Home

Owner`s Manual and Installation Instructions

1. 19 oi eton T 6 Compartment Floor 0 5 20 OPERATING INSTRUCTIONS 20 Generator Control 7 COOLING AND VENTILATION AIR Automatic Choke Gasoline only 7 Generator Air Flow tees 21 Before Starting the 7 8 Cooling Air Inlet Openings 21 22 Starting AR ER 8 Compensating for REStriCtiONS 22 Stopping the Generator nennen 8 Inverter Location 22 Applying Loads to Generator enter 8 Testing the een 22 Attention Required After Submersion 8 Operation in High Grass or 8 GASOLINE FUEL SYSTEM Operating Precautions 8 9 Fuel Tank 23 Effects of Moisture and 9 Generator Fuel Supply Line 23 24 Do Not Overload the Generator 9 PROPANE GAS FUEL SYSTEM ENGINE PROTECTIVE DEVICES Parts Not Included in Fuel
2. m m M gt DESCRIPTION LOCK WASHER M8 M6 1 x 20MM TAPTITE HEX HD CAPSCR M8 1 25 x 20MM HEX HD CAPSCR 3 8 16 x 1 25 LOCK WASHER 3 8 PHMS M4 0 7 x 8MM LOCK WASHER M4 PHILLIPS PAN HD MACH SCREW M6 1 x 90MM WOODRUFF KEY 4 x 19MM TAPTITE 3 8 16 x 75 ASSEMBLY IGNITION SENSOR SPACER ENGINE MOUNT BRACKET ENGINE MOUNT FRONT BRACKET ENGINE MOUNT REAR RUBBER MOUNTS ASSEMBLY OIL FILL CAP O RING 1 062 1 0 OIL FILL TUBE O RING 562 CARBURETOR SPACER GASKET OIL FILTER ADAPTOR BRACKET STARTER SIDE ENGINE MNT COVER BREATHER CANAL 8 x 3 8 PLASTITE SCREW STARTER WIRE TEMP SWITCH GROUND WIRE PLASTITE SCREW 4 x 37 EXTENSION SPRING WRAPPER ENGINE TOP HOSE BREATHER WASHER INTERNAL SHAKEPROOF 25 10 M5 FLAT WASHER SWITCH THERMAL OIL TEMP ADAPTOR OIL FILTER 4 PSI OIL PRESSURE SWITCH SCREEN OIL PICK UP DRAIN PLUG M12 1 75 x 20MM GASKET OIL DRAIN PLUG PPHMS M3 0 5 x LOCK WASHER M3 A C DECAL SHCS M6 1 0 x 25 LG SKIRT BAFFLE CRIMPTITE 10 24 x 1 2 SHIM STARTER EXPLODED VIEW ENGINE LONG BLOCK Drawing No A6202 D dd cut REPAIR PARTS ENGINE LONG BLOCK Drawing No A6202 D ITEM PART NO DESCRIPTION 1 78621 1 ASSEMBLY CONNECTING ROD 8 2 76389 1 PISTONPIN 3 88411 1 SET PISTON RING STD SIZE 4 72657 2 PIPE PLUG 1 4 NPT 5 77176 1 COVER BREATHER 6 88057 1 PISTON 75 DIA
3. 24 Automatic Low Oil Pressure 9 Some Important Considerations 24 High Temperature Shutdown eee 9 Vapor Withdrawal 000000 24 OVerspeed nn ne 9 Primary 24 25 LOW Voltage eee ex 9 Gaseous 8 3 0 25 Fuel Supply ae 25 SPECIFICATIONS Excess Flow n an 25 FUEL Requirements nannten 10 Leakage TESS DESE ee ande 25 Engine Oil Requirements 10 Generator Specifications 10 EXHAUST SYSTEM Engine Specifications eee 10 Mufflers and Spark Arrestors 26 Type of Exhaust System 2 2 2 2 2 2 00000 0000 26 MAINTENANCE Exhaust System Safety 26 Checking Engine Oil 11 Change Engine Olsen 11 E
4. DESCRIPTION BUS BAR OUTER TAPTITE M6 1 0 x 10MM BRACKET HEAT SINK PCB TERMINAL BLOCK BUS BAR INNER GROUND WIRE DC POWER HARNESS REMOTE PANEL HARNESS SNAP BUSHING CLAMP CONTROL PANEL HARNESS HARNESS CONTROL PANEL 6 32 x 1 4 PHILLIPS ROUND HD MACH SCREW RUBBER U CHANNEL M4 0 7 x 10MM HEX HEAD CAPSCREW HOUR METER PPHMS 10 32 x 3 8 LG BUS BAR CENTER BLACK TIE WRAP 7 LG SHAKEPROOF EXT 10 INVERTER ASSEMBLY WIRE HARNESS 7 CONDUCTOR WIRE HARNESS 2 CONDUCTOR WIRE HARNESS HEATSINK TO PCBI HARNESS PCBI TO PANEL HARNESS HEATSINK TO TERM BLOCK M3 0 5 NUT M6 FLAT WASHER 616 L33HS 3NION3 41 6 64 UNIT 8 yb s e 68 f g7 63 v x4 4 62 29 42 Drawing No A9193 D PARTNO QTY ITEM R DD 86705 56893 86718 A3666 74908 A3667 22129 39414 50830 A3638 89680 89471 86731A 86715 86726 86671 86727 86719 C3296 90141A 86724 43790 22127 22097 86729 90518 89048 90537 22145 75211 40173 234840 23762 22471 22264 79246 23897 22447 1 3 3 5 n FP He Q m m m m c Mm REPAIR PARTS LP ENGINE SHEET METAL DESCRIPTION PLATE DIVIDER CRIMPTITE 10 24 x 1 2 SEA
5. Electronic Air Paper element 51311617 D 12 volt DC electric Ignition System Solid state Recommended Spark Plugs Champion RC12YC Spark Plug 0 030 inch 0 8mm 10 This section includes information about simple main tenance which includes the foll Checking engine oil level Changing engine oil Changing oil filter Air cleaner maintenance Cleaning the air intake screen Cleaning spark arrestor Cleaning spark plug Replacing fuel filter Servicing inverter CHECKING ENGINE OIL LEVEL Check engine crankcase oil level at least every eight hours of operation or before each use Figure 2 Be sure the generator is as level as possible Remove oil dipstick and wipe dry with clean lint free cloth Install and tighten oil dipstick then remove again Oil should be at dipstick FULL mark If necessary add the recommended oil to the FULL mark only DO NOT FILL ABOVE FULL MARK Install and tighten oil dipstick cap before operating the engine Figure 2 Oil Dipstick and Fill Tube NOTE See Engine Oil Requirements on Page 10 for recommended oils CHANGE ENGINE OIL Change engine oil after the first 8 hours of operation Thereafter change oil every 50 operating hours Change oil more frequently if operating consistently under heavy load
6. IMPORTANT IF YOU PLAN TO INSTALL THE GEN ERATOR IN A COMPARTMENT BE SURE TO LEAVE AT LEAST ONE INCH 2 RECOMMENDED OF CLEARANCE BETWEEN THE GENERATOR AND COMPARTMENT WALLS AND CEILING INCLUDE 26 GAUGE GALVANIZED STEEL LINING AND SOUND INSULATION WHEN YOU MEASURE FOR THIS 1 INCH 2 RECOMMENDED CLEARANCE When the unit is installed on a suspended mounting system one of several different methods of supplying air flow may be used as follows Provide a door in the vehicle skirt having an air inlet open ing Figure 24 Figure 24 Suspended Mount Inlet Door i Using ductwork Figure 25 on Page 23 The installer must be sure air is available to the top of the generator since air inlets are located at the top By providing an opening in the vehicle skirt and space above the generator for cooling air flow Figure 26 on Page 23 Recommended clearance above the top of the gener ator is at least 2 inches ELIT Figure 25 Air Inlet Using Ductwork ANTI SPLASH BAFFLE GENERATOR RECOMMENDED CLEARANCE iz MINIMUM CLEARANCE VEHICLE FLOOR COMPENSATING FOR RESTRICTIONS Such materials as screening louvers or expanded metal can restrict the free flow of air Compensate for this restriction by making the actual air opening propor tionately larger Some materials may offer only a 60 percent free air inlet area Other more efficient mat
7. 3NVd 30014 3 Drawing No A9192 B ITEM 1 24 25 26 27 28 30 31 32 33 34 35 PART NO 91526 20093 A9180 36937 22158 74908 23484M AB592 49226 75476 51715 22985 23897 A9179 30809 87798 92113 A9611 32300 A6422 65795 22264 C2336 96874 A6060 43181 43182 89744 QTY 7 Qo Qo A REPAIR PARTS CONTROL PANEL DESCRIPTION M5 0 8 x 12MM PHILLIPS PAN HD MACH SCR BOX CONTROL TOP BOX CONTROL PANEL 10 32 x 1 PHILLIPS PAN HD MACH SCR 10 32 HEX NUT M5 8 x 10MM SNAP BUSHING CIRCUIT BREAKER 15A LOCK WASHER M5 M4 0 7 x 16MM M4 0 7 HEX NUT 4 FLAT WASHER M5 FLAT WASHER CONTROL PANEL FRONT RUBBER GROMMET SWITCH SPDT ROCKER SWITCH SPSTMOM ROCKER FUSE 7 5A AGC FUSE HOLDER EXTRUSION CONTROLLER RECTIFIER BATTERY CHARGE LOCK WASHER M4 PANEL DECAL DIODE DUAL 30A ASSEMBLY PCB CCG PHMS M3 05 x 10MM LOCK WASHER M3 RESISTOR POWER 1 OHM ITEM 36 37 38 41 45 46 47 48 49 50 51 52 53 57 58 59 60 61 62 64 65 66 69 70 47 PART NO A6423A 45756 86722 75210A A6423B 025 91297 A6470 91269A 23484D 82121A A9183 25105 84867 51718 01457 36933 A6423C 29333A 23762 A6187 A6429 A6430 A6464 A6516 A6700 51714 20769 QTY gt A gt A M
8. 5 Out of 14 INSTALLATION CHECK LIST 33 Return the Unit to Service after Storage 14 MAJOR FEATURES AND DIMENSIONS 34 35 Service Dealer Location a en 14 TROUBLESHOOTING 36 INSTALLATION SAFETY 5 15 NOTES sii 0100 37 Notice to Installer eri rrt n br Nele 15 u n UM 15 ELECTRICAL DATA 36 29 GENERAL STALL ATION REPAIR PARTS 40 to 51 Purpose and Scope of 16 EMISSIONS WARRANTS SA M d e D hal 16 WARRANTY enn back page Standards Booklets ettet 16 IDENTIFICATION RECORD Please record the foliowing information from the generator DATA DECAL or information decal 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage 5 Phase 6 Hertz IMPACT 36G plus FEATURES 6 IMPACT 36 plus 8 7 GASOLINE REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake Screen 8 Data Decal 2 Air Cleaner 9 12 Volt Battery Connection 3 Air Intake Tube 10 Engine Start Stop Switc
9. first Reconnect that cable last TABLE OF CONTENTS OPERATING INSTRUCTIONS Equipment Description nenn 16 GENERAL SAFETY RULES aa Engine Generator Operating Speed 16 IDENTIFICATION pus PORATION ANE SUPPOHI Generator Location nn 17 GENERATOR and INVERTER FEATURES 2 4 Generator Support 22 17 Suspended Mounting ee 17 READ THIS MANUAL THOROUGHLY Generator Restraint 18 Operation and 5 How to Obtain Service e apis doo 5 GENERATOR COMPARTMENTS Service Dealer Location Compartment Seams 18 Compartment Size ee eene 19 GENERATOR FAMILIARIZATION Compartment Construction 19 Generator Applicability anne 6 Sound Insulation
10. 7 76390 2 RETAINER PISTON PIN 8 83379A 1 ASSEMBLY CRANKSHAFT AND GEAR 10 89923 1 SEPARATOR OIL BREATHER 11 89213L 1 ASSEMBLY CRANKCASE 13 81695 2 SEAL OIL CRANKSHAFT 14 90604 1 BREATHER BAFFLE 17 78699B 3 SLEEVE DOWEL DIA 12 18 A9878 1 ASSEMBLY CAMSHAFT 19 89096 1 GASKET CRANK CASE FLANGE 21 A8822 1 GASKET CYLINDER HEAD 22 78691 1 RETAINER OIL PRESSURE SPRING 23 5772 1 SPRING OIL PRESSURE 24 A5776 1 BALL OIL PRESSURE 25 74908 1 M5 0 8 X 10 26 78606 4 SCREW 8 LOCK WASHER M6 1 x 12 LONG 28 89230 6 M8 1 25 x 35 LONG 30 A1720 2 RETAINER VALVE SPRING 31 88401 2 SPRING VALVE 32 88590 1 DOWEL PIN DIA 12 x 18 LONG 33 83152 1 GEROTOR INNER 34 76381 2 BOLT CONNECTING ROD 36 21705B 1 ASSEMBLY CYLINDER HEAD W GUIDES amp SEATS 37 90082 1 VALVE EXHAUST 38 90081 1 VALVE INTAKE 39 88396A 2 PUSH ROD 40 83235 2 TAPPET 42 96362 1 GASKET ROCKER COVER 43 77161 2 STUD BALL PIVOT 44 77160 2 ROCKER ARM 45 76307 2 NUT ROCKER ARM 46 88403 1 PLATE PUSH ROD GUIDE 47 77168 5 HEADBOLT M8 x 56MM 48 88413B 1 COVER ROCKER 49 78629 2 GASKET BREATHER 50 90388 2 TAPTITE M6 x 12 LONG 51 83153 1 GEROTOR OUTER 52 92977 1 ASSEMBLY SUMP OIL 53 84186 2 WASHER WEAR VALVE SPRING 54 88156 1 SEALVALVE INTAKE 58 72347 1 SPARKPLUG CHAMPION 59 99922 1 WASHER WAVE 45 TEMS 49 65 8 66 HARNESSES NOT SHOWN FOR CLARITY 2616
11. 84 85 86 87 88 90 91 94 96 97 99 100 101 102 103 104 105 106 107 108 109 110 41 PART NO 52618 005 91297 42907 22129 74906 39253 22511 22237 55822 22264 89050 82774 59637 86697 86704 86701 86702 38353 89263 90071 94637 90072 86708 87478 96627 90613 59635 002 91297 004 91297 59636 88905 92800 89062 23762 22447 23484P 23897 94090 86675A 71667 86714 52617 C2908 C1085 43182 C2334 97962 86726 56893 A9257 QTY e 4 m 0 DO mA c DESCRIPTION M5 0 8 X 12 MM CAPSCREW TEMP SWITCH WIRE HEX HD CAPSCR M8 1 25 x 15MM LOCK WASHER M8 M6 1 x 20MM TAPTITE HEX HD CAPSCR M8 1 25 x 20MM HEX HD CAPSCR 3 8 16 x 1 25 LOCK WASHER 3 8 PHMS M4 7 x 8MM LOCK WASHER M4 PHILLIPS PAN HD MACH SCR M6 1 x 90MM WOODRUFF KEY 4MM x 19MM TAPTITE 3 8 16 75 LONG ASSEMBLY IGNITION SENSOR SPACER ENGINE MOUNT BRACKET ENGINE MOUNT FRONT BRACKET ENGINE MOUNT REAR RUBBER MOUNTS ASSEMBLY OIL FILL CAP O RING 1 062 1 0 OIL FILL TUBE O RING 562 CARBURETOR SPACER GASKET OIL FILTER ADAPTOR BRACKET STARTER SIDE ENGINE MNT COVER BREATHER CANAL 8 x 37 LG PLASTITE SCREW STARTER WIRE TEMP SWITCH GROUND WIRE PLASTITE SCREW 4 x 37 EXTENSION SPRING WRAPPER ENGINE TOP HOSE BREATHER WASHER
12. DANGER If an LP propane gas fuel system has been installed it must have been properly tested for leaks before operating the system in compliance with ANSI A119 2 NFPA 501C No leakage is permit ted You must be sure no gaseous fuel vapors enter the vehicle interior INITIAL START When absolutely certain that the unit has been proper ly installed and prepared for use start the engine as follows 1 Turn off all electrical loads Do this by setting the generator main circuit breaker to its OFF or OPEN position 2 Refer to the Owner s Manual shipped with unit for cranking and starting instructions The engine may require more cranking for initial starting since the fuel lines have to be primed Use of the Primer Switch on gasoline units will shorten this time POST INSTALLATION TESTS 3 Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are completed apply electrical loads and check for proper operation under load See Testing Under Load Run the unit at least 30 minutes with loads applied 6 Turn off all electrical loads by setting the generator main circuit breaker to DFF or OPEN 7 18 the unit run at no load for a few minutes to stabilize internal engine genera
13. REMOTE PANEL CABLES Interconnection cables are available from Generac for connecting the optional remote panels to the generator REMOTE PANEL MODELS AR Model 9042 This remote panel Figure 37 mounts a To order a 10 foot long 4 wire cable specify Model 9045 rocker type start stop switch and a Generator Run e To order a 30 foot long 4 wire cable specify Model 9046 advisory lamp The lamp will turn on to indicate the engine is running Figure 37 Model 9042 Remote Panel GENERAC GENERATOR GEN RUN modu The air cooled Impact 36 plus generator set was facto ry tested and adjusted using gasoline as fuel The air cooled Impact 34 plus generator set was factory tested and adjusted using LP gas as fuel You should not be required to adjust the unit any further except under special circumstances WARNING Do not make any unnecessary adjust ments Factory settings are correct for most appli cations When making adjustments however be careful to avoid overspeeding the engine BEFORE INITIAL START UP Before starting complete the following 1 Check engine crankcase oil level and if necessary fill to dipstick FULL mark with the recommended oil Do not fill above FULL mark 2 Check the fuel supply Gas fuel lines must have been prop erly purged and leak tested in accordance with applicable fuel codes All fuel shutoff valves in the fuel supply lines must be open
14. such as 1 inch thick fiberglass with a 2 pound density Figure 20 Compartment Floor Cutout 460nnl 18 11 400 15 75 93 Sen 3 68 ip 558 412 16 ern MEGA 15 5m640 617 63mm 0 2507 4 HOLES FULL SIZE COMPARTMENT TEMPLATE DRAWING NUMBER A6203 43817 24 OPTIONAL AIR INLET OPENING TMENT v D IN OPEN AREA MUST BE PROVIDED INTO THE COMPART 0 63 FOR A FULL SIZE TEMPLATE CONTACT GENERAC RV SERVICE DEPARTMENT AT 1 800 526 2871 DRAWING PART NO A6203 469 18 46 93 524 3 68 Ku MOUNTING HOLES 4 REQUIRED COOLING AND VENTILATING AIR It is absolutely essential that an adequate flow of air for cooling ventilating and engine combustion be supplied to the generator set Without sufficient air flow the engine generator quickly overheats Such overheating can cause serious operating difficulties and may also cause fire and personal injury The installer must make sure that sufficient air is available to the generator for cooling ventilating and combustion The installer must also provide for a path for exhausting the cooling air to the exterior of a compartment if so equipped DANGER Never use discharged cooling air for heating or permit such air to enter the vehicle interi or This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases GENERATOR AIR FLOW Engine
