vehicle.
• Check engine carburetor adjustments.
• Check engine ignition system.
• Inspect entire electrical system.
• Inspect the engine exhaust system.
■ OPERATION IN HIGH GRASS OR
BRUSH
WARNING: NEVER OPERATE THE GENERATOR
WHILE THE VEHICLE IS PARKED IN HIGH GRASS,
A
WEEDS, BRUSH OR LEAVES. SUCH MATERIALS
CAN IGNITE AND BURN FROM THE HEAT OF THE
EXHAUST SYSTEM. THE GENERATOR EXHAUST
BECOMES EXTREMELY HOT DURING OPERATION
AND REMAINS HOT FOR A LONG TIME AFTER IT
HAS SHUT DOWN.
Recreational Vehicle Generator
11
Generac NP-66LPG Recreational Vehicle Generator
FUEL REQUIREMENTS
The “NP" series generator is equipped with a liquefied petro
leum (LP) gas fuel system. LP gas is usually supplied as a
liquid in pressuré tanks.
“NP” series generators require a “vapor withdrawal” type fuel
system. This type of gaseous fuel system uses the vapors form
ing above the liquid fuel in the storage tank. Air temperature
around the storage tank must be high enough to sustain ade
quate fuel vaporization. In colder climates, you may need to
use an independent heat source to be sure the fuel sufficently vaporizes in the storage tank.
LP gas may consist of propane, butane or mixture of two
gases. Propane vaporizes at temperatures as low as -20^
(-29®C), but butane returns to its liquid state when the temperture drops below about 32°F (0“C). For that reason, a
higher ratio of propane is desired in the gas mixture when tem
peratures drop below freezing.
ENGINE OIL REQUIREMENTS
Use a high quality detergent oil classified “For Service SP and
with an oil viscosity rating of SAE10W-30 oil. Do not pour in
any additives to the recommended oil. Engine crankcase
capacity is 1.5 U.S. quarts (1.4 liters). See MAINTENANCE
section for oil level check and filing procedures.
ENGINE SPECIFICATIONS
Type of Engine
Cooling Method..................................................................... Air-cooled
Rated Horsepower......................................................,.16 at 3600 rpm
Displacement
Compression Ratio........................................................................8.6 to1
Cylinder Block
Type of Governor
Engine Governed Speed
Air Cleaner
Starter...................................................................... 12 volts DC electric
Ignition S^tem
Recommended Spark Plugs
Champion.................................................................................RC12YC
AC
............................................................■...........
Fram Autolite.......................................................65
Spark Plug Gap......................................................................... 0.030 inch (0.8mm)
.......................................... .......................
..............................................................................
........................................................
......................................................
............................................
..............................................................
.............................. ................................
Aluminum with cast
Mechanical, fixed
See chart above
Paper element with
foam pre-cleaner
flywheel magneto
R45S
Twin Cylinder
479.4cc
iron sleeve
speed
Solid state with
GENERATOR SPECIFICATIONS
Rotor RPM...................................................-
Rotor Poles................................................
Engine RPM......................................................................................2700
Rated Maximum Continuous
AC Output................................................................6600 watts (6.6 kw)
Voltage.......................................................................................120 volts*
Rated Maximum Continuous AC Current.......................55 amperes
Phase................................................................................................single
Frequency....................................................................................60 Hertz
Weight.................................................................................. 213 pounds
Length...................................................................................................... 25 inches
Width.....................................................................................................18.5 inches
Height.................................................................................................15.75 inches
* The unit is reconnectable to 120 and/or 240 volts, dual voltage
output.
Rated maximum continous current at 240 volts is 27.5 amps.
...........................
................................'..............
.........
3600
2
Recreational Vehicle Generator
12
Generac NP-66LPG Recreational Vehicle Generator
This section includes information about simple maintenance
which includes the following tasks:
• Checking engine oil level.
• Changing engine oil.
• Changing oil filter.
• Changing the air cleaner.
• Cleaning the air intake screen.
• Cleaning spark plugs.
CHECKING ENGINE OIL LEVEL
Check engine crankcase oil level at least every eight hours of
operation, or before each use (Figure 7).
• Be sure the generator is as level as possible.
• Remove oil dipstick and wipe dry with clean, lint-free cloth.
• Install and tighten oil dipstick, then remove again.
• Oil should be at dipstick FULL mark. If necessary„add the
recommended oil to the FULL mark only. DO NOT FILL
ABOVE “FULL” MARK.
• Install and tighten oil dipstick cap before operating the
engine.-
NOTE: See “Engine Oil Requirements" on Page 12 for rec
ommended oiis.
With engine still warm from running, remove capifrom oil
drain hose (Figure 8). Drain oil completely into a suitable
container.
When oil has drained, install and tighten drain hose cap.
Remove oil dipstick and fill crankcase with the recom
mended oil (See Page 12). The engine crankcase can hold
about 1.4 liters. DO NOT FILL ABOVE “FULL” MARK.
Install and tighten dipstick cap before operating engine.
Figure 8 — Location of Oil Drain Plug
OIL DFIAIN
PLUG
CHANGE OIL FILTER
Replace the engine oil filter after the first 25 hours of opera
tion, every 100 operating hours thereafter.
Figure 7 — Oil Dipstick and Fill Tube
CHANGE ENGINE OIL
Change engine oil after the first 25 hours of operation (after
the 25 hour break-in period. Page 8). Thereafter, change oil
every 50 operating hours. Change oil more frequently if oper-
-.ating consistently under heavy load or at high ambient
temperatur^
• Warm up erigine for at-least.five minutes, then shut down.