15. 1 1 1 2 O R gt m m m m mm REPAIR PARTS GASOLINE GENERATOR DESCRIPTION ENGINE LONG BLOCK GN220 FLYWHEEL FAN WASHER CONICAL HEX NUT M16 1 5 FILTER OIL TUBE EXHAUST OUTLET GASKET EXHAUST SOCKET HD CAPSCR M8 1 25 x 20MM STARTER EATON GENERAC PLATE DIVIDER LOCK WASHER 1 4 M6 STEPPER MOTOR SPEED CONTROL ROD THROTTLE CONTROL CLIP ADJUSTMENT SNAP RETAINING WASHER CARBURETOR ASSEMBLY CARBURETOR GASKET CARBURETOR SPACER HEAD GASKET CARBURETOR SKIRT GASKET CARBURETOR INLET ADAPTOR ADAPTOR CARBURETOR INLET HOSE CLAMP BAND 20 HOSE CARBURETOR INLET ELBOW AIR CLEANER OUTLET HEX HD CAPSCR M5 8 x 16MM GASKET AIR CLEANER OUTLET BRACKET AIR CLEANER SUPPORT HOUSING FAN UPPER FAN GENERATOR ASSEMBLY MAGNET HOUSING TEMP SWITCH WIRE BASE AIR BOX ELEMENT AIR FILTER COVER AIR BOX BOLT AIR CLEANER COVER HEX HD CAPSCR M6 1 x 80MM LOCK WASHER M5 RETAINING RING STATOR ASSEMBLY STATOR ADAPTOR STATOR TAPTITE M5 0 8 x 10MM COVER CHOKE MOUNT SCREW 4 40 x 3 16 LOCK WASHER 4 FLAT WASHER 4 SOLENOID CHOKE PIN COTTER 3 32 x 1 2 ASSEMBLY BI METAL amp HEATER LINKAGE CHOKE CONTROL M6 1 x 10MM TAPTITE TAPTITE M8 1 25 x 15MM ITEM 55 56 57 58 59 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83
16. EXTERNAL SHAKEPROOF 10 WASHER INTERNAL SHAKEPROOF 25 SNAP BUSHING 10 5 FLAT WASHER SWITCH THERMAL OIL TEMP ADAPTOR OIL FILTER SWITCH OIL PRESSURE SCREEN OIL PICK UP DRAIN PLUG M12 1 75 x 20MM GASKET OIL DRAIN PLUG 0 5 x 8MM LOCK WASHER M3 AIR CLEANER DECAL SHCS M6 1 0 x 25 LG SKIRT BAFFLE CRIMPTITE 10 24 x 1 2 SHIM STARTER MON 4 1 42 Mm 43 1 9 ON Buimeiq YOLVYANAD d 02300163 Drawing No A6413 G ITEM c N 21 22 23 24 25 26 27 28 29 30 31 32 34 35 36 37 38 39 40 41 42 43 44 53 54 95 56 5 PART NO A2467 94583 83312 81810 70185 86730 89476 40976 99948 86705 22097 92059 86706 89477 89478 90192 2774 90051 78631 96459 86709 35586 86710 87993 49815 90536 90021 94665 93859 5892 003 91297 86673 78601 86674 78609 66449C 49226 80934 A6420 86692 74908 45756 83512 52618 005 91297 42907 M amma REPAIR PARTS LP GENERATOR DESCRIPTION ENGINE LONG BLOCK FLYWHEEL FAN WASHER CONICAL HEX NUT 16 1 5 FILTER OIL TUBE EXHAUST OUTLET GASKET EXHAUST SOCKET HD CAPSCR M8 1 25 x 20MM STARTER MOTOR PLATE DIVIDER LOCK WASHER 1 4 M6 STEPPER MOTOR SPEED CONTROL ROD THROTTLE CONTROL
17. SKIRT CARB BAFFLE COVER ROCKER COVER SKIRT SPARK PLUG SIDE PAN BELLY FRAME GROUND STRAP PLATE BASE COVER PUMP FUEL BARBED 90 1 8 x 1 4 HEX NUT 1 4 20 LOCK WASHER 1 4 M6 CONTACTOR STARTER BOOT CONTACTOR SEAL OIL FILTER HOLE RETAINER SEAL M8 FLAT WASHER 1 4 FUEL LINE 4 LONG 1 4 HOSE CLAMP SNAP BUSHING EXTERNAL SHAKEPROOF 8 HEX NUT 8 LOCK WASHER ITEM 42 44 45 47 48 49 50 51 53 54 57 59 60 61 62 63 64 65 67 68 69 70 7i 72 73 74 75 76 77 78 79 80 81 zu Ed PART NO QTY 79246 22447 103 74260 39450 92000 30340 82580D 86311 007 91297 89045 A3638 56893 A5767 A3764 66443B 20668 45711 38353 79119 7213 23897 9172 89047 86711 89049B 49721 49813 91526 51716 49226 64867 56892 A9196 2 nc coro N N 25 DESCRIPTION HEX HD CAPSCR M6 1 0 x 16MM W LOCK WASHER WASHER INTERNAL SHAKEPROOF 1 4 M6 GROUND STRAP UNIT 1 8 x 3 16 NPT 90 DEG BARBED FITTING BRACKET MUFFLER HANGER 1 4 FUEL LINE 8 LONG 3 16 CARBURETOR LINE 4 LONG FUEL FILTER STARTER CONTACTOR GROUND WIRE SEAL WASHER EXHAUST PIPE PANEL WRAPPER BOX CRIMPTITE 10 24 x 1 2 HEX HD CAPSCR 5 0 8 x 6MM CUSTOMER MOUNTING BRACKET VIBRATION MOUNT EARTHING STRAP HEX NUT MB VIBRATION MOUNT TAPTITE 1 4 20 x 1 1 4 TAG REMOVE BOLT FLAT WASHER 10 M5 BRACKET IGNITI
18. Using special sound insulating materials Construction of a special noise abatement compartment IMPORTANT ANY METHOD USED TO REDUCE NOISE MUST NOT ADVERSELY AFFECT THE FLOW OF COOLING AND VENTILATING AIR INTO OR OUT OF THE COMPARTMENT In addition to the effective use of sound insulating materials construction of a special noise abatement compartment might be considered to reduce noise lev els Such a compartment might be constructed as fol lows Figure 21 Use 5 8 inch thick or 3 4 inch thick plywood in the com partment Construct the compartment floor of a double thickness of 5 8 inch or 3 4 inch plywood Line the compartment interior walls and floor as well as the underside of the floor with 26 gauge galvanized steel Vapor seal all compartment seams and joints Over the galvanized steel lining install a selected combi nation of acoustical materials as mentioned in Sound Insulating Materials Figure 21 Typical Noise Abatement Compartment PLYWOOD EXTERIOR 5 9 OR 3 4 THICK SOUND IRSOLATION MATERIAL PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION DANGER Do not install any insulation or other A absorbent materials on the interior or underside of the compartment floor Seal all compartment door edges to prevent noise leakage around the door perimeter e Line the compartment door interior for air open ings with suitable fire proof sound insulation
19. VENTILATING AIR __ 1 Air flow is adequate ___2 Air inlet opening is correct 3 Compensate for restrictions 4 Installation has been tested 5 Inverter has adequate ventilation FUEL SYSTEM _ 1 Fuel tank complies with code ___2 Fuel system properly installed 22243 Fuel system checked for leaks DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER EXHAUST SYSTEM _ 1 Complies with code requirements _ 2 Properly and safely installed ELECTRICAL CONNECTIONS _ 1 Comply with code requirements ___ 2 Inverter properly installed ___3 Wiring meets all standards _ 4 All connections are correct ___ 5 Conduit properly installed and sealed ___6 Generator properly bonded to vehicle BATTERY INSTALLATION _ 1 Recommended battery is installed _ 2 Recommended cables are installed _ 3 Cables are clean and tight _ 4 Cables are properly connected _ 5 Proper ventilation is provided POST INSTALLATION TESTS ___1 All tests properly completed OPTIONS AND ACCESSORIES Check that remote start stop panels if used are prop installed If an hourmeter kit is installed check that job was done properly If any other options and accessories are installed check that they were installed properly 258 10 27 M8 MOUNTING FASTENERS m d 4 TOTAL REQUIRED 2511 01 38 1 57 4 i 281 11 1 421 16 67 118 4 71 4 1 1310 51 MINIMUM DISTANCE INSIDE
20. amp hours and capable of delivering 450 cold cranking amperes IMPORTANT IF THE BATTERY IS TO BE USED TO POWER OTHER VEHICLE ACCESSORIES AS WELL AS START THE GENERATOR YOU MAY NEED A BATTERY WITH A LARGER CAPACITY BATTERY CABLES Using battery cables that are too long or too small in diameter may cause a drop in voltage which causes starting problems For best cold weather starting the voltage drop between battery terminals and the gener ator connection point should not exceed 0 12 volts per 100 amperes of cranking current Select battery cables based on a cable length and b prevailing ambient temperatures Generally the longer the cable and the colder the weather the larger the cable size must be as shown in the chart below CABLE SIZE 16 to 20 4 5 to 6 For warm weather use No 2 cable up to 20 feet BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or 4 to the large lug on the starter contactor as indicated in Figure 35 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connec tion Figure 35 NOTE If the generator compartment is grounded to the vehicle chassis you need not connect a NEGA TIVE battery cable to the frame ground on the genera tor base Connect the negative cable to the frame ground of the chassis 3 Connect cables so the connections are clean and tigh
21. down by itself and the fuel tank has enough fuel check the engine oil level INITIAL STARTUP During initial startup a time delay built into the shut down control system allows oil pressure to build The delay allows the engine to run for about 10 seconds before sensing oil pressure SENSING LOW PRESSURE If the system senses low oil pressure during opera tion the engine shuts down If you do restart the engine after a low oil pressure shutdown and have not corrected the low oil level the engine runs for about 10 seconds as described above then stops HIGH TEMPERATURE SHUTDOWN A temperature switch with normally open N O con tacts is mounted near the oil filter If engine tempera ture were to exceed a preset temperature the switch contacts close and the engine shuts down OVERSPEED If engine speed is increased manually or otherwise beyond the control of the computer control system the computer disables the load capability of the gen erator and shuts down the engine WARNING Do not attempt to physically adjust or control the engine speed Equipment damage or personal injury may result LOW VOLTAGE The computer monitors the voltage output of the gener ator If voltage sensors indicate that voltage has dropped below a preset level the engine will automati cally shut down Once the unit has shutdown the com puter is automatically reset when you restart the engine NOTE The computer allows for the
22. engine is found to be defective in materials or workmanship repairs or replacement will be performed by a Generac Authorized Warranty Service Facility PURCHASER S OWNER S WARRANTY RESPONSIBILITIES As the engine purchaser owner you are responsible for the completion of all required maintenance as listed in your factory supplied Owner s Manual For warranty purposes Generac recommends that you retain all receipts covering maintenance on your engine However Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the completion of all scheduled maintenance As the engine purchaser owner you should however be aware that Generac may deny any and or all warranty coverage responsibility if your engine or a part component thereof has failed due to abuse neglect improper maintenance or unap proved modifications or the use of counterfeit and or grey market parts not made supplied or approved by Generac You are responsible for presenting your engine to a Generac Authorized Warranty Service Facility as soon as a problem occurs 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 your selling dealer or a Generac Authorized Warranty Service Facility To locate the Generac Authorized Warranty Service Facility nearest you call our toll free number 1 800 333 1322 IMPORTANT NOTE This warranty
23. for installing such products or similar products that Generac manufactures Generac also assumes that ersonnel have been trained in the recommended installation procedures for these products and that such training includes a use of common hand tools b use of special Generac tools and c use of any tools and or equipment from other suppliers We could not possibly know of and advise the recre ational vehicle trade of all conceivable methods proce dures or techniques by which to perform an installa tion We could not know of the possible hazards that might result from each installation method procedure or technique We have not undertaken any such wide evaluation Therefore people who use a method pro cedure or technique that Generac does not specifically recommend must first completely satisfy themselves that their safety the safety of the vehicle s occupants and the product s is not endangered by the method procedure or technique selected Information illustrations specifications etc contained in this Installation Manual are based on the latest infor mation available at the time of publication Every effort has been expended to be sure that such data is both accurate and current However the manufacturer reserves the right to change alter or otherwise improve this product at any time without prior notice SAFETY RULES Gasoline is extremely FLAMMABLE and its vapors are EXPLOSIVE Do not permit smoking ope
24. for fuel leaks and other abnormalities FUEL CONSUMPTION IN GALLONS PER HOUR GASOLINE FUEL REQUIREMENTS LP UNITS These generators are equipped with a liquefied petro leum LP gas fuel system LP gas is usually supplied as a liquid in pressure tanks These generators require a vapor withdrawal type fuel system This type of gaseous fuel system uses the vapors forming above the liquid fuel in the storage tank Air temperature around the storage tank must be high enough to sustain adequate fuel vaporization in colder climates you may need to use an indepen dent heat source to be sure the fuel sufficiently vapor izes in the storage tank LP gas may consist of propane butane or a mixture of the two gases Propane vaporizes at temperatures as low as 20 F 29 but butane returns to its liq uid state when the temperature drops below about 32 F 0 For that reason a higher ratio of propane is desired in the gas mixture when temperatures drop below freezing ENGINE OIL REQUIREMENTS The recommended oils include the following During summer months SAE 30 An acceptable substi tute is SAE 10W 30 During winter months SAE 5W30 DO NOT USE SAE 10W 40 Crankcase and oil filter capacity is about 950ml or one 1 quart Use no special additives See Maintenance section for oil level check and fill pro cedures GAS GENERATOR SPECIFICATIONS 1 1606 ea Impact 36G plus Rated Maximum Conti
25. of the inverter must be handled by an authorized service dealer see Page 12 in Maintenance You can use this generator to supply electrical power for operating 120 volts single phase 60 Hertz elec trical loads These loads can require up to 3400 watts 3 4 kW for the Impact 34 plus or 3600 watts 3 6 kW for the Impact 36 plus The maximum current at 120 volts is 28 3 amperes for the Impact 34 plus or 30 amperes for the Impact 36 plus CAUTION Do not overload the generator Some installations may require that electrical loads be alternated to avoid overloading Applying exces sively high electrical loads may damage the gener ator and may shorten its life Add up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one time This total should not be greater than the wattage capacity of the generator If an electrical device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts Some electric motors require more watts of power or amps of current for starting than for continuous operation SAFETY Before using the generator set carefully read GEN ERAL SAFETY RULES inside the cover Comply with these RULES to prevent accidents and damage to equipment and or property Generac suggests copy ing and posting the GENERAL SAFETY RULES in potential hazard areas of the recreationa vehicle Safety should be stressed to all operators
26. of this equipment GENERATOR CONTROL PANEL Mounted on the generator control panel Figure 1 are the following features Figure 1 Typical Control Panel CIRCUIT BREAKER FUEL PRIMER Before starting a cold engine if it has not been start ed in more than two weeks you must press this switch to bring fuel from the tank to the fuel carbure tor This rocker type switch springs back into its origi nal position when you release it START STOP SWITCH To crank and start the engine hold this switch at its START position Release the switch when the engine starts To stop an operating engine press and hold the switch in its STOP position until the engine shuts off The switch center position is the RUN position FUSE Protects the engine DC control circuit against electrical overload If the fuse element has melted open due to overloading the engine cannot be cranked you must replace it use only an identical replacement fuse CIRCUIT BREAKERS Protects generator s AC output circuit against over load i e prevents unit from exceeding wattage amperage capacity E HOUR METER Indicates the time the engine generator has operated in hours and tenths of hours Use the hourmeter along with the periodic maintenance schedule for your generator set AUTOMATIC CHOKE GASOLINE ONLY The engine is equipped with an automatic choke not shown that consists of two main components choke solenoi