Recreational Vehicle Generator
• Turn oil filter counterclockwise to remove (Figure 9).
• Coatgasketof new filter with engine oil.
• Turn new filter clockwise until its gasket contacts tightly with
the filter adapter. Then tighten with an additional 3/4 to one
turn by hand.
• Run engine.and check for leaks.
NOTE: Check oil level and fill to full mark after checking for
leaks. Filter will retain some oil.
Figure 9 — Engine Oil Filter
TO LOOSEN
13
Generac NP^6tt?G ftecreational \M«cle Genwator
ENGINE AIR CLEANER
Clean and re-oil the foam pre-cleaner every three months or
ever 25 hours of operation, whichever occurs first. Service
the foam pre-cleaner more frequently if you operate the gen
erator in extremely dusty or diiiy conditions (Rgure 10):
• Turn KNOB counterclockwise to loosen.
• Remove COVER, FOAM PRE-CLEANER and PAPER
FILTER.
• Remove foam pre-cleaner from cover
• Wash foam pre-cleaner in liquid detergent and water.
• Wrap foam pre-cleaner in a cloth and squeeze dry.
• Saturate foam pre-deaner in engine oil. Squeeze to remove
excess oil and to distribute oil.
• Install foam pre-cleaner into cover, followed by paper filter.
Tabs at edges of paper fitter must lock into slots on cover.
Once each year or every 100 operating hours (whichever
comes first), replace the paper filter. The new replacement
filter must be a flame retardent type.
Figure 10 — Engine Air Cleaner
CLEAN AIR INTAKE SCREEN
Clean all foreign material from the air intake screen (Figure
11) at lease once every 100 hours of operation. Clean more
often if necessary. *
Inspect the area around the generator exhaust muffler peri
odically and remove all grass, leaves, dirt, etc. from this area.
Figure 11 — Cleaning Air Intake Screen
PAPER
FILTER
FOAM
PRE
CLEANER
COVER
KNOBl
ENGINE SPARK PLUGS
Clean each engine spark plug and set gaps4o 0.030 inch
(0.76mm) every 100 hours of operation (Figure 12). Clean by
scraping or wire brushing and washing with commercial sol
vent. DO NOT BLAST CLEAN SPARK PLUGS.
CAUTION: Sparking can occur if wire terminal
does not fit firmly over spark plug terminal end. If
necessary, reform wire terminal to obtain a tight fit
Figure 12 — Engine Spark Plug
Recreational Vehicle Generator
14
Generac NP-66LPG Recreational Vehicle Generator
MISCELLANEOUS MAINTENANCE
■ SPARK ARRESTOR MUFFLER
If the generator is not equipped with a spark arrestor exhaust
muffler and is to be used On any forest covered, brush cov
ered or grass covered unimproved land, you may have to
install a spark arrestor. The spark arrestor must be maintained
in effective working order by the vehicle owner/operator.
For assistance in ordering, installing and maintaining spark
arrestor exhaust mufflers, contact your nearest authorized
service facility.
Exhaust mufflers supplied by Generac are spark arrestor
types. Generac exhaust mufflers for recreational vehicle gen
erators do not have a spark arrestor screen, but are of the more
efficient “toriod" or “swirl” type. To remove carbon and com
bustion deposits from such mufflers, remove the PLUG from
muffler ahd run engine for about 15 minutes. Shut engine.down,
let the muffler cool and install the plug.
WARNING: BE SURE TO REINSTALL THE PLUG
FROM THE MUFFLER TIGHaY. ENGINE VIBRATION
A
COULD CAUSE A LOOSE PLUG TO FALL OUT.
WITHOUT THE PLUG IN PUCE, HOT ENGINE
EXHAUST IS DIRECTED OUT THE OPENING. THIS
HOT EXHAUST, DEPENDING ON THE INSTALUTION, COULD BE DIRECTED TO AREAS NOT ABLE
TO WITHSTAND THE EXTREME HEAT SUCH AS
WOODEN FLOOR BOARDS OR OTHER FUMMA-
BLE MATERIAL THIS COULD RESULT IN A RRE.
BAHERY
All lead-acid storage batteries will discharge when not iif use.
Inspect the generator battery as follows: ^
Once Weekly
Inspect battery posts and cabl^ for tightness, corrosion. Clean
and/or tighten as necessary.
Also check battery fluid level, and, if necessary, fill with DIS
TILLED WATER ONLY. DO NOT USE TAP WATER IN
BAHERY.
Every Six Months
Have the battery state of charge and condition checked by an
automotive service facility. This should be done with an auto
motive type battery hydrometer.
DANGER: STORAGE BAHERIES GIVE OFF
EXPLOSIVE HYDROGEN GAS. THIS GAS CAN
A
FORM AN EXPLOSIVE MIHURE AROUND THE
BAHERY FOR SEVERAL HOURS AFTER CHARG
ING. THE SUGHTEST SPARK CAN IGNITE THE GAS
AND CAUSE AN EXPLOSION. SUCH AN EXPLO
SION CAN SHAHER THE BAHERY AND CAUSE
BUNDNESS OR OTHER INJURY. ANY AREA THAT
HOUSES A STORAGE BATTERY MUST BE PROP
ERLY VENTIUTED. DO NOT ALLOW SMOKING,
OPEN FUME, SPARKS OR ANY SPARK PRODUC
ING TOOLS OR EQUIPMENT NEAR THE BAHERY.
■ CLEANING THE GENERATOR
Keep your generator set as dean and dry as possible. Dirt and mois
ture that are permitted to accumulate on electrical windings have
an adverse affect on the insulation resistance of those wkidngs.
Moisture that is allowed to remain in contact with windings will
be retained in voids and cracks of the windings. Dirt makes
the problem worse, since it tends to hold the moisture into con
tact with the windings. Salt, as from sea air, worsens the
problem since it tends to absorb moisture from the air. The com
bination of salt and moisture makes a good electrical conductor.
CAUTION! Do NOT use a forceful spray of water to
clean the generator. Water will enter the generator
A
Interior and cause problems, and may also conta
minate the generator fuel system.
_________________
Recreational Vehicle Generator
15
DANGER: BATTERY ELECTROLYTE FLUID
IS AN EXTREMELY CAUSTIC SULFURIC ACID
SOLUTION THAT CAN CAUSE SEVERE BURNS.
DO NOT PERMIT FLUID TO CONTACT EYES, SKIN,
CLOTHING, PAINTED SURFACES, ETC. WEAR
PROTECTIVE GOGGLES, PROTECTIVE CLOTHING
AND GLOVES WHEN HANDLING A BAHERY. IF
YOU SPILL THE FLUID, FLUSH THE AFFECTED
AREA IMMEDIATELY WITH CLEAR WATER.
DANGER: DO NOT USE ANY JUMPER CABLES OR
BOOSTER BAHERY TO CRANK AND START THE
A
GENERATOR ENGINE. IF ANY BAHERY HAS DIS
CHARGED, REMOVE IT FROM THE VEHICLE FOR
RECHARGING.
Generac NP-<i6LPG Recreafionai Vehtcie Generator
MAJOR SERVICE MANUAL
To obtain a service manual for your generator, order it from
your deaier/distrttxitor or contact the factory. Be sure to iden
tify your unit’s MODEL NUMBER and SERIES.
DRIVE BELTS
The engine drives the generator rotor by means of a pulley
and drive belt arrangement. The drive train, drive belt and pul
leys are warranted for the life of the generator. Drive belt
tension was properly adjusted before the unit was shipped from
the factory. If you suspect that drive belt tension is incorrect,
contact an authorized service facility.
OUT OF SERVICE PROTEQION
If you cannot exercise the generator every seven days and it
is to be out of service longer than 30 days, prepare the gen
erator for storage as follows:
• Start the engine and let it warm up.
• Close the fuel shutoff valve in the fuel supply line and let
the engine “run out of fuel.”
• While the engine is still warm from running, drain the oil com
pletely. Refill the crankcase with SAE10W-30 oil having an
API classification “For Service SP
• Attach a tag to the engine indicating the viscosity and clas-
sification of the oil in the crankcase.
• Remove spark plugs and pour about two or three table
spoons of clean, fresh engine oil into spark plug threaded
openings. Crank engine several times to dtetribute oil, then
iristaU and tighten spark plugs. ,
• Remove the battery and store in a cool, dry room on a
wooden board. Never store the battery on any concrete or
wooden floor.
• Clean and wipe the entire generator.
RETURN THE UNIT TO SERVICE
AFTER STORAGE
To return the unit to service after storage, proceed as follows;
• Check tag on engine for oil viscosity and classification.
Verify that the correct recommended oil is used in the
engine. If necessary, drain and refill with proper oil.
• Check battery. Fill all cells to the proper level with distilled
water. DO NOT USE TAP WATER IN THE BAHERY.
Recharge battery to 100% state-of-charge, or, if defective,
replace the battery.
• Turn OFF all electrical loacte, then start the engine.
• Let the engine warm up.
• Apply electrical loads to at least 50% of the unit’s rated
wattage capacity.
• Mien the engine is thoroughly warmed, shut it down.
THE GENERATOR IS NOW READY FOR SERVICE.
Recreational Vehicle Generator
16
Generac NP-66LPG Recreational Vehicle Generator
TROUBLESHOOTING POINTS
PROBLEM
Engine woni crank.
Engine cranks but woni start
Engine starts hard, runs rough.
CAUSE
1. 15 amp fuse blown.
2. Loose or corroded or defective
battery cables
3. Defective starter contactor.
4. Defectiva starter motor.
5. Battery is discharged or defective.
6. Defective Controller Circuit Board
1. Out of fuel.
2. Fuel shutoff valve to RV fuel system
(if so equipped) is closed.
3. Engine is flooded.
4. Defective Controller Circuit Board
5. Spark plugs defective.
6. Defective ignition magneto on engine.
7. Bad carburetor.
8. Dirty engine air cleaner filter.
1. Dirty engine air cleaner filter.
2. Defective spark plugs.
3. Defective ignition magneto on engine.
CORRECTION
1.
2.
Trghten, dean or replace
as necessary.
3.
Replace contactor.
4
Replace starter motor.
5.
Recharge or replace battery.
6.
Replace defective drcuit board.
1. Replenish fuel tank.
2. Open fuel shutoff valve.
3. Wait 5-10 minutes; try again.
4. Replace defective circuit board.
5. Clean, regap or replace plugs.
6. Replace, if defective.
7. Adjust, repair or replace.
8. Clean or replace filter as needed.
1. Clean or replace fitter as needed.
2. Clean, regap or replace plugs.
3. Replace, if defective.
Engine starts, shuts dovm when
Start/Stop switch is released.
No AC output from generator.
1. Engine oil level is low. 1.
2. Defective Controller Circuit Board. 2.
3. Defective Low Oil Pressure Switch 3.
4. Loss of generator AC-output. 4.
1. Check main line circuit breaker.
2. Transfer switch (if so equipped) is set
to wrong position.