27. operation drives cooling fans for the 2 stage cooling air system A pressure fan draws cooling air into the top of generator and into the side of the control panel Figure 22 This air flow cools the engine gener ator and electronic components The second part of cooling system a suction fan draws air that is heated from a hot engine into a collector pan at the base of the unit This heated air although cooler than exhaust muffler is directed across the muffler to cool it The heated air flow is then deflected out the bottom toward the ground Figure 22 Air Flow Through Engine Generator COOLING AIR INLET OPENINGS Ideally you should provide three air inlet openings whether the generator is housed in a conventional compartment or not Two of the openings should be 10 square inches and located as shown in Figure 23 The third opening should provide for a minimum of 40 square inches unrestricted and be located lower on the compartment door NOTE Screening louvers or expanded metal that cover air openings restrict air flow that you must com pensate for by making the actual air opening propor tionately larger See Compensating for Restrictions For conventional compartment mounted units the air inlet is generally provided in the compartment door Figure 23 Air Inlet in Compartment Door ARE INCHES NAL OPENINGS 40 SQUARE INCHES SER MINIMUM OPENING
28. strongly rec ommend that the operator read this Owner s Manual and thoroughly understand all instructions before using this equipment We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them if they need to operate the equipment in an emergency OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safety checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked by an Authorized Dealer periodi cally Normal maintenance service and replacement of parts are the responsibility of the Owner Operator and as such are not considered defects in materials or workmanship within the terms of the warranty Individual operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your generator assures a minimum number of problems and keeps your operating expenses at a minimum See your authorized Dealer Distributor for service aids and accessories HOW TO OBTAIN SERVICE When your RV generator set requires servicing or repairs simply contact an Authorized Service Facility for assistance Service technicians are factory trained and are capable of handling all of your service needs When contacting an Authorized Service Facility or the factory about parts and service always supply the complete model number and serial number of your un
29. 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 exclusion or limitation of incidental or consequential damages so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For service see your nearest GENERAC authorized warranty service facility or call 1 800 526 2871 Warranty service can be performed only by a GENERAC authorized service facility This warranty will not apply to service at any other facility At the time of requesting warranty ser vice evidence of original purchase date must be presented Generac Power Systems Inc Box 8 Waukesha WI 53187
30. 17 Figure 17 Types of Lock Seams FOLD LOCKED STANDING DOUBLE LOCK OFF SET DOUBLE SEAM oS GORDON SEAM LOCK SEAM STANDARD LAP JOINT COMPARTMENT SIZE Plan the compartment size carefully Provide a mini mum of at least 1 inch 2 recommended of clearance between the generator and compartment walls and 1 inch 2 recommended of clearance between the generator and the ceiling AFTER you have lined the compart ment with metal and AFTER you have installed sound insulation Figure 18 NOTE Refer to the Major Features and Dimensions drawing in the back of this manual Figure 18 Provide Clearance Around Generator 1 INCH MINIMUM CLEARANCE COMPARTMENT ON ALL SIDES 2 RECOMMENDED ii 1 INCH MINIMUM CLEARANCE ABOVE GENERATOR 2 RECOMMEND ED SIC YGD DS OSU TOP VIEW OF GENERATOR INSULATION COMPARTMENT CONSTRUCTION The generator compartment should be constructed of 1 2 inch thick plywood Make the compartment floor a double thickness of 1 2 inch plywood with the grain of the wood at cross section for added strength Figure 19 Figure 19 Typical Compartment Construction X FLAME PROOF SOUND ISNULATION N M METAL LINING nn gt VAPOR SEALED AT ALL TIMES A 2 METAL LINING Line the entire compartment interior with 26 gauge galva nized stee
31. 83 BRI 4 BRI J Z 18 E CBI CIR Py a3 85 CC CHO Je 17 WHITE CH CHU Eh R Fl FUS FUE J4 56 ia sc GRN St M i HTO SWI CCL BLU RED I 120 IC IGN CUSTOMER AC 29302 ELECTRICAL DATA Drawing No A6412 B Sheet 2 of 2 REMOTE PANEL 13 CONNEC TOR i EES BATTERY i 0 Rx 18 15 13 cd GD inl B Fi Cm l D ET as 14 4 64 0 0 e GENERATOR CONTRO RED RE D K 14 56 BLU RI IS RE WEEK ET 5 DJ RED B 85 15 f 18 4 RED 55 BRE BLK 55 BLK 14 BLK 15 RED i RIN WHT R RED Fame 4 ERN 3 a SENSE ORG p SHIELD SHLD i R Lr RED HER DC DC BUS RED AIN III H i BLUE OE AK 2 Bir as EARTH LET BE GRN Eh Ea S TRIN pnus CONTROL BOE Ji BL Ps2 55 PSI NEUTRAL CONNECTION BY CUSTOMER CUSTOER AC CDMNECTION LEGEND BCR BATTERY CHARGE RECTIFIER IND INDUCTOR ASSEMBLY BRI BRIDGE RECTIFIER IM IGNITION MODULE BR2 BRIDGE RECTIFIER IS IGNITION SE
32. AFETY Maintain a clearance of at least 3 inches 76mm between exhaust system parts and any combustible material such as wood felt cotton organic fibers or other like material If you cannot maintain the 3 inch clearance locate insu late or shield the exhaust part s so that the temperature of any combustible material is not raised more than 117 F 65 above the ambient air temperature Extend the exhaust system at least one inch 25mm past the outer edge of the vehicle Do not terminate the exhaust system under the vehicle Terminate the exhaust tailpipe such that exhaust gases will not be drawn back into the generator compartment and recirculated If there is any possibility of the tailpipe or muffler being damaged protect these damage prone areas by means of a protective device such as a skid bar Install the generator exhaust system according to safe automotive practices Use enough exhaust system hangers to prevent any part of the system from being dislocated Use exhaust system parts recommended by Generac Using unapproved exhaust mufflers and exhaust system parts is the responsibility of the person s installing such unauthorized parts Do not terminate the exhaust system under any opening window or vent which can be opened or is not permanently sealed from the vehicle interior Exhaust piping must be large enough to prevent excessive back pressure on the generator engine Never tee the generator e
33. CKET LP nts 2 CAPSCR HEX HD 1 4 20 x 1 2 1 LP HOOK UP FITTING 2 CUSTOMER MOUNTING BRACKET 4 VIBRATION MOUNT 2 EARTHING STRAP 8 HEX NUT M8 3 VIBRATION MOUNT 1 CRIMPTITE 10 24 x 3 8 1 1 4 20 TAPTITE 1 1 4 1 BOLT REMOVAL 1 BRACKET IGNITION SYSTEM 2 SPACER IGNITION COIL 1 MODULE IGNITION 1 ASSEMBLY IGNITION COIL 2 6 1 0 35MM HEX HD CAPSCREW 4 6 1 0 HEX NUT 2 M5 0 8 x 12MM PHILLIPS PAN HD MACH SCR 2 5 0 8 HEX NUT 5 LOCK WASHER M5 2 5 RUBBER U CHANNEL 1 10 24 x 3 8 1 WIRE ASSEMBLY BLOCKING DIODE 1 COVER IGNITION BRACKET 8 4 7 onou Na 30 Dalali 616 Buiweig 1 1 L33HS 3NION3 31 110595 8318030071473 REPAIR PARTS GASOLINE ENGINE SHEET METAL Drawing No A9194 C PART QTY ITEM 1 86705 49813 86718 A3666 74908 A3667 22129 39414 50830 89680 94670 89471 86731A 86715 86726 86671 86727 86719 C3296 90141A 86724 90475 28740 22127 22097 86729 90518 89048 90537 22145 30340 48031C 23484D 23762 22471 22264 1 2 3 5 DESCRIPTION PLATE DIVIDER M6 1 0 HEX NUT SEAL RUBBER EXTRUSION WRAPPER BOX TAPTITE M5 8 x 10MM LONG MOUNTING RAILS M8 LOCK WASHER M8 1 25 x 35MM HEX HD CAPSCR HHCS M5 0 8 x 40MM SPARK ARRESTOR U BOLT W SADDLE amp NUTS DEFLECTOR AIR OUT ASSEMBLY MUFFLER HOUSING LOWER FAN
34. CLIP ADJUSTMENT SNAP RETAINING WASHER CARBURETOR CARBURETOR ASSEMBLY GASKET CARBURETOR SPACER HEAD GASKET CARBURETOR SKIRT GASKET CARBURETOR INLET ADAPTOR ADAPTOR CARBURETOR INLET HOSE CLAMP BAND 20 HOSE CARBURETOR INLET ELBOW AIR CLEANER OUTLET HEX HD CAPSCR M5 8 x 16MM GASKET AIR CLEANER OUTLET BRACKET AIR CLEANER SUPPORT HOUSING FAN UPPER FAN GENERATOR ASSEMBLY MAGNET HOUSING TEMP SWITCH WIRE BASE AIR BOX ELEMENT AIR FILTER COVER AIR BOX BOLT AIR CLEANER COVER HEX HD CAPSCR M6 1 x 80MM LOCK WASHER M5 RETAINING RING STATOR ASSEMBLY STATOR ADAPTOR STATOR TAPTITE M5 0 8 x 10MM M6 1 x 10MM TAPTITE TAPTITE M8 1 25 x 15MM HEX HD CAPSCR M5 0 8 x 12MM OlL PRESSURE SWITCH WIRE HEX HD CAPSCR M8 1 25 x 16MM ITEM 58 59 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 91 96 97 99 100 101 102 103 104 105 106 107 108 109 110 Lo TON PART NO 22129 74906 39253 22511 22237 55822 22264 89050 82774 59637 86697 86704 86701 86702 38353 89263 90071 94637 90072 86708 87478 96627 90613 59635 002 91297 004 91297 59636 88905 92800 89062 22447 23897 94090 86675 77667 86714 52617 C2908 C1085 43182 C2333A 97962 86726 56893 A9257 QTY 10 2 R m 3 KH m O
35. ENCLOSURE 555 21 8 L P UNITS MINIMUM DISTANCE INSIDE ENCLOSURE 508 20 0 GAS UNITS 802 19 8 403 5 91 387 15 24 33131 1 2 2 4 60 4 400 15 71 438 17 27 21 25 1 07 GASUNTS 7 25 1 0 77 Pec 27 06 OD EXHAUST OUTLET UP REGULATOR u 399 15 7 18272 SNOISNAWIQ 514 1 31 HOP VIN 305 12 0 27500 8 137 55 4 150 6 TYP e i 9 pe 145 4 5 7 127 3 5 0 o L 9 044 0 4 IV MOUNTING HOLE DETAIL nn 20581 ALLOW APPROXIMATELY 8 FOR AIRFLOW ON BOTH ENDS OF INVERTER NOTE DIMENSIONS IN MM INCHES O b ea OG GANNILNOD SNOISNAWIG 5232011933 HOPVIN TROUBLESHOOTING POSSIBLE CAUSES REMEDY PROBLEM Engine won t crank Engine cranks but won t start low full load power Engine starts hard runs rough Engine starts shuts down when Start S
36. H VOLTAGE UNIT TO BE SERVICED ONLY BY AN AUTHORIZED GENERAC SERVICE DEALER ALLOW 2 MINUTES FOR UNIT TO POWER DOWN BEFORE OPENING TO REDUCE RISK OF INJURY OR ELECTROCUTION CLEANING THE GENERATOR Keep your generator set as clean and dry as possible Dirt and moisture that are permitted to accumulate on electrical windings have an adverse affect on the insulation resistance of those windings Moisture that is allowed to remain in contact with wind ings will be retained in voids and cracks of the wind ings Dirt makes the problem worse since it tends to hold the moisture into contact with the windings Salt as from sea air worsens the problem since it tends to absorb moisture from the air The combination of salt and moisture makes a good electrical conductor CAUTION Do NOT use a forceful spray of water to A clean the generator Water will enter the generator interior and cause problems and may also conta minate the generator fuel system sze BATTERY All lead acid storage batteries will discharge when not in use Inspect the generator battery as follows ONCE WEEKLY Inspect battery posts and cables for tightness corro sion Clean and or tighten as necessary Also check battery fluid level and if necessary fill with DISTILLED WATER ONLY DO NOT USE TAP WATER IN BATTERY EVERY SIX MONTHS Have the battery state of charge and condition checked by an automotive service facili
37. L RUBBER EXTRUSION BOX WRAPPER TAPTITE M5 8 x 10MM MOUNTING RAILS M8 LOCK WASHER M8 1 25 x 35MM HEX HD CAPSCR HHCS 5 0 8 x 40MM WRAPPER END PANEL SPARK ARRESTER DEFLECTOR AIR OUT ASSEMBLY MUFFLER HOUSING LOWER FAN SKIRT CARB BAFFLE COVER ROCKER COVER SKIRT SPARK PLUG SIDE PAN BELLY FRAME GROUND STRAP PLATE BASE COVER BARBED 90 DEG 3 8 x 3 8 FITTING HEX NUT 1 4 20 LOCK WASHER 1 4 M6 CONTACTOR STARTER BOOT CONTACTOR SEAL OIL FILTER HOLE RETAINER SEAL FLAT WASHER M8 REGULATOR HOSE CLAMP 5 5 SNAP BUSHING EXTERNAL SHAKEPROOF 10 8 32 NUT 8 LOCK WASHER HD CAPS M6 1 0 x 16MM W L WASHER FLAT WASHER 10 5 WASHER INTERNAL SHAKEPROOF 1 47 6 45 47 48 49 50 51 53 54 55 57 58 59 60 61 62 63 64 65 66 67 68 70 71 72 73 74 75 76 77 78 79 80 81 82 49 PARTNO QTY DESCRIPTION 103 74260 47290 92000 25425 26490 94670 007 91297 89045 A2666 22145 A4603 22507 A5606 A3764 66443B 20668 45771 38353 56892 79119 A7213 A9172 89047 86711 89049B 49721 49813 91526 51716 49226 84867 56892 A9031 A9196 1 GROUND STRAP UNIT 1 HOSE 3 8 1 0 x 11 1 2 LONG 1 BRACKET MUFFLER HANGER 2 STREET ELBOW 45 DEG 3 4 NPT 1 PIPE NIPPLE 3 4 x 2 2 UBOLTW SADDLE amp 2 NUTS 1 STARTER CONTACTOR GROUND WIRE 1 SEAL WASHER EXHAUST PIPE 1 FUEL SOLENOID 12V DC 2 5 16 FLAT WASHER 1 BRA
38. LECTRICAL CONNECTIONS Change Oll Filter eius 11 WINO ces 27 Engine Air Cleaner 11 12 Generator AC Connection 27 Clean Air Intake Screen 12 Isolating Different Power 27 Engine Spark PwIU0 u u u eei er 12 Power Supply 1 01 202000 000000000022 27 Fuel acr eee wi AAS 12 Ground Fault Circuit Interrupters 28 ACC tama 12 Sensing 2 2 220 28 Cleaning the 12 Transfer Switch Isolation 29 Battery ui ER RR ewan AO 13 Installation with Isolation Receptacle 29 Service and Adjustments 13 Adjusting the CarbUretor Mena 13 BATTER INS TACCA ee 30 Adjusting Valve 13 OPTIONAL 31 d 1 O eels val 0 POST INSTALLATION 78575 32 xercising the Generator 222
39. NSOR ENGINE GENERATOR BR3 BRIDGE RECTIFIER Li gt LIGHT RUN OPTIONAL BR4 BRIDGE RECTIFIER LOP SWITCH LOW DIL PRESSURE CIRCUIT BREAKER 10 2 POLE CLOSES ON LOW PRESSURE C CHOKE COIL M STEPPER MOTOR THROTTLE CONTROL CH CHOKE HEATER PCBi CONTROL CIRCUIT BOARD Fi FUSE 81 1 50 5 FP FUEL PUMP ON GASOLINE SC STARTER CONTACTOR SHUT DFF VALVE L P M STARTER MOTOR INY INVERTER BOX 1 SWITCH START STOP HM HOUR METER SW2 SWITCH FUEL PUMP PRIME SWITCH HIGH TEMPERATURE DIL SPARK PLUG CLOSES ON HIGH TEMPERATURE LUG BARREL IGNITION COIL TC TERMINAL CONNECTOR 4 TAB TB TERMINAL BLOCK 3 7 Ly9v Suimeiq YOLVYANAD 3NIIOSVO 02300113 Drawing No A6414 E ITEM SOO gt WP m m m OO gt 21 22 23 24 25 26 27 28 29 30 31 32 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 PART NO A2467 94583 83312 81810 70185 86730 89476 40976 99948 86705 22097 92059 86706 89477 89478 90192 90881A 90051 78631 96459 86709 35586 86710 87993 49815 90536 90021 94665 93859 A5892 003 91297 86673 78601 86674 78609 66449C 49226 80934 A6420 86692 74908 86735 47488 22159 31879 91306 36544 89473 86736 45756 83512 QTY 1 1 2 2 1 1 1 4 1 1 8 1 1 1
40. ON SYSTEM SPACER IGNITION COIL MODULE IGNITION ASSEMBLY IGNITION COIL M6 1 0 x 35MM HEX HD CAPSCREW M6 1 0 HEX NUT M5 0 8 x 12MM PPHMS M5 0 8 HEX NUT LOCK WASHER M5 RUBBER U CHANNEL CRIMPTITE 10 24 x 3 8 COVER IGNITION SYSTEM CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board CARB and the United States Environmental Protection Agency EPA together with Generac Power Systems Inc Generac are pleased to explain the Emission Control System Warranty on your new engine New utility and lawn and garden equipment engines must be designed built and equipped to meet stringent anti smog standards for the state of California and the federal government Generac will warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect unapproved modification or improp er maintenance of your engine Your emission control system may include parts such as the carburetor ignition and exhaust systems Generac will repair your engine at no cost to you for diagnosis replacement parts and labor should a warrantable condition occur MANUFACTURER S EMISSION CONTROL SYSTEM WARRANTY COVERAGE Emissions control systems on 1997 and later model year engines are warranted for two years as hereinafter noted If during such warranty period any emission related component or system on your