3. Failure in vehicle electrical system.
4. Generator component failure.
Recreational Vehicle Generator
17
Check oil and add oil as needed.
Replace if defective.
Replace defective switch.
Contact an authorized service
facility.
1. Reset to ON or CLOSED.
2. Reset transfer switdi.
3. See vehicle manual.
4. Contact an authorized service
facility.
Generac NP-66LPG Recreational Vehicle Generator
► cr ' ^
EXPLODED VIEW - BASE AND PULLEYS
-.-■ip
Drawing No. 95956
Recreational Vehicle Generator
18
Genefacl№-€6LPGRecrealionalVi8hicleGenefatof
REPAIR PARTS - BASE AND PULLEYS
Drawing No. 95956
%
ITEM PART NO
1
86318
Ml 41 1
2
3 46911
4 25017
46526 10
5
6 22129
7
72391
8 77603
9 22259
10 52858
11
21
-46 75712-
51730
12 29459 , 2
13 75215
14
73146
75209 2
15
73174 1 Exhaust Manifold
16
17
79678 2
18 55173
19 72383
20 90859
75224F 1
73106F
22
75216
23
24
49451
25 42633
77017
26 .
27
73118
74906
28
29 23152 ' 4 3«*-16x3/4* Capsaew
30 723/5
31
73185
32
22097
77682
33
34
75242
35
49813
45757
36
42
26925
43
7571OA
44
74958
45
67871
QTY.
1
4 Rubber Mount
8
2
2 Rubber Mount Skid 61 74951
2
2 5/16-18 Hex Nut
6
2
2
4 N^n Slide 69 75281
4
2 Collector Pan Gasket 75
1 Cover Plate A External 76 90800
1 Altemator Pulley 78 75226
1 40* Poly Vinyl 4L Belt
1 Pulley Retainer Washer 80
1
1
1
5
1 Blower Housing
1
6
1
4
2
2
1
1
1
1
1 0-ring Drän
DESCRIPTION ITEM PART NO. QTY.
IteuntingBase
GroimdCäbie 56 73179
3/r-16x1^Capsaew
MIO Lock Washer 59 74948 3
M8 Lock Waster
Ol/O’-lOx 3-1/2* Bolt
M8-1.25 Ranged Lock Nut
M8-1.25 X 60mm Capscrew
Belt Tension Spring
Spring Center Washer
Nylon Slide Support 70
Exhaust Manifold Gasket 73
M8-1.25 X 20nm Capsaew 74
Engine Pulley
3/8*-24 X r Capscrew
Blower Housing Guide
3/8*-24 X 2-1 /2“ Capscrew
M6-1.00 X 20mm Screw
Blower Housing Spacer
M6 Lock Washer
M5-0.8 X 80mm Capsaew
Generator Mounting Spring
M6-1.00HexNut
M6-1.0 X 25mm Capsaew
3/8*NPTOil Drän
Oy Fill and Drän Tube
Cap and Dipstick Assembly
0-ringCap
______________
DESCRIPTION
47 75711 1
1
57
70185
58 60108
60 74950
62 73134
63 38750
64 74949
68548
65
62684 1 Grounring Lug
66
67
29289
74027 2
71 43182
75237 4 Spring Retainer Wa^
77681
75474 1
77 74907 1
79 56893 14 #10-24 X1/2* Saew
752M 1
75227
81
82
79246
83
22473
85
72384C
87
77643
22447 1
90
91
90088
92-
74908
93
81105
94
23897
95
67210
96
45756
97
22131
68527
98
1 Oil RIter
1
1
1
1
3 M6-1.00 X 30mm Capsaew
1
1
A
1
2
1
1
1
1
4
A
1
2
1
10
2
6
1
4
1
4
0-ring Adaptor
Oil Rtter Support
Oil Pressure Switch
5/16* Fitting
Outer Oil Tube
Inner Oil Tube
Oil Pad Adaptor
5/16* 90-degree Fitting
Oil Pad Gasket
1/16* X 8* Foam Tape
Hi{^ Temperature Switch
M3-0.5 Pan Head Screw
M3 Lock Washer
LOS 2-wire Vinyl Cap
irx42*x2*VinylCap
Exhaust Elbow
1-1/8* Exhaust Clamp
Air Cover
Slide Pan Gasket
SndePan
M6-1.0X 16mm Capsaew
with lock washer
M6 Rat Washer
Exhaust Outlet Cover
Exhaust Outlet Gasket
M6 Toothed Lock Washer
Vinyl coaled Clamp
M5-0.8X 10mm Saew
5/16'-18 Flange Nut (special)
M5 Rat Washer
Decal A Ground
M6 X 10mm Ts^tite Saew
Ml 0 Rat Washer
M6-1.0 X 2№rm Capsaew with
Lockwasher
Recreational Vehicle Generator
19
Generac NP-66LPG Recreational Vehicle Generator
^
-------------------
Drawing No. 92118
EXPLODED VIEW - ALTERNATOR AND PANEL
Recreational Vehicle Generator
20
Generac NP-66LPG Recreational Vehicle Generator
Drawing No. 92118
REPAIR PARTS - ALTERNATOR AND PANEL
ITEM PART NO QTY. DESCRIPTION
75995
1
77004G
2
87845G
3
73159
4
31971
5
72379
6
7 77006
52858
8
66386
9
66849
10
27756
11
86314 1
12
75234
13
14 22473
22097 5
15
74095
16
90141
17
22447 1
18
74906
19
92234
20
10-74260
21
22129
22
22259
23
86316
24
53650
25
20575 ,
26
75244 1
27
28 66476
86729
29
30 75476
22264
31
32 65795
90987
33
1
1
1 Stator Assembly
1
1
1
4
8
1
2
4
1
3
1
2
4
1
1
2
2
1
1
1
2
1
3
4
1
2
Lovrar Bearing Carrier
Rotor Assembly
Ball Bearing
Ball Bearing
Upper Bearing Carrier
Stator Stud
M8-1.25 Range Lock Nut
Brush Holder
M5-0.80X 15mm
Nylon Washer
Generator Top Housing
Resistor
Rat Washer
M6 Lod( washer
M6-1.00 X 60mm Capscrew
Ground Cable
Shakeproof Lock Washer
M6-1.00 x 20mm Screw
Controller Circuit Board
Starter Cable
5/16‘ Lock Washer
5/16M 8 Hex Nut
Panel Sheet Metal
4-pin Connector
Connector
Remote Harness
M6-1.0 X 12mm Capscrew
with lock washer
Starter Contactor
M4-0.7 X 16mm Capscrew
M4 Lock Washer
Battery Charge Rectifier
M3-0.5 X 15mm Capscrew
ITEM PART NO. QTY. DESCRITPOlN
34 86317
75235
35
82737 4
36
37 49813
38 49815
43182 2 M3 Lock Washer
39
54502 1 3A Circuit Breaker
41
67444
42
83049
43
49226 6
44
51716
45
46 90145
90145
47
25105
48
86315
49
90734
50
22985
51
52 32300
22676
53
54 87798
92113
55
7521OA
56
57 23365
51715
58
90157 1
59
90156
60'
61
89438B 1
62 31791
23897 . 1 M5 Rat Washer
63
64 74908
23484S
65
75763A
66
1 Panel Support Bracket
4 M5-0.8 X 30mm Capscrew
Vibration Mount
4 M6 Hex Nut
1 M5-0.8 X 16mm Capscrew
1 M5 Shakeproof Washer
1
4 M5-0.80 Hex Nut
1 30A Circuit Breaker
1 30A Circuit Breaker
4 No. 6-32 Screw with lock washer
1 Panel Cover
4
1
1
1 15 Amp Fuse
1 Start/Stop Switch
1
1
1
1
1
1 Hose Clamp
1
1
1 Battery Cable Boot
Voltage Regulator
M5 Lock Washer
M4-0.7 X 16mm Capscrew
and Rat Washer
M4 Rat Washer
Fuse Holder
Fuel Pump Switch
Terminal Block
M4 Shakeproof Washer
M4-0.7 Hex Nut
Decal — C.B. Rating 30 Amp
Decal — C.B. Rating 20 Amp
Customer Connection Decal
M5 X 10mm Taptite Screw
Bushing
Recreational
Vehicle Generator
21
C/^ Generac NP-66LPG Recreational Vehicle Generator
-V
Drawing No. 89403
EXPLODED VIEW - ENGINE ENCLOSURE
TEM
PART NO QTY.
_____
1
2 99258
3
4
5
7
8
10 87750
11 74916
12 74908 9
13
14 78858
15
16 74902
17 66476 5
19
—
67198N
67890
87865 1
86313
56893
73190
78859
73191 1
DESCRIPTION
1
1 6 X 25 Woodruff Key
1 Belleville Washer
1 M20-1,50HexNut
1
23 No. 10-24 X 3/8' Crimptite Screw
1 Flywheel Scroll
■ 1 No. 2 Base Cover
1
1
1 No. 1 Cylinder Wrapper
2
See Engine Exploded View
Flywheel Access Plug
Engine Housing Top
M5 X 10mm Taptite Screw
No. 2 Cylinder Wrapper
Valley Cover
Wrapper A Barrel
M6-1.00 X 12mm Capscrew with 35
lock washer
No. 1 Base Cylinder Cover
Recreational
ITEM
Vehicle Generator
PART NO. QTY.
42907
20
21 22129 2
22 75246 4
23 10-74260
24
74900
25
73186 ,
26 81108
27
22717B. 1
22717A
28
29 . 67866 1
77001
30
31 73132 2
87858A
33
34 29289 2 ft.
87858B 1
.36 50277
22
DESCRIPTION
2
1 No. 16 Wire Assembly
1
1 .
1
3
1
1
1 Oil Drain Decal
M8-1.25 X 16mm Capscrew
M8 Lockwasher
3/8’-16x 1-1/4'Screw
Starter Cover
Crankcase Wrapper
Snap Bushing
Rubber Grommet
Rubber Grommet
0-ring
Oil Fill Plug
Spark Plug Boot
Ground Wire Assembly—#2 cyl.
Foam Tape
Ground Wire Assembly — #1 cyl.
Oj, Generac NP-66LPG Recreational Vehicle Generator
o
i Drawing No. A4029
EXPLODED VIEW- CARBURETOR
1 A1662A 1 V-TWIN CARBURETOR
2 57822 2 HOSE CLAMP
3 74994 1 1/2” I.D.x10”.LONG HOSE
4 26307 3 STREET ELBOW
5 26915 1 3/4” PIPE SLEEVE
6 75211 1 GASEOUS FUEL regulator
7 A2666 1 GASEOUS FUEL solenoid
8 78864 1 REGULATOR MOUNTING
BRACKET
9 49813 4 M6 HEX NUT
10 22097 4 M6 LOCK WASHER
11 47411 2 M6-1.0X16MMHEXHD.CAPSCR.
12 38750 2 M6-1.0X30MMHEXHD.CAPSCR.