41. OWNER S MANUAL and Installation Instructions IMPACT 36 plus with Inverter AIR COOLED RECREATIONAL VEHICLE GENERATORS Model Nos 00940 1 00941 1 GENERAC POWER SYSTEMS INC GENERAL SAFETY RULES SAFETY SHOULD BE STRESSED TO ALL OPERATORS AND POTENTIAL OPERATORS OF THE MANUFACTURER SUGGESTS THAT THESE RULES FOR SAFE OPERATION BE COPIED AND POSTED IN POTENTIAL HAZARD AREAS OF THE RECREATIONAL VEHICLE THIS EQUIPMENT Study these SAFETY RULES carefully before operat ing or servicing applicable equipment Become familiar with this Owner s Manual and with your generator Safe efficient and reliable operation can only be achieved if generator is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions The manufacturer suggests that these GENERAL SAFETY RULES be copied and posted in potential hazard areas of the recreational vehicle Safety should be stressed to all operators and potential operators of equipment The manufacturer cannot possibly anticipate every cir cumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If you use a proce dure work method or operating technique Generac does not specifically recommend you must satisfy yourself that it is safe for you and others You must also make sure the procedure work method or operat ing techni
42. PARTMENT GENERAC POWER SYSTEMS INC P O BOX 8 WAUKESHA WI 53187 Part 1 52 EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1997 and later model year engines Applicability This warranty shall apply to 1997 and later modei year engines The ECS Warranty Period shall begin on the date the new engine or equipment is purchased by delivered to its original end use purchaser owner and shall continue for 24 consecutive months thereafter b General Emissions Warranty Coverage Generac warrants to the original end use Ml A of the new engine or equipment and to each subsequent purchaser owner that each of its engines is 1 Designed built and equipped so as to conform with all applicable Fel OR adopted by the EPA and CARB pursuant to their respective authority and 2 Free from defects in materials and workmanship which at any time during the ECS Warranty Period may cause a war ranted emissions related part to fail to be identical in all material respects to the part as described in the engine manu facturer 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 that 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 re
43. TLY TO GAS TANK PRESSURE DO NOT TEE THE GENERATOR LINE INTO A GAS CIRCUIT FEEDING OTHER APPLIANCES GASEOUS CARBURETION LP gas vapors should be supplied to the generator regulator inlet at about 11 inches water column posi tive pressure The engine piston draws air in during the intake stroke Figure 29 This air passes through a carburetor venturi which creates a low pressure that is proportional to the quantity of air being pumped The low pressure from the carburetor venturi acts on the regulator diaphragm to pull the diaphragm toward the source of low pressure A lever attached to the diaphragm opens a valve to permit gas flow through the carburetor The greater the air flow through the carburetor venturi the lower the pressure at the venturi throat the greater the diaphragm movement and the greater the move ment of the regulator valve The more the regulator valve opens the greater the gas flow that is propor tional to air flow through the carburetor The following facts about the secondary regulator must be emphasized The regulator must be sensitive to venturi throat pressure changes throughout the operating range The regulator must be properly adjusted so it will stop the flow of gas when the engine is not running no air flow through the carburetor The slightest air flow and vacuum in the venturi throat should move the regulator valve off its seat and permit gas to flow FUEL SUPPLY LINES Propane ga
44. an or replace as needed Clean regap or replace plug Check oil add as needed Check adequate ventilation Have serviced replaced Have board serviced replaced Have board serviced replaced Replace switch Reconnect or close wire Reconnect or close wire Replace board Reset to ON or CLOSED Reset and replace if necessary Set to GENERATOR position Take generator to an Authorized Generac facility Take generator to an Authorized Generac facility NOTES sue 37 ELECTRICAL DATA Drawing No A6412 B Sheet 1 of 2 CUSTOMER SUPPLIED BATTERY i SC 13 1 16 SM swe 144 REMOTE 15 PANEL 20 CONNECTOR cc o 1 1 e e 14 CH 3 3 4 4 15 14 12 ug 2 90 14 mx x om gt 0 UEM IC R1 SP BCR 99 66 77 66 BATTERY CHARGE WINDING 77 0 55 18 SLE A AA POWER WINDING AC TIMING POWER SUPPLY TIM2 TIMI A AC 17 85 JI 1 1 REMDTE PANEL OPTIONAL 1 E ri MM m DEN JE SHIELD I J3 Js SENSE gt 8 3 6 TEMP gt 6 a 3 FAN 7 2 KN 30 bine 3 FEET T BCR BAT 2 RTN 2 HH 881 BRI 1 L 1 882 BRI 8
45. and e primary regulator used to store the gaseous 25 and deliver it to the gaseous fuel solenoid Figure 28 DANGER Use only approved components in the gas supply system All components must be properly installed in accordance with applicable codes Improper installation or use of unauthorized components may result in fire or an explosion Follow approved methods to test the system for leaks No leakage is permitted Do not allow fuel vapors to enter the vehicle interior SOME IMPORTANT CONSIDERATIONS When installing an LP gas system consider seriously the following items All fittings lines hoses and clamps must be tight and free of leaks Apply a pipe sealant to threads when assembling threaded connections This reduces the possibility of leak age Test the entire fuel system for leaks using approved test methods Optimum gas pressure at the inlet to the gaseous fuel solenoid valve and secondary regulator is 11 inches water column The installer s fuel supply connection point is at the gaseous fuel solenoid valve This is a 3 4 inch female connection Provide a suitable 3 4 inch NPT male con nector to attach to the fuel supply line Use a length of approved flexible fuel hose between gaseous fuel solenoid valve and rigid gas piping The flex ible line should be at least six 6 inches longer than nec essary VAPOR WITHDRAWAL Liquid propane LP gas is stored in pressure tanks as a liquid The gas syst
46. d and prechoke OPERATING INSTRUCTIONS During engine cranking start stop switch at START a solid state control circuit board signals the choke solenoid to actuate and cycle choke on choke off until engine starts The choke solenoid thus opens and closes the carburetor choke valve only when the engine is cranking When the engine starts the choke cycling stops PRECHOKE GASOLINE ONLY The choke system also has a temperature sensitive metal strip that adjusts the choke valve angle accord ing to ambient temperatures i e in cold ambient temperatures the choke valve closes more Once the engine starts an element heats the temperature sensitive strip to a normal operating condition open ing the choke valve This may take about 3 minutes in cooler weather BEFORE STARTING THE ENGINE IMPORTANT INSTRUCTIONS AND INFORMATION IN THIS MANUAL ASSUME THE GENERATOR HAS BEEN PROPERLY INSTALLED CONNECTED SERVICED TESTED AND ADJUSTED BY A QUALI FIED INSTALLATION TECHNICIAN OR INSTALLA TION CONTRACTOR INSTALLATION Generator installation must have been properly com pleted so it complies with all applicable codes stan dards and regulations and with the manufacturer s recommendations ENGINE LUBRICATION Have engine crankcase properly serviced with recom mended oil before starting Refer to Maintenance and Specifications sections for oil servicing proce dures and recommendations CAUTION Any attempt
47. d registration identification and must be presented at time of requesting Warranty service Claims will not be accepted without presentation of this Registration Card THREE YEAR WARRANTY SCHEDULE All generators used in a recreational vehicles shall be warranted for a period of three 8 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 The drive belt and pulleys if so equipped on air cooled generator used in recreational vehicles shall be warranted against failure due to defective materials or normal usage for the life of the generator For the original owner this drive belt and pulley warranty shall include parts and labor plus 50 00 payment upon return of the failed belt or pulley by the original owner For succeeding owners this drive belt warranty shall cover belt or pulley parts only 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 fi
48. d surface If the filter is too dirty replace it with a new one Dispose of the old filter properly Clean air cleaner cover then insert new paper filter into cover and assemble to the base of the air cleaner CLEAN AIR INTAKE SCREEN Clean all foreign material from the air intake screen Figure 5 at lease once every 100 hours of operation Clean more often if necessary Inspect the area around the generator exhaust muffler periodically and remove all grass leaves dirt etc from this area Figure 5 Clean Air Intake Screen AIR INTAKE SCREEN ENGINE SPARK PLUG Clean engine spark plug and set gap to 0 030 inch 0 76mm every 100 hours of operation Figure 6 Clean by scraping or wire brushing and washing with commercial solvent DO NOT BLAST CLEAN SPARK PLUG Figure 6 Setting Gap on Spark Plug SET PLUG GAP AT 0 030 inch 0 76 mm G SEX CAUTION Sparking can occur if wire terminal does not fit firmly over spark plug terminal end necessary reform wire terminal to obtain a tight fit FUEL FILTER Remove and replace fuel filter Figure 7 every 100 hours of operation or once each year whichever occurs first Figure 7 Fuel Filter TO FUEL PUMP Mg CUSTOMER FUEL CONNECTION INVERTER repairs of the inverter MUST be handled by an authorized service dealer see Figure 8 Figure 8 Inverter Warning Label WARNING HIG
49. e unit shows signs of overheating you will need to enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is ade quate IMPORTANT YOU MUST TEST THE INSTALLATION ESPECIALLY IF YOU BRING IN AIR FROM BELOW THE GENERATOR SET GASOLINE FUEL SYSTEM Installing a gasoline fuel system Figure 27 for recre ational vehicle generator sets must comply with applic able codes standards and regulations The entire fuel system must be completely free of leaks There must be no possibility of gasoline vapors entering the vehi cle interior Figure 27 Generator Fuel System FUEL INLET CARBURETOR FUEL PUMP vapors are explosive Comply with all codes stan dards and regulations pertaining to gasoline fuel systems used in mobile generators Properly install and maintain the fuel system and keep it entirely free of leaks Gasoline vapors must not enter the vehicle interior DANGER Gasoline is highly flammable and its Factory installed generator fuel system components include a fuel filter b 12 volt DC electric pump c engine carburetor and d interconnecting lines and fit tings Connect a fuel supply line to the fuel filter inlet Use a flexible length of approved fuel hose between the fuel filter inlet connection and rigid fuel lines FUEL TANK Either the generator must share the vehicle engine s fuel tank or you must install a separate fuel tank for the g
50. ems used with these generators were designed only for vapor withdrawal type sys tems Vapor withdrawal systems use the gas vapors that form above the liquid fuel in the tank Do NOT attempt to use the kit along with any liquid withdrawal type system PRIMARY REGULATOR Gas pressure delivered to the solenoid valve must be properly regulated by means of a primary gas regula tor Mount the primary regulator at the gas tank outlet or in the supply line from the gas tank The following rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inches water column Do NOT exceed 14 inches water column The installer must be sure the primary regulator is rated at sufficient gas flow to operate the generator plus all other gas appliances in the circuit Figure 28 Diagram of LP Gas System CARBURETOR REGULATOR um Em A S DEBIT TANK 24 NOTE Recommended MINIMUM gas flow rate for all air cooled Impact 34 plus series generators is 67 cubic feet per hour IMPORTANT IF AN EXISTING PRIMARY GAS REG ULATOR DOES NOT HAVE A SUFFICIENT FLOW CAPACITY FOR THE GENERATOR AND OTHER GAS APPLIANCES IN THE CIRCUIT a INSTALL A PRIMARY REGULATOR WITH ADEQUATE FLOW RATE OR b INSTALL A SEPARATE REGULATOR RATED AT LEAST 67 CUBIC FEET PER HOUR THE INLET SIDE OF ANY PRIMARY REGULATOR THAT SUPPLIES THE GENERATOR MUST CONNECT DIREC
51. enerator set All fuel tanks installed on the vehicle must be constructed installed restrained so it com plies with applicable codes standards and regulations If the generator is to share the vehicle engine s tank separate fuel pickup tubes are required for the engine and the generator Generac recommends that you make the fuel pickup tube 2 to 3 inches shorter than the vehicle engine s pickup tube This prevents the generator from depleting the entire fuel supply during prolonged generator operating periods CAUTION Do NOT tee the generator fuel supply line into the vehicle engine fuel supply line If this is done the generator will be starved of fuel when both engines are operating at the same time Also while the vehicle engine is not running generator operation may drain the vehicle engine supply line making it difficult to start the vehicle engine GENERATOR FUEL SUPPLY LINE RIGID FUEL LINES Those lines used to supply fuel from a tank to the gen erator must comply with applicable codes standards and regulations The following generator rules apply to rigid fuel lines Rigid lines should be of annealed seamless drawn alu minum or steel Lines and fittings must comply with SAE J512F Standard Automotive Fittings or with ANSI B126 26 latest edition Route the fuel line so that at least 2 inches of clearance is maintained between the line and any exhaust system parts Do not attach electrical w
52. erator supplies correctly rated frequency and voltage only at the proper governed speed Some electrical appliances may be extremely sensitive to voltage and frequency Incorrect frequencies and or voltages can damage those appliances If electrical loads are applied at reduced operating speeds such loads imposed on the engine when suf ficient power is not available may shorten engine life Never turn ON electrical loads until after the genera tor engine has started and stabilized ON speed ATTENTION REQUIRED AFTER SUBMERSION If the motor home generator has been submerged in water it must NOT be started or operated Following any submersion in water have an authorized Generac Service Facility thoroughly clean and dry the generator OPERATION IN HIGH GRASS OR BRUSH Never operate the generator while the vehicle is parked in high grass weeds brush or leaves Such materials can ignite and burn from the heat of the exhaust system The generator exhaust system becomes extremely hot during operation and remains hot for a long time after it has shut down OPERATING PRECAUTIONS Never operate the motor home generator set while the vehicle is parked over dry leaves dry grass or any other combustible substance The generator s exhaust system becomes extremely hot and can cause a fire if it is too close to combustible materials The generator s exhaust system gives off DEADLY carbon monoxide gas This dangerous gas if b