13 37398 1 HEX LOCK NUT'(NYLON)
14 74961 1 GOVERNOR ADJUSTER BRACKET
15 56893 5 #10-24x1/2” SCREW
16 47227 1 GOVERNOR ADJUSTER SCREW
Recreational Ve
74962C
17
18:
66476
19
91351
75944
20
21
73130
22
70155
23
76242
24
70125
25
70108
+
28739
+
55162
26
81190
27
70103
28
61695
+ NOT SHOWN
hide Generator
23
2 M6-1.0X12MM HEX SCREW
2 M6-1.0X12MM HEX SCREW
W/LOCKWASHER
1 AIR CLEANER DECAL
1 GOVERNOR SPRING BRACKET
1 FLYWHEEL ASSEMBLY
1 GOVERNOR LEVER
2 1/8” I.D.x 1/8” RIVET
1 ANTI-LASH SPRING
1 GOVERNOR-TO-CARBURETOR
ROD
4 4” LONG TIE WRAP
9cc PIPE SEALANT
1 LP HOOK UP FITTING
1 AIR CLEANER SUPPORT BRACKET
1 BARBED 90 DEG. 3/8” X1/2”
Oi Generac NP-66LPG Recreational Vehicle Generator
EXPLODED VIEW - GN-480 ENGINE
Drawing No. 79216
Recreational Vehicle Generator
24
Oj.
Generac NP-66LPG Recreational Vehicle Generator
w ^ ■
^•r
EXPLODED VIEW - GN-480 ENGINE
57
/
Drawing No. 79216
25
Os Generac NP-66LPG Recreational Vehicle Generator
0
Drawing No. 79216
EXPLODED VIEW - ENGINE PARTS
Recreational Vehicle Generator
26
Oj, GeneracNP-66LPG Recreational Vehicle Generator
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REPAIR PARTS LIST - 6N-480 ENGINE
Drawing No. 79216
1
3
4
5
6
7
8
9
PART NO.
69331
69333
67805
79234
79235
70169
69332
72301
72315
70190
70596
69336
69325
72334
75247
67924
67878
75248
75249
69327
72520
72521
72346
69316
69317
67816
■ 69320
70513
70584
70530 .
72358
69379
67895
70594
67158
68574
68554
68573
70506
70554
70568
75253
75254
70535
75255
75256
75257
67891
ITEM
. 2
10
11
12
13
14 67888
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44 67885
45
46
47
48
49
50
QTY. DESCRIPTION
1
1
1
1
1
4 Sealing Washer
2
1 Breather Assembly
1
2
1 Breather Tube
1 Oil Sump Gasket
8
2 3/8” NPT Oil Drain Plug
1
1
1 Oil Seal Assembly
9 Oil Sump Bolt
2
2
4
2
2
4
2
2 Intake Valve
4 Valve Spring
4 Valve Spring Retainer
4 Valve Keeper
4 Valve Tappet
1
1
2
2
'2
4
1
1
1 Oil Pump 0-ring
1
1
4
4
4 ,
4
1
1
2
4
1
Cylinder Assembly
Sleeve Bearing
Oil Seal
No. 1 Cylinder Head Assembly
No. 2 C^inder Head Assembly
Cylinder Head Gasket
Breather Gasket
Breather Screw 61
Cylinder Head Bolt
Crank Shaft Assembly
Oil Sump Assembly
Standard Piston Assembly
Standard Piston Ring Set
Piston Locking Ring
Standard Piston Ring
Connecting Rod Assembly
Connecting Rod Bolt
Exhaust Valve
Camshaft Assembly
Intake Manifold
Carburetor Mounting Gasket
Intake Manifold Gasket
Carburetor Mounting Bolt
Intake Manifold Mounting Bolt
1/8” NPT Plug Pipe
Governor Shaft Seal
Oil Galley 0-ring
Carburetor Spacer
Rocker Arm Stud
Washer Valve Cover Seal
M6 Nylon Nut
Valve Adjust Screw
Oil Screen
Starter Motor
Starter Motor Bolt
Brush Assembly
Ignition Armature Assembly
ITEM
51
52
53 75258
55
56 75261
57
58 75269
59
60
62
63
64 72365
65
66
67
68
69
70 75265
71
. 72
73
74 75272
75
76
77 67911
78
79
80 75270
81
82
83
84 72300
85
86
87
8889 69358
90 67920
91
92
93 70536
94
95
96
97
98
100
101
PART NO.
72536 2
72347 2 “D” Spark Plug
75260
66480
72361
72362
70199
72366
72367 1 Governor Fork
68555 2
67806
75262
75263
75264
75266
75267
68572
70122
67910
67813
75268
70592
73123
70593
67156 2
69341
80011
70597 1 Air Inlet Tube
69328
70547 1
70577 4 Push Rod
70599 4
70567
70566
75271
67897
99 .
91481
91480
QTY. DESCRIPTION
Ignition Armature Screw
1
1
1 Clutch Assembly
1
1
1 Governor Shaft Bushing
1 Governor Shaft Bushing
1
1
1 Governor Shaft Washer
4 Cylinder Head Dowel
1 Breather Screw Seal
1 Breather Seal Screw
1
1 Starter End Cap Assembly
1 Commutator Cap Assembly
1 Starter Housing Assembly
2 Oil Pump Screw
2 Spark Plug Terminal
2 Valve Stem Seal
2
2 Exhaust Valve Seat
4
1 Retainer and Pin
1
1 Air Cleaner Base
1 Air RIter
1 Air Cleaner Cover
1 Wr Cleaner Cover Screw
1 Foam Pre-cleaner
1 Brush Set Spring
1 Breather Deflector
2
2 Valve Cover
1
2.