53. erials may provide up to a 90 percent free air inlet area The percentage of free air inlet opening is usually available from the material supplier or manufacturer TO DETERMINE THE ACTUAL AIR INLET OPENING SIZE REQUIRED DIVIDE 40 SQUARE INCHES BY THE PERCENTAGE OF FREE AIR INLET AREA FOR THE MATERIAL YOU WILL USE For example If you plan to use screening with an 80 free air inlet area divide 40 by 0 8 which results in 50 square inches Minimum actual size of air inlet opening in this case is 50 square inches An opening that mea sures 4 inches wide by 12 1 2 inches long provides the required air flow 4 x 12 5 50 square inches INVERTER LOCATION The inverter should be located in a dry well ventilated area in order for the inverter to work effectively Approximately eight inches of space should be allowed at each end of the inverter for adequate ventilation The sensing harnesses supplied with the inverter have a maximum length of 12 feet If the cables are longer than needed coil the excess near the inverter unit If a greater length is needed contact Generac DO NOT ATTEMPT TO SHORTEN OR LENGTHEN THE SUP PLIED SENSING HARNESSES The DC power wires may be cut to the required length Allow enough length to make connection Coil excess inside J Box TESTING THE INSTALLATION Generac recommends testing the installation to be sure adequate cooling air flow is available to the unit before placing the unit into service If th
54. ets a Spark plug C Fuel pump if so equipped b Ignition module 1 2 LPG carburetion assembly and its 4 Catalytic Muffler Assembly if so equipped including internal components if so equipped a Muffler gasket a Fuel controller if so equipped b Exhaust manifold b Mixer and its gaskets if so equipped Carburetor and its gaskets if so equipped d Primary gas regulator if so equipped e LP liquid vaporizer if so equipped 5 Crankcase Breather Assembly including a Breather connection tube Generac engine types covered by this warranty statement include the following 1 Utility 2 Lawn and Garden Equipment 3 Recreational Vehicle RV Generator 4 Industrial Mobile IM Generator Part 2 RBA Generac s Three Year Limited Warranty For Recreational Vehicle Generators Generac warrants io the original owner and subsequent purchasers from date of purchase by the original owner that its generators be free from defects in materials or workmanship for the period as set forth below During said warranty period Generac will at its option repair or replace any part which upon examination by Generac or a Generac Authorized Distributor and or Dealer thereof is found to be defective from normal use and service This warranty is only effective upon Generac s receipt from the original owner a completed Warranty Registration Card prior to the expiration of the warranty period This card is the only vali
55. gnite char or discolor seat cushions fiberboard and other flammable materi als You may need to use approved non flammable insulating materials in high temperature areas SOUND INSULATING MATERIALS Once installers have determined that compartments are properly constructed and metal lined they can add acoustical material This may include additional sealant or insulating material to reflect noise away from the vehicle interior Sound insulating materials should be of a non flamma ble type One excellent insulating material is a 1 inch thick fiberglass having a 2 pound density When fiber glass is used its coated side should face toward the compartment interior Using a combination of sound insulating materials can often reduce noise more effectively than a single mate rial For example a sheet of lead or visco elastic mate rial along with a layer of other acoustical material is more effective than when a single material is used ssj Oz COMPARTMENT FLOOR CUTOUTS You must provide openings in the generator compart ment for the following items Figure 20 Engine exhaust and cooling air outlets Generator cooling air inlet Four holes for passage of generator mounting bolts See Generator Restraint on Page 19 DANGER Fuel lines and exhaust piping must not penetrate into vehicle living area ACOUSTICS If excessive noise levels should become a problem the installer may wish to consider the following
56. h 4 Oil Dipstick and Filler Tube 11 Generator DC Output Leads 5 Fuel Pump 12 Circuit Breaker 6 Gasoline Carburetor 13 Fuse 7 Fuel Primer Switch 14 Hour Meter E CO A N IDENTIFICATION RECORD Please record the followina information from the generator DATA DECAL or information decal 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage 5 Phase 6 Hertz IMPACT 36LPG plus FEATURES repo ET M 12 11 10 9 6 Impact 36 plus 8 LP VAPOR REFERENCE NUMBER IDENTIFICATION Generator Air Intake Screen 9 Data Decal Air Cleaner 10 12 Volt Battery Connection Air Intake Tube 11 Engine Start Stop Switch LP Fuel Regulator 12 Generator DC Output Leads Oil Dipstick and Filler Tube 13 Circuit Breaker LP Carburetor 14 Fuse LP Fuel Solenoid 15 Hour Meter Fuel Primer Switch INVERTER FEATURES PART No A6187 INVERTER REFERENCE NUMBER IDENTIFICATION 1 Inverter 4 2 Pin Connection 2 9 Pin Connection 5 DC Input 3 Customer AC Output 6 Cooling Fan READ THIS MANUAL THOROUGHLY If you do not understand any portion of this manual contact Generac or your nearest Generac Authorized Service Dealer for starting operating and servicing procedures Throughout this publication and on tags and decals affixed to the generator DANGER WARNING CAU TION and NOTE blocks are used to alert you to spe cial instruction about a particular operation that may be
57. h 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 A fuel and oil spills immediately Never leave oily or fuel soaked rags in the generator compartment or on the generator itself Keep the area around the generator clean and free of debris Adequate ventilation is required to expel toxic fumes and fuel vapors from the generator com partment Do not alter the installation of this equip ment in any manner that might obstruct air and ventilation openings Such openings must be kept clear and unobstructed Keep hands feet clothing etc away from drive belts fans and other moving parts of this equip ment Never remove any drive belt or fan guards while the unit is operating Inspect the generator periodically Repair or replace all damaged or defective parts immediately These generators can be converted to use LP gas 48 propane as a fuel Liquid Propane gas is highly XPLOSIVE The gas is heavier than air and tends to settle in low areas where even the slight est spark can ignite the gas and cause an explo sion Ake performing any maintenance on the gener ator set disconnect its battery cables to prevent accidental start up Disconnect the cable from the battery post indicated by a NEGATIVE NEG or
58. hazardous if performed incorrectly or carelessly Observe them carefully These safety warnings cannot eliminate the hazards that they indicate Strict compliance with the special instructions while performing the service plus com ron sense are major measures to prevent acci ents The following definitions apply to DANGER WARN ING CAUTION and NOTE blocks found throughout the manual DANGER After this heading you can read han dling installing operating or servicing instruc tions that if not strictly complied with will result in personal injury WARNING After this heading you can read han dling installing operating or servicing instruc tions that if not strictly complied with may result in personal injury CAUTION After this heading you can read instruc tions for handling installing operating or servicing the generator that if not strictly complied with could result in damage to equipment and or 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 followed could endanger personal safety and or property of yourself and others Potential explosion hazard Potential fire hazard Potential electrical shock hazard The operator driver is responsible for proper and safe use of the vehicle equipment on the vehicle and the safety of all vehicle occupants We
59. heck valve clearance to make sure it did not change Figure 12 on page 13 SRA A Figure 12 Tightening Jam Nut Tighten Jam Nut to 65 85 inch pounds 7 10 N m MAJOR SERVICE MANUAL To obtain a service manual for your generator order it from your dealer distributor or contact the factory Be sure to identify your uni s MODEL NUMBER and SERIAL NUMBER EXERCISING THE GENERATOR Generac recommends that you start and operate the generator at least once every seven days Let the unit run for at least 30 minutes to exercise the engine OUT OF SERVICE PROTECTION If you cannot exercise the generator every seven days and it is to be out of service longer than 30 days prepare the generator for storage as follows Start the engine and let it warm up While the engine is still warm from running drain the oil completely Refill crankcase with recommended oil See Specifications Attach a tag to the engine indicating the viscosity and classification of the oil in the crankcase Remove spark plug and add about 1 2 ounce 15ml of clean fresh engine oil into spark plug threaded opening Crank engine several times to distribute oil then install and tighten spark plug Remove the battery and store in a cool dry room on a wooden board Never store the battery on any concrete or earthen floor Clean and wipe the entire generator RETURN UNIT TO SERVICE AFTER STORAGE To return the unit to ser
60. hich is connected to the genera tor and should be connected to the chassis of the recreational vehicle Figure 31 Inverter J Box for AC Output WIRES PROVIDED BY OWNER Circuit breaker protection is provided on the generator and protects the unit against overload Do not apply loads which exceed the rated wattage capacity of the generator Add the watts or amperes of all lighting appliance tool and motor loads that the generator will operate at one time This total should be less than the units rated wattage amperage capacity ISOLATING DIFFERENT POWER SOURCES Conductors from the junction box must terminate in a double pole double throw transfer switch Figure 33 on Page 30 An alternate method for isolating different power sources is by using an isolating receptacle Figure 34 on Page 30 Whichever method you use you must be certain that both power sources are NOT connected at the same time POWER SUPPLY CORD The power supply cord must comply with all applicable codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected nU eun Figure 32 Generator to Inverter Connection J BOX GENERATOR TO INVERTER INPUT 2 PIN SENSING HARNESS GENERATOR TO DC CONVERTER GROUND FAULT CIRCUIT INTERRUPTERS The National Electric Code NFPA 70 551 7 requires that you install ground fault circuit interrupters GFCls on all external and some internal elect
61. hile using soap and water or equivalent solution to check for leaks Other approved methods of testing for leaks may be used if appropriate DO NOT USE ANY FLAME TO TEST FOR LEAKS DANGER Gaseous fuel lines between the tank and the secondary regulator are under a positive pres sure about 11 inches water column Gas pressure at the outlet side of the secondary regulator howev er is a negative pressure about 1 inch water col umn and can draw flame inside a line or fitting and cause an explosion Figure 29 Propane Gas Carburetion Diagram AIR FLOW LOW PRESSURE AREA GAS AT POSITIVE PRESSURE GAS AT ZERO PRESSURE The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used properly installed exhaust system must be vapor tight quiet and completely safe CAUTION Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine DANGER The generator engine gives off deadly carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death Symptoms of carbon monoxide poisoning are a inability to think coherently b vomiting c twitching muscles d throbbing in temples e dizzine
62. ically or mentally fatigued Stay alert at all times Storage batteries give off EXPLOSIVE hydrogen gas w ile charging The battery used for cranking and starting this generator should be installed in its own vented compartment Provide adequate ventilation for the battery to prevent explosive hydrogen gas from accumulating Never insert any tool or other object through open ings in the generator interior even if the unit is not running You might seriously injure yourself or damage the equipment Staying alert and using common sense are major measures for preventing accidents GENERAL INSTALLATION INFORMATION PURPOSE AND SCOPE OF MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners of the applicable equipment with the product s installation requirements Give serious consideration to all information and instructions in the Manual both for safety and for continued reliable operation of the equipment Because of the different recreational vehicle models and the variations between the models it would be extremely difficult if not impractical to provide detailed instructions on every installation possibility For that reason instructions and illustrations in this manual are general in nature lllustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all applica ble codes standards and reg
63. iring to fuel lines Route the wiring so it cannot come into contact with any fuel line Route fuel lines so if they leak fuel does not drip onto any electrical or exhaust system parts Use non ferrous metal straps without sharp edges to secure fuel lines B FLEXIBLE FUEL LINE Use an approved flexible length of fuel hose between the generator fuel inlet connection and rigid fuel lines This prevents breaking of the line caused by vibration shifting settling or movement The following rules apply The flexible hose must comply with SAE J30B Standard for Fuel and Oil Hose It must be approved for use with gasoline The hose should be at least 6 inches longer than is need ed to prevent the hose from rupturing if the generator shifts or settles ZR B PROPANE GAS FUEL SYSTEM DANGER LP propane gas is highly explosive The gas is heavier than air and tends to settle in low areas where even the slightest spark can ignite it and cause an explosion Only competent qualified persons should be allowed to install test adjust or service an LP gas fuel system Install the optional fuel system in compliance with applicable codes standards and regulations After the installation do nothing that might render the system in non compliance with applicable codes and standards PARTS NOT INCLUDED IN FUEL SYSTEM The propane fuel system does NOT include such items as a gas tank b gas piping c fittings d valves
64. it as given on its data decal The warranty on your generator is included in this Owner s Manual as well as listings for repair parts SERVICE DEALER LOCATION TO LOCATE THE NEAREST GENERAC SERVICING DEALER PLEASE CALL OUR 800 NUMBER ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER 1 800 333 1322 GENERATOR FAMILIARIZATION GENERATOR APPLICABILITY These generators have been designed and manufac tured for supplying electrical power for recreational vehicles You should not modify the generator or use it for any application other than for what it was designed If there are questions pertaining to its application write or call the factory Do not use the unit until you have been advised by a competent authority DANGER For fire safety the generator must have been properly installed in compliance with 1 ANSI 119 2 1975 NFPA 501C 1974 Standard for Recreational Vehicles Part Installation of Electrical Systems The generator also must have been installed in strict compliance with the manu facturer s detailed installation instructions After installation do nothing that might render the unit in non compliance with such codes standards and instructions This generator has been designed to work with an inverter P N A6187 The inverter changes the volt age from the generator from a DC to an AC voltage This generator will not operate properly without the inverter box connected All repairs
65. l as described above Line the exterior underside of the compartment floor with 26 gauge galvanized steel Vapor seal all compartment seams and joints to prevent poisonous flammable or explosive vapors from entering the vehicle interior Refer to the sealant information as noted previously NOTE Silicone rubber base sealant is an acceptable caulking material Pressing putty tape onto compart ment joints and seams is NOT acceptable After the compartment has been metal lined and vapor sealed line the compartment interior walls and ceiling with an approved non flammable sound insulating material See Sound Insulating Materials DANGER Do not install sound insulation or any absorbent material on the compartment floor interi or Such materials will become soaked with com bustible or explosive vapors and liquids and will become a fire hazard Openings in compartment walls for passage of electrical conduit conductors hoses cables etc must be made vapor tight with suitable caulking material Flexible conduit must be sealed internally at the end where it terminates inside a compartment s electrical junction box NOTE The preceding is required because flexible conduit due to its unique construction is not vapor tight along its entire length DANGER Do not install any flammable material directly above or around the compartment Heat transferred through the compartment structure may be sufficient to i
66. low voltage out put that occurs during startup A time delay that allows the engine to start and warm up is pro grammed into the monitoring system CAUTION Before restarting a generator that has been shutdown disconnect all loads the generator might power by whatever means provided such as the recreational vehicle s main circuit breaker ies ees SPECIFICATIONS FUEL REQUIREMENTS GASOLINE UNITS These generators are equipped with gasoline fuel systems as standard equipment Specific installa tions may provide either a separate fuel tank for the generator or the generator may share the vehicle engine s fuel tank NOTE Installations using a shared fuel tank may have a generator fuel pickup tube that is shorter than the vehicle engine s pickup tube Such an arrange ment causes the generator engine to run out of gas while adequate fuel for the vehicle remains in the tank To reduce lead and carbon deposits use high quality UNLEADED gasoline with the generator Leaded REGULAR grade gasoline is an acceptable substi tute NOTE Using Unleaded gasoline contributes to longer engine valve life by reducing lead and carbon deposits CAUTION Generac does not recommend using any gasoline containing alcohol it must not con tain more than 10 percent ethanol and it must be removed from the generator during storage Do NOT use any gasoline containing methanol If you use gasoline with alcohol inspect more frequently
67. ly complied with in the instal lation and use of this equipment The generator must be properly grounded bond ed to the vehicle chassis or frame If the vehicle electrical circuits can be powered by any other source of electricity such as a dockside power receptacle there must be no possibility of connecting the different power sources to the vehi cle circuits at the same time The dockside utility power source must be positively isolated from the vehicle circuits whenever the generator is operat ing Failure to isolate the vehicle circuits from the dockside power supply when the generator is run ning may result in damage to the generator or seri ous injury or death to dockside utility power work ers due to backfeed of electrical energy Never work on the equipment while standing in water while barefoot or while hands or feet are wet Dangerous electrical shock will result Jewelry conducts electricity which can cause dan gerous electrical shock Remove all jewelry such as rings watches or bracelets before working on this equipment The generator requires an adequate flow of air for cooling and ventilation Without sufficient cooling air flow the engine generator quickly overheats which causes serious damage to the generator a fire or an explosion Generator air inlet and outlet openings must be provided in strict compliance with the manufacturer s recommendations Never work on this equipment while phys
68. n flame sparks or any source of heat in the vicinity while handling gasoline Comply with all laws gov erning the storage and handling of gasoline Fuel lines must be properly installed properly fas tened and free of leaks There must be no possi bility of gasoline vapors entering vehicle interior You are required to install an approved flexible non conductive fuel line between the generator fuel connection point and rigid fuel lines If the e LP ga can be equipped with a liquid propane oie fuel system install the unit so it complies with all codes standards and an pertaining to such systems LP gas is highly explo sive The gas tends to settle in low areas where even the s Pra spark can ignite it and cause an ex on o not allow gas vapors to enter the vehicle e Engine exhaust gases contain DEADLY carbon monoxide gas This dangerous gas if breathed in sufficient concentrations can cause unconscious ness or even death Install the exhaust system in strict compliance with applicable codes standards and regulations There must be no possibility for exhaust gases entering the vehicle interior and xus endangering people or animals The generator set produces dangerously high elec ioa voltage Contact with bare wires bare terminals etc will result in extremely hazardous and possibly lethal electrical shock applicable electrical codes standards and reg ulations must be strict
69. nability to think coherently b vomiting c twitching muscles d throbbing temples e dizzi ness f headache g weakness and sleepiness If you feel any of these symptoms move into fresh air immediately If symptoms persist get medical help STARTING IMPORTANT Read the vehicle manufacturer s instructions The owner operator should become familiar with the vehicle in which this generator is installed Differences exist between vehicles For example some vehicles may use a transfer switch to isolate dockside power from the generator while other vehicles may use an isolating receptacle Some vehicles may be equipped with a DC converter which allows the generator to power certain DC lighting and other DC loads To crank and start the generator engine proceed as follows 1 Turn OFF electrical loads using whatever means provid ed in your vehicle such as a main line circuit breaker or transfer switch NOTE If you start the engine with the start stop switch on the generator control panel turn OFF loads by setting the panel s main breaker to its OFF or OPEN position Electrical load circuits may be turned ON after the generator has started stabilized and warmed up NOTE On gas units you only need to use the fuel primer during the initial startup after the unit has not been used for an extended period of time two weeks or the fuel line has been disconnected The primer is used to prime the fuel pump and carb
70. nductors are used they must be the same size as other leg wires Route power supply conductors from generator DC output leads DC Red and DC Blue the return Black and the ground Green wire through approved flexible conduit through the compartment floor and to the terminal block located in the DC junction box on the inverter Refer to ANSI RVIA standard EGS 1 1993 for conduit selection If flexible metal conduit is used between the generator and the compartment junction box the conduit end that termi nates at the compartment junction box must be vapor sealed Flexible metal conduit is NOT vapor tight along its entire length From the AC output junction box on the inverter route the three wires T1 Black T2 White and the Green ground wire through approved flexible conduit to either a double pole double throw transfer switch or b approved isola tion receptacle Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being connected to two different power supplies at the same time such as generator and dockside power Conductors must be rated 221 F 105 or must be of larger conductor size GENERATOR AC CONNECTION SYSTEM The Impact plus AC generator output is provided by the remote located inverter module 120V AC is provid ed from the terminal block located inside one of the J boxes on the inverter unit Figure 31 The unit is pro vided with a ground w
71. ngine exhaust pipe into the vehi cle engine exhaust piping This causes excessive back pressure on the generator engine Also water from one engine can damage the other engine Plan exhaust system installation carefully Comply with all applicable codes standards and regulations Figure 30 Exhaust System 0 oll RB EJ MUFFLER ELECTRICAL CONNECTIONS The following general rules apply to electrical connec tions in a recreational vehicle Qualified electricians who are familiar with applicable codes standards and regulations should install electrical wiring The wiring should comply with codes standards and regu lations The National Electric Code NFPA 70 as well as state and local codes apply Switches and circuit breakers should be of a type approved for use in recreational vehicles and must be mounted and installed to prevent damage from road shock Wiring must be of adequate size with approved insulative qualities and properly supported Conduit and wire openings into generator compartment if used must be vapor sealed to prevent entry of flamma ble explosive or poisonous gases into the vehicle WIRING Wiring should be of stranded copper to reduce chance that vibration may cause breakage Wire gauge size of wires should be large enough to handle at least 115 of the installed generator s rated maximum current If neutral co
72. nuous AC Power Output 3600 watts 3 6 kW Rated Voltage 120 volts AC Rated Maximum Continuous Current at 120 voltS 30 AC amperes anti Single Phase Rated AC Frequency 60 Hz Recommended Battery Cranking Current 400 amps Gross Weight ated 86 Ibs Maximum Cranking Current 250 Amps Maximum Charging Current 2 Amps LP GENERATOR SPECIFICATIONS 1 006 BOO Impact 36LPG plus Rated Maximum Continuous AC Power Output 3400 watts 3 4 kW Rated Voltage 120 volts AC Rated Maximum Continuous Current at 120 volts 28 3 AC amperes Pas Single Phase Rated AC Frequency 60 Hz Recommended Battery Cranking 400 8 05 Gross 87 Ibs Maximum Cranking Current 250 Amps Maximum Charging 2 Amps ENGINE SPECIFICATIONS Type of Engine ou ea GN 220 Cooling Air cooled PISPIACEMION aanita 22000 Type of Governor
73. o automati cally shutdown To avoid overloading add up the wattage of all con nected electrical lighting appliance tool and motor loads This total should not be greater than the gener ator s rated wattage capacity Most lighting appliance tool and motor loads indi cate their required watts on their nameplate or data plate For light bulbs simply note the wattage rating of the bulb f a load does not show its rated wattage multiply that load s rated VOLTS times AMPS to obtain WATTS Induction type motors such as those that run the vehicle s furnace fan refrigerator air conditioner etc need about 2 1 2 times more watts of power for starting than for running for a few seconds during motor starting Be sure to allow for this when con necting electrical loads to the generator First figure the watts needed to start electric motors in the sys tem To that figure add the running wattages of other items that will be operated by the generator On a new generator do not apply heavy electrical loads for the first two or three hours of operation ENGINE PROTECTIVE DEVICES This generator has a computer that monitors low oil pressure oil temperature engine speed and low volt age output This section discusses those protective devices AUTOMATIC LOW OIL PRESSURE SHUTDOWN The engine is equipped with an oil pressure sensor that shuts down the engine automatically when oil pressure is too low If the engine shuts
74. onding con ductor to any generator part that might be removed or disassembled during routine mainte nance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 AWG copper wire minimum Incase of accident caused by electric shock shut down the source of electrical power down at once If this can not be done free victim from live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a dry board dry rope or other non conducting implement to free the victim from live conductor Apply first aid and get medical help AP 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 The generator engine gives off DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentra tions can cause unconsciousness or even death This exhaust system must have been properly installed in strict compliance with applicable codes and standards Following installation you must do nothing that might render the system unsafe or in non compliance with such codes and standards The generator compartment must be completely vapor sealed from vehicle interior There must be no possibility of exhaust fumes entering the vehi cle interior Never operate this equipment wit