4
1
2
1
1
Engine Gasket Kit
Starter Drive Assembly
Air Cleaner Gasket
Armature Assembly
Breather Baffle
Cotter Pin
Crankcase Dowel
Starter Gear
Intake Valve Seat
Valve Guide
Roll Pin
Air Cleaner Base Screw
Valve Cover Gasket
Oil Pump Assembly
Governor Slider
Rocker Arm Assembly
Rocker Arm Shaft
Rocker Arm Support
Valve Overhaul Kit
Exhaust Gasket
Gasket and Cap Assembly
Rocker Arm and Cover
Recreational
Vehicle Generator
27
Oj. Generac NP-66LPG Recreational Vehicle Generator
"
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Drawing No. 92116
ELECTRICAL DATA
Recreational Vehicle Generator
28
Of
Generac NP-66LPG Recreational Vehicle Generator
NOTES
Recreational Vehicle Generator
29
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRAtfTYRIQHTS AND OBUGAnONS
The California Air Resources Board (“CARS“) and Generac Corporation are pleased to explain the Emission Control Sysl^^^
Warranty on your new recreational vehicle generator engine. In California, new utility and lawn and garden equipmt.
engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. Generac Corporation will
warrant the emission control system on your recreational vehicle for the periods of time listed below provided there has
been no abuse, neglert, unapproved modification, or improper maintenance of your recreational vehicle generator engine.
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Also included
may be the compression release system and other emission-related assemblies.
Where a warrantable condition exists, Generac Corporation will repair your recreational vehicle generator engine at no cost
to you for diagnosis, parts and labor.
MANUFACTURER'S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:
Emissions control systems on 1995 and later model year recreational vehicle generator engines are warranted for two years
as hereinafter noted. If, during such warranty period, any emission-related part on your engine is defective in materials or
workmanship, the part will be repaired or replaced by Generac Corporation.
OWNER'S WARRANTY RESPONSIBILITIES:
As the recreational vehicle generator engine owner, you are responsible for the performance of the required maintenance
listed in your owners manual. Generac Corporation recommends that you retain all receipts covering maintenance on your
recreational vehicle generator engine, but Generac Corporation will not deny warranty solely due to the lack of receipts or
for your failure to provide written evidence of the performance of all scheduled maintenance.
As the recreational vehicle generator engine owner, you should, however, be aware that Generac Corporation may deny
you warranty coverage if your recreational vehicle generator engine or a part thereof has failed due to abuse, negle^^
improper maintenance or unapproved modifications.
You are responsible for presenting your recreational vehicle engine to a Generac Corporation Authorized Service Outlet as
soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
Warranty service can be arranged by contacting either a Generac Corporation Authorized Service Outlet or by contacting
Generac Corporation at:
GENERAC CORPORATION PH: (414) 544-4811
P.O. BOX 8 FX: (414) 544-0179
WAUKESHA, Wl 53187
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System
Warranty (“ECS Warranty“) which is provided to you by Generac Corporation pursuant to California law. See also the
Generac Corporation Limited Warranties for Generac Corporation which is enclosed herewith on a separate sheet and also is
provided to you by Generac Corporation. The ECS Warranty applies only to the emission control system of your new engine.
To the extent that there is any conflict in terms between the ECS Warranty and the Generac Corporation Warranty, the ECS
Warranty shall apply except in any circumstances in which the Generac Corporation Warranty may provide a longer warranty
period. Both the ECS Warranty and the Generac Corporation Warranty describe important rights and obligations with
respect to your new engine.
Warranty service can only be performed by a Generac Corporation Authorized Service Outlet. At the time of requesting
warranty service, evidence must be presented of the date of the sale to the original purchaser. The purchaser shall pay any
charges for making service calls and/or for transporting the products to and from the place where the inspection and/or war
ranty work is performed. The purchaser shall be responsible for any damage or loss incurred in connertion with the trans
portation of any engine or any part(s) thereof submitted for inspection and/or warranty work.
IF YOU HAVE ANY QUESTIONS REGARDING YOUR WARRANTY RIGHTS AND RESPONSIBILITIES, YOU SHOULD CON.
GENERAC CORPORATION AT 1-800-222-3136
EMISSION CONTROL SYSTEM WARRANTY
Emission Control System Warranty (“ECS Warranty“) for 1995 and Later Model Year recreational vehicle generator Engines:
Applicability: This warranty shall apply to 1995 and later model year recreational vehicle generator engines. The ECS
Warranty Period (“ECS Warranty Period“) shall begin on the date the new engine or equipment is delivered to its original,
it
end-use purchaser and shall continue for 24 consecutive months thereafter.
B. General Emissions Warranty Coverage: Generac Corporation warrants to the original, end-use purchaser of the new engine
or equipment and to each subsequent purchaser that each of its recreational vehicle generator engines is:
1. Designed, built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pur
suant to its authority, and
2. Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, will cause a warrant
ed emissions related part to fail to be identical in all material respects to the part as described in the engine manufactur
er's application for certification.
C. The ECS Warranty only pertains to emissions-related parts on your engine, as follows:
1. Any warranted, emissions-related parts which are not scheduled for replacement as required maintenance in the Owner's
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall be
repaired or replaced by Generac Corporation according to Subsection (4) below. Any such part repaired or replaced under
the ECS Warranty shall be warranted for any remainder of the ECS Warranty Period.
2. Any warranted, emissions-related part which is scheduled only for regular inspection as specified in the Owner's Manual
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or
replace as necessary“ shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS
Warranty shall be warranted for any remainder of the ECS Warranty Period.