75. or at high ambient temperatures Warm up engine for at least five minutes then shut down With engine still warm from running clean area around oil drain plug and remove oil drain plug Figure 3 Drain oil completely into a suitable container When oil has drained install and tighten drain plug MAINTENANCE Remove oil dipstick and fill crankcase with the recom mended oil See Page 10 The engine crankcase can hold about 1 quart 950ml DO NOT FILL ABOVE FULL MARK Install and tighten dipstick cap before operating engine CHANGE OIL FILTER Replace the engine oil filter after the first 8 hours of operation every 100 operating hours thereafter Turn oil filter counterclockwise to remove Figure 3 a 9 TO LOOSEN Coat gasket of new filter with engine oil Turn new filter clockwise until its gasket contacts lightly with the filter adapter Then tighten an additional 3 4 to one turn by hand Run engine and check for leaks NOTE Check oil level and fill to full mark after checking for leaks Filter will retain some oil ENGINE AIR CLEANER Paper Filter Once every 25 operating hours or once each year whichever comes first clean or replace the paper filter Figure 4 Follow the steps on page 12 Figure 4 Engine Air Cleaner Assembly x 344 9 Remove air cleaner cover then remove paper filter Clean air filter by gently tapping it on a soli
76. placed by Generac according to Subsection 4 below Any such part repaired or replaced under the ECS Warranty shall be warranted for the remainder of the ECS Warranty Period 2 Any warranted emissions related part that 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 the remainder of the ECS Warranty Period 3 Any warranted emissions related part that is scheduled for replacement as required maintenance in the Owner s Manual shall be warranted for the period of time prior to the 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 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 Authorized Warranty Service Facility 5 When the engine is inspected by a Generac Authorized Warranty Service Facility the owner shall no
77. ply to compartments The generator compartment should be either con UPRA of or lined with 26 gauge galvanized steel IMPORTANT ALUMINUM IS NOT AN ACCEPTABLE ALTERNATIVE TO GALVANIZED STEEL DUE TO ALUMINUM S LOW MELTING POINT e f the compartment is lined with galvanized steel it may be constructed of any material Generac rec ommends that the compartment be constructed of 1 2 inch thick plywood with the floor made of a double thickness of plywood for added strength All seams splices and joints of the compartment nes vapor tight by design should be caulked IMPORTANT CAULKING MUST BE DONE SO THAT THE CAULKING MATERIAL WILL STAY IN PLACE PERMANENTLY PRESSING SUCH MATERIALS AS PUTTY TAPE ONTO JOINTS AND SEAMS WILL NOT MEET THAT REQUIREMENT A HIGH QUALITY SILI CONE RUBBER SEALANT IS RECOMMENDED Holes and openings through the compartment walls for passage electrical conduit conductors etc into vehicle living area must be sealed vapor tight with silicone rubber base sealant f you use flexible metal conduit seal the conduit at the end where it terminates inside the junction box Flexible metal conduit is NOT vapor tight along its entire length Seams and joints of the galvanized steel whether used as a liner or the compartment itself must be lapped and mechanically secured Such seams may be manufactured welded bolted riveted or screwed Manufactured lock seams are shown in Figure
78. porting frame with horizontal support tubing is shown in Figure 14 The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design per mits Another method is to suspend the generator below the horizontal support tubing by means of suit able structurally sound metal framework The following general rules apply Vehicle construction MUST be capable of supporting the weight of the generator Whether the generator is mounted above the horizontal support tubing or suspended below the tubing the sup porting frame used must be structurally sound If the generator cannot be bolted directly to the supporting frame or support tubing consider using additional tubing angle brackets or other supports to give the supporting frame sufficient strength Figure 14 Typical Horizontal Support Frame SUPPORT TUBING SUSPENDED MOUNTING If you are going to suspend the generator below the horizontal support tubing the suspension method you use with the vehicle frame members must have the fol lowing a be able to support the weight of the genera tor and b provide sufficient restraint for the genera tor One typical suspended mounting system is shown in Figure 15 The location of a suspended mounting system must be carefully planned keeping the follow ing general rules in mind Protect the generator against road splash and debris Baffles or splash guards may be required to pro
79. que that you chose does not render the gen erator to be unsafe WARNING The engine exhaust from this product contains chemicals known to the State of California 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 compliance with applicable codes and standards In addition the generator must be installed in conformance to the manufacturer s detailed installation instructions Following installation nothing must be done that might render the generator in noncompliance with such codes standards and instructions A The RV generator produces extremely high and dangerous electrical voltages and can cause dan gerous and possibly fatal electrical shock Avoid contact with bare wires terminals etc while the unit is running If you must work around an operat ing generator stand on an insulated dry surface to reduce shock hazard Never work on this equipment or handle any elec trical device while standing in water while bare foot or while hands or feet are wet Dangerous electrical shock will result Have the generator properly grounded bonded during installation onto the vehicle either by solid mounting to the vehicle frame or chassis or b means of an approved bonding conductor D NOT disconnect the bonding conductor if so equipped DO NOT reconnect the b
80. rator compartment provided by the vehicle manufacturer Plan the generator location based on the following The generator set must be installed on a framework that is part of the recreational vehicle as outlined in the para graph entitled Generator Support The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from underneath the supporting framework The location must provide easy access to frequently ser viced components such as filters oil drains spark plugs and other common maintenance parts The location must provide sufficient room to allow mini mum clearance of at least 1 inch between all sides and 1 1 2 inches on top of the generator If sound insulation is to be used on compartment walls and ceiling the minimum recommended applies to the space between the generator and such insulation The location must provide adequate cooling and ventilating air flow for the generator without a great deal of work and expense GENERATOR SUPPORT The generator must be securely attached to a metal framework that has been made part of the vehicle frame structure by bolting or welding The metal frame work on which the generator will rest and which will restrain the generator set should consist of at least two horizontal beams These beams should consist of a 1 1 2 inch square 11 gauge steel tubing OR b 1 1 2 inch 11 gauge angle iron A typical sup
81. reathed in sufficient concentrations can cause unconsciousness and even death Never operate the generator set with the vehicle inside any garage or other enclosed area Never operate the generator if it has a leaky exhaust system Close windows in the vicinity of the generator exhaust outlet and take any other steps to prevent exhaust gases from entering rooms or areas occupied by people or animals EFFECTS OF MOISTURE AND DIRT Keep the generator set as clean and dry as possible Protect unit against excessive dust dirt corrosive vapors road splash etc Permitting dirt and moisture to accumulate on generator windings will have an adverse effect on the insulation resistance of those windings When moisture is allowed to remain in contact with windings some of the moisture will be retained in voids and cracks in the insulation This causes a reduced insulation resistance and will eventually cause problems Dirt will make the problem worse since dirt tends to hold moisture in contact with wind ings Salt as from sea air will also worsen the prob lem since it tends to absorb moisture from the air Salt and moisture when combined form a good electrical conductor DO NOT OVERLOAD THE GENERATOR You can read the rated wattage amperage capacity of your generator on the generator data decal see Identification Record on Pages 2 3 Applying electrical loads in excess of the unit s rated capacity will cause the engine generator t
82. rical receptacles Contact your manufacturer or dealer for recommenda tions REMOTE HARNESS SENSING HARNESSES Sensing harnesses have been provided with the generator to connect to the inverter Figure 32 They are 12 feet long each however they are available in 24 feet lengths Part 4 s A6429A and A6430A The four 4 DC power wires Red Blue Black and Green may be cut to the desired length to meet the installation see Figure 32 CAUTION DO NOT in any way cut or shorten the two sensing harnesses the harnesses are too long simply tie the excess up neatly with standard cable ties Figure 33 Transfer Switch Isolation Method INVERTER VEHIGLE WIRING DOUBLE POLE DOUBLE THROW SWITCHING DEVICE FLEXIBLE CONDUIT 30 AMP MAIN BREAKER ern CONDITIONERS VEHICLE A C DISTRIBUTION BREAKERS PANEL FLEXIBLE CONDUIT DOCKSIDE POWER RECEPTICAL n r ee ah mmm VEHICLE A C DISTRIBUTION PANEL 29 BATTERY INSTALLATION RECOMMENDED BATTERY Install a battery that meets the following requirements Battery must be a 12 volt automotive type storage battery 1 AO FN For prevailing ambient temperatures above 32 F 0 C use a battery rated 70 amp hours and capable of deliver ing 400 cold cranking amperes For prevailing ambient temperatures below 32 0 use a battery rated 95
83. ring the overall noise emitted NOTE The computer will disable the electrical load capabilities of the generator and enter a fault condi tion if you accelerate the throttle manually or any other way ADJUSTING THE CARBURETOR The carburetor of your generator is preset at the fac tory The carburetor should not be tampered with as this wili void the emission controi system warranty your generator is used at altitudes in excess of 5 000 feet consult your Generac Authorized Service Facility regarding high altitude jetting changes ADJUSTING VALVE CLEARANCE After the first 50 hours of operation you should adjust the valve clearance in the engine When adjusting valve clearance the engine should be at room temperature and the piston should be at Top Dead Center TDC of its compression stroke both valves closed Correct clearance is 0 001 0 003 inch 0 03 0 07mm Adjust valve clearance as follows 1 Loosen the rocker arm jam nut Use an allen wrench to turn the pivot ball stud while checking clearance between the rocker arm and the valve stem with a feeler gauge Figure 11 Figure 11 Adjusting Valve Clearance K IN aX Allen Wrench CN Feeler Gauge Loosen Jam Nut 2 When valve clearance is correct hold the pivot ball stud with the allen wrench and tighten the rocker arm jam nut with a crows foot Tighten the jam nut to 65 85 inch pounds torque After tightening the jam nut rec
84. rst 4 This transferable warranty is in effect for all Recreational Vehicle Generators purchased after Jan 1 1998 THIS WARRANTY DOES NOT COVER Costs of maintenance installation and start up Failures due to a normal wear and tear from GN engine or b accident misuse abuse negligence or improper installation Products which are modified or altered in a manner not authorized by Generac in writing Any incidental consequential or indirect damages caused by defects in materials or workmanship or any delay in repair or replacement of defective parts Failure due to misapplication Telephone telegraph teletype or other communication expense Living or travel expenses of persons performing service Any and all transportation travel expenses Rental equipment used while warranty repairs are being performed 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 merchantabil ity and fitness for a particular purpose to the extent permitted by law The duration of any implied warranties which cannot be disclaimed is limit ed to
85. s lines must be accessible but protected against possible damage Do NOT connect electrical wiring to any propane gas fuel line or run wiring alongside the lines Route gas lines away from hot engine exhausts Retain gas lines with metal clamps that do not have sharp edges Install an approved length of flexible hose between the gaseous fuel solenoid valve and rigid fuel supply lines The flexible line must be non metallic non organic and non conductive It must be approved for use with LP gas EXCESS FLOW VALVE Propane gas tanks should have an excess flow valve according to NFPA 501C Paragraph 3 4 4 This valve and the gas lines must be carefully sized so the valve will close when a fuel line is severed or broken Consult the Natural LP Gas Association for information and limitations of excess flow valves Manual shutoff valves on the supply tank and else where in the system must be fully open when operat ing the generator The excess flow valve functions properly only if all valves are fully open LEAKAGE TESTS Do not place the generator into service until you have properly tested the gas system for leaks To test the system you need a separate source of 12 volts DC to open the gaseous fuel solenoid valve The leak test must comply fully with NFPA Paragraph 318 All connections hoses valves regulators fitting and other fuel system parts must be tested under gas or air pressure of not less than 90 psi 620kPa w
86. ss f headache g weakness and sleepi ness If any of these symptoms ar experienced move into fresh air immediately If symptoms per sist get medical attention Do not operate the gen erator until its exhaust system has been inspected and repaired MUFFLERS AND SPARK ARRESTORS Exhaust mufflers and spark arrestors that Generac supplies meet code and standard requirements and are approved by the U S Forest Service Use only mufflers and parts approved by Generac Any person s installing an unapproved muffler or an unap proved exhaust system part or modifying an exhaust System in any way that might cause a hazard is liable for any damage injury or warranty expense that might be caused by such unapproved installation or modifi cation Failure to provide and maintain a spark arrestor may be in violation of the law If this generator is used on any forest covered brush covered or grass covered unimproved land you must provide a spark arrestor The vehicle owner or operator must maintain this device in good condition In the State of California the preceding is required by law Section 4442 of the California Public Resources Code Other states may have similar laws Federal laws apply on federal lands TYPE OF EXHAUST SYSTEM The Impact 36 plus and Impact 34 plus generators have a configuration for a bottom out exhaust system and is equipped with such an exhaust muffler Figure 30 EXHAUST SYSTEM EXHAUST SYSTEM S