3. Any warranted, emissions-related part which is scheduled for replacement as required maintenance in the Owner's
Manual shall be warranted for the period of time prior to first scheduled replacement point for that part. If the part fails
prior to the first scheduled replacement, the part shall be repaired or replaced by Generac Corporation according to
Subsection (4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted
for the remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related
part.
4. Repair or Replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no charge
to the owner at a Generac Corporation Authorized Service Outlet.
5. The owner shall not be charged for diagnostic labor which leads to the determination that a part covered by the ECS
Warranty is in fact defective, provided that such diagnostic work is performed at a Generac Corporation Authorized
Service Outlet.
6. Generac Corporation shall be liable for damages to other original engine components or approved modifications proximately caused by a failure under warranty of any emission-related part covered by the ECS Warranty.
7. Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient to
meet the expected demand for such emission-related parts.
8. Any Generac Corporation authorized and approved emission-related replacement part may be used in the performance
of any ECS warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce
Generac Corporation ECS warranty obligations.
9. Unapproved add-on modified parts may not be used to modify or repair a Generac Corporation engine. Such use voids
this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim. Generac Corporation shall not
be liable hereunder for failures of any warranted parts of a Generac Corporation engine caused by the use of such an
unapproved add-on or modified part.
EMISSION RELATED PARTS
1. Fuel Metering System,
a. Gasoline carburetor assembly (if so equipped)
1) Fuel filter (if so equipped)
2) Carburetor gaskets
3) Fuel pump
a. LP/Natural gas carburetion assembly
1) Fuel controller
2) Mixer and its gaskets (if so equipped)
3) Carburetor and its gaskets (if so equipped)
4) Primary gas regulator (if so equipped)
5) LP liquid vaporizer (if so equipped)
INCLUDE THE FOLLOWING:
2. Air cleaner assembly
a. Air filter element
b. Intake pipe
3. Ignition system including:
a. Spark plug
b. Ignition module
4. Catalytic muffler (if so equipped)
a. Muffler gasket (if so equipped)
b. Exhaust manifold (if so equipped)
5. Crankcase breather assembly and its components,
a. Breather connection tube
Generac NP-66LPG Recreational Vehicle Generator
------------------------------------------------------------------------------------------------------------------------------------------------------
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<r
GENERAC S THREE-YEAR LIMITED WARRANTY FOR RECREATIONAL VEHICLE NP GENERATORS
Generac warrants to the original purchaser that its generators will be free from defects in materials or 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.
This warranty is effective only upon Generac's receipt prior to expiration of the warranty period of a completed Warranty
Registration Card. This card is the only valid registration identification and must be presented at time of service. Claims
will not be accepted without presentation of Registration Card.
THREE YEAR WARRANTY SCHEDULE
1. All NP Series generators used in a recreational vehicle shall be warranted for a period of three (3) years or 2,000 hours of
operation, whichever occurs first. All parts, labor, removal and reinstallation shall be covered for the first two
years. Parts and labor on selected generator and engine parts shall be covered during the third year or 2,000 hours,
whichever occurs first. These selected parts are limited to: the main Rotor and Stator, Computer Control Board (if
applicable) with regard to the generator; the Cylinder Block, Cylinder Head, Crankshaft, Piston, Valve, Valve Lifter, and
Manifolds with regard to the engine.
2. The drive train belt and pulleys (if so equipped) on NP air-cooled generator used in recreational vehicles shall be war
ranted against failure due to defective materials or normal usage for the life of the generator. For the original owner, this
drive train warranty shall include parts and labor plus $50.00 payment upon return of the failed belt or pulley by the origi
nal owner. For succeeding owners, this power train warranty shall cover belt or pulley parts only.
3. Rental units, demonstrators, prime power, or commercial applications, such as construction or utility, are warranted for (1)
one year or 2,000 hours, whichever comes first.
THIS WARRANTY DOES NOT COVER:
• Costs of maintenance, installation, and start-up.
• Failures due to (a) normal wear and tear from GN engine, or (b) accident, misuse, abuse, negligence or improper installa
tion.
• Products which are modified or altered in a manner not authorized by Generac in writing.
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair
or replacement of defective parts.
• Failure due to misapplication.
• Telephone, telegraph, teletype or other communication expenses.
• Living or travel expenses of persons performing service.
• All and all transportation/travel expenses.
• Rental equipment used while warranty repairs are being perfortfied.
• Overtime labor.
• Starting batteries, fuses, light bulbs, and engine fluids.
**NORMAL WEAR: As with all mechanical devices, the GN-Series engines need periodic parts service and
replacement to perform well. This warranty will not cover repair when normal use has exhausted the life of a part
or an engine.
There is no other express warranty, Generac hereby disclaims any and all implied warranties, including but not limited to
those of merchantability and fitness for a particular purpose to the extent permitted by law. The duration of any implied
warranties which cannot be disclaimed is limited to the time period (one year) as specified in the express warranty. Liability.
for consequential, incidental, or special damages under any and all warranties is excluded to the extent permitted by law.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusions or limitations of incidental or
consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal
rights and you may also have other rights, which vary from state to state.
For service, see your nearest Generac authorized warranty service facility or call 1-800-333-1322. Warranty service can be
performed only by a Generac authorized service facility. This warranty will not apply to service at any other facility. At the
time of requesting warranty service, evidence of original purchase date must be presented.
Generac Corporation
P.O.Box 8 Waukesha, W153187 Telephone: (414) 544-4811 Fax:(414)544-4851
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