87. statement explains your rights and obligations under the Emission Control System Warranty ECS Warranty which is provided to you by Generac pursuant to California and federal law See also the Generac Limited Warranties for Generac Power Systems Inc which is enclosed herewith on a separate sheet also provided to you by Generac The ECS Warranty applies only to the emission control system of your new engine If there is any conflict in terms between the ECS Warranty and the Generac Warranty the ECS Warranty shall apply except in circumstances where the Generac Warranty may provide a longer warranty period Both the ECS Warranty and the Generac Warranty describe important rights and obligations with respect to your new engine Warranty service can be performed only by a Generac Authorized Warranty Service Facility When requesting warranty ser vice evidence must be presented showing the date of the sale to the original purchaser owner The purchaser owner shall be responsible for any expenses or other charges incurred for service calls and or transportation of the product to from the inspection or repair facilities The purchaser owner also shall be responsible for any and or all damages or losses incurred while the engine is being transported shipped for inspection or warranty repairs If you have any questions regarding your warranty rights and responsibilities you should contact Generac at the following address ATTENTION WARRANTY DE
88. t BATTERY COMPARTMENT Install the generator battery in its own vented com partment Place the battery compartment away from any source of heat sparks or flame Provide ventilation openings in the battery compart ment The minimum size of openings should be 2 square inches at the top of the compartment Mount the battery on a strong rigid supporting structure where leaks and spills of battery fluid will not cause damage Figure 35 Connecting Battery Cables 13 TO PANEL 16 TO STARTER POSITIVE CUSTOMER CONNECTION STARTER eb CONTACTOR GROUND WIRE FRAME GROUND uc ducc OPTIONAL ACCESSORIES A plug in receptacle Figure 36 is provided on the Model 9043 This panel mounts a rocker type switch generator set near the DC power wires Use this Generator Run lamp and an hourmeter Figure 38 receptacle to connect an optional remote mounted Use the hourmeter in conjunction with the periodic start stop panel to the generator Installation of such maintenance schedule for your generator Figure 38 Model 9043 Remote Panel panel will permit you to start and stop the generator engine from any convenient location inside the vehicle Figure 36 Remote Panel Plug In Receptacle 0 GENERAC R V GENERATOR GEN RUN TOTAL HOURS _ WIRE 418 STOP WIRE 14 WIRE 0 ENGINE RUN WIRE 17 GROUND SIGNAL CRANK
89. t be held responsible for diagnostic costs if the repair is deemed warrantable 6 Generac 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 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 purchaser owner Such use shall not reduce Generac s ECS Warranty obligations 9 Unapproved add on modified counterfeit and or grey market parts may not be used to modify or repair a Generac engine Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of such an unapproved add on modified counterfeit and or grey market part EMISSION RELATED PARTS INCLUDE THE FOLLOWING 1 Fuel Metering System 2 Air Induction System including 1 1 Gasoline carburetor assembly and its a Intake pipe manifold internal components if so equipped b Air cleaner a Fuel filter if so equipped 3 Ignition System including b Carburetor gask
90. tect certain areas of the generator To make sure the generator is ade quately protected road test the installation through mud water and slush Figure 15 Typical Suspended Mounting System GENERATOR MOUNTING HOLES FOR 3 8 16 SUPPORT TUBING GENERATOR SUPPORT FRAME The installer must make certain that selected location will permit adequate cooling and ventilating air flow to be sup plied ud zz GENERATOR RESTRAINT gt On ctas halt Use four 3 8 16 hardened steel bolts Grade 5 to fas ten the generator to the supporting frame or the sup port tubing These bolts must pass through a the generator mounting base b the compartment floor if a compartment is used and c the supporting frame work Figure 16 All bolts must be long enough so that when tight at least 3 threads are visible past the retaining lock nuts Refer to section for location of generator mounting holes L Figure 16 Typical Generator Restraint METAL LINED 1 2 INCH THICK BASE PLYWOOD dE VEHICLE METAL UNED CHASSIS BOTTOM GENERATOR COMPARTMENTS COMPARTMENTS The generator set may or may not be installed inside a compartment that is constructed specifically for hous ing a generator This section applies to generator com partments when they are installed The following gen eral rules ap
91. the State of California Documents Section P O Box 1015 North Highlands CA 95660 6 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to Generac Impact air cooled generators more specifi cally the installation of Impact 34 plus and Impact 36 plus recreational vehicle generators These generators are designed specifically for installing in recreational vehicles ENGINE GENERATOR OPERATING SPEED The generators are driven by gasoline powered sin gle cylinder engines The engines drive revolving fields rotors high frequency permanent magnet alterna tors The generators supply 120 volts AC at 60 Hertz with DC inverter The generators revolving fields are driven at a variable speed depending on the demand for power Computers monitor that demand and adjust the engine speed to provide adequate power to the connected loads cc LOCATION AND SUPPORT GENERATOR LOCATION The most desirable location for the generator set is between the vehicle s main frame members However this is seldom possible Most units must be installed on the side of the vehicle and are difficult to reinforce Many recreational vehicles have been factory equipped with an area for the generator set Some vehicles may even have a gene
92. to crank or start the engine before you have properly serviced it with the rec ommended oil may result in engine failure FUEL SUPPLY The engine must have adequate supply of proper fuel to a Before starting check that sufficient fuel is available NOTE On some gasoline installations the generator engine may share the vehicle s gasoline fuel tank with the vehicle engine Some installations may provide separate fuel tanks for generator and vehicle engine COOLING AND VENTILATING AIR Air inlet and outlet openings in the generator compart ment must be open and unobstructed for continued proper operation Without sufficient cooling and venti lating air flow the engine generator quickly overheats which causes it to automatically shutdown Overheating could also damage the unit or your vehicle M ENGINE EXHAUST GAS Before starting the generator engine you should be sure there is no way for exhaust gases to enter the vehicle interior and endangering people or animals Close windows doors and other openings in the vehi cle that if open might permit exhaust gases to enter the vehicle DANGER The generator engine gives off deadly carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient con centrations can cause unconsciousness or even death Do not operate the generator if its exhaust system is leaking or has been damaged Symptoms of carbon monoxide poisoning are a i
93. top switch is released Start Stop switch at Stop engine continues to run No output from generator m gt Fuse is blown Loose corroded or defective battery cables Defective engine Start Stop switch Defective starter contactor Defective starter motor Low or defective Battery Out of fuel Fuel pump is defective Gasoline OR fuel solenoid is defective LP Open Wire 14 from Eng Control Bd Engine is flooded Spark plug defective Loose spark plug boot Air cleaner plugged or damaged Defective spark plug Engine oil is low Engine is overheated Defective Low Oil Pressure System Defective Control Board Defective Computer Control Board Defective Start Stop switch Open disconnected wire 18 between Start Stop switch and Control Open disconnected wire 0 between Start Stop switch amp Control Bd Defective Control Board Check circuit breaker Check vehicle circuit breaker amp fuses Transfer sw set to NORMAL position Generator internal failure Inverter defective po Dr dw oe Qu Replace 15 amp fuse Tighten clean or replace as necessary Replace Start Stop switch Replace contactor Replace starter motor Charge or replace battery Replenish fuel Replace defective fuel pump or fuel solenoid Reconnect wire Wait 5 10 min before trying Clean regap or replace plug Press boot on securely Cle
94. tor temperatures Then shut down the engine IMPORTANT THE GENERATOR SET WAS THOR OUGHLY TESTED AND ADJUSTED AT THE FACTO RY BEFORE SHIPPING NO ADDITIONAL ADJUST MENT SHOULD BE NECESSARY ONLY QUALIFIED SERVICE TECHNICIANS WHO HAVE BEEN TRAINED SHOULD PERFORM ADJUSTMENTS OUTLINED IN THIS MANUAL TESTING UNDER LOAD Apply electrical loads equal to about 75 100 of the unit s rated wattage amperage capacity Let the unit run at least 30 minutes with load applied During this part of the test check that the unit is not running excessively hot and that adequate cooling air flow is available You must not allow the unit to over heat during prolonged operation NOTE The generator engine is equipped with a high temperature switch The switch has normally open N O contacts When the temperature is too high switch contacts close and engine shuts down auto matically IMPORTANT GENERAC RECOMMENDS THAT YOU TEST THE GENERATOR FOR ADEQUATE COOL ING 32 INSTALLATION CHECK LIST LOCATION AND SUPPORT 1 The generator is properly located ___2 The generator is properly supported 3 The generator is properly restrained _ 4 The inverter is mounted securely COMPARTMENT ___1 Compartment construction is proper ___2 Holes openings are vapor sealed 2 3 Compartment size is correct _ 4 Compartment is vapor sealed ___5 Sound insulation is _ 6 Floor cutouts properly completed COOLING and
95. ty This should be done with an automotive type battery hydrometer DANGER Storage batteries give off explosive hydrogen gas This can form an explosive mixture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explosion can shatter the battery and cause blindness or other injury Any area that houses a storage battery must be proper ly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery DANGER Battery electrolyte fluid is an extremely y caustic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear protec tive goggles protective clothing and gloves when handling a battery If you spill the fluid flush the affected area immediately with clear water DANGER Do not use any jumper cables or boost er battery to crank and start the generator engine If any battery has discharged remove it from the vehicle for recharging SERVICE AND ADJUSTMENTS ENGINE SPEED Engine speed is completely computer controlled There is no adjustment for speed on the unit The computer adjusts the engine speed using an electron ic governor throttle control The computer monitors the demand for power and adjusts the engine speed accordingly This allows the un to produce only the power required resulting in fuel economy as well as lowe
96. ulations pertaining to the installation and use of this product If any portion of this manual appears to be in conflict with such codes standards or regulations the applicable codes stan dards or regulations must take precedence over the manual SAFETY Before handling installing operating or servicing this equipment be sure to read carefully the Notice to Installer and Safety Rules at front of this manual Comply with all SAFETY RULES to prevent death per sonal injury or damage to equipment and or property Stress safety to all installers operators and service technicians who work on this equipment STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufacturer s recommendations The following stan dards booklets latest revision are available from the sources indicated 1 NFPA Standard 5010 Standard for Recreational Vehicles available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 NFPA 70 NFPA Handbook of the National Electric Code obtained from same address as 1 3 ANSI C1 1975 and ANSI 119 2 1975 available from the American National Standards Institute 1430 Broadway New York NY 10018 4 ANSI A119 2 NFPA 501C available from the Recreational Vehicle Association 1896 Preston White Drive Reston VA 22090 5 California Administrative Code Title 25 available from
97. uretor 2 To crank and start the engine hold the start stop switch at START Release the switch when the engine starts CAUTION If the engine does not start after it has been cranking for 15 seconds release the start stop switch and try again Holding the switch for longer than 15 seconds may damage the starter motor 3 Let the engine run at no load for a few minutes to stabi lize and warm up the engine 4 Turn ON electrical loads using whatever means provided such as a main circuit breaker or transfer switch NOTE f you start a warm generator engine you may press the start switch only slightly to engage the ignition system However you should press and hold the starter switch for a minimum of two 2 seconds to energize the field boost system If you start the engine without energizing the field boost system the generator produces no output STOPPING THE GENERATOR 1 Turn OFF all electrical loads using whatever means pro vided such as a main circuit breaker or transfer switch 2 Let the generator run at no load for a few minutes to sta bilize internal engine generator temperatures 3 Hold Start Stop switch in its STOP position APPLYING LOADS TO GENERATOR When applying electrical loads to the generator observe these guidelines Before applying electrical loads let the generator stabilize and warm up for a minute or two DO NOT overload the generator LETTING ENGINE STABILIZE The gen
98. vice after storage proceed as follows Check tag on engine for oil viscosity and classification Verify that the correct recommended oil is used in engine If necessary drain and refill with proper oil Check battery Fill all cells to the proper level with distilled water DO NOT USE TAP WATER IN THE BATTERY Recharge battery to 100 state of charge or if defective replace the battery Turn OFF all electrical loads then start the engine Let engine warm up Apply electrical loads to at least 50 of the unit s rated wattage capacity e When engine is thoroughly warmed up shut it down THE GENERATOR IS NOW READY FOR SERVICE SERVICE DEALER LOCATION TO LOCATE THE NEAREST GENERAC SERVICING DEALER PLEASE CALL OUR 800 NUMBER ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER 1 800 333 1322 INSTALLATION SAFETY RULES DANGER FOR FIRE SAFETY INSTALLATION OF A GENERATOR INTO A RECREATIONAL VEHICLE MUST COMPLY STRICTLY WITH ARTICLE 551 NFPA 70 ANSI C1 1975 AND ANSI A119 2 1975 NFPA 501C STANDARD FOR RECREATIONAL VEHICLES PART 3 INSTALLATION OF ELECTRICAL SYSTEMS IN ADDITION THE MANUFACTURER S a INSTRUCTIONS AND RECOMMENDATIONS MUST BE COMPLIED WITH NOTICE TO INSTALLER The Installation Instructions have been published by Generac to aid in the installation of the products described in this manual Generac assumes that instal lation personnel are familiar with the procedures

Owner`s Manual and Installation Instructions

Contents

Download Pdf Manuals

Related Search

Related Contents