Generac Power Systems 00940-2 Owner'S Manual And Installation Instructions Download Page 48 | Manualshive

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46

Generac

®

Power Systems, Inc.

Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator
Impact-36 plus Sheet Metal – Drawing No. 0A9194-H

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Summary of Contents for 00940-2

Page 1: ...POWER SYSTEMS INC Owner s Manual and Installation Instructions Air cooled Recreational Vehicle Generator Model Nos 00940 2 00941 2 IMPACT 36 plus II with Inverter ...

Page 2: ... of the vehicle and its equipment and for the safety of all vehicle occupants Before using this equipment we strongly recommend that the operator read this manual and thoroughly under stand all instructions We also strongly recommend instructing other occupants in the vehicle to properly start and operate the generator This prepares them to operate the equipment in case of an emergency CONTENTS Th...

Page 3: ...15 Major Service Manual 15 3 16 Exercising the Generator 15 3 17 Out of Service Protection 15 3 18 Return Unit to Service After Storage 15 Notes 16 Part II Installation Instructions Safety Rules 18 Section 1 General Information 20 1 1 Purpose and Scope of the Manual 20 1 2 Safety 20 1 3 Standards Booklets 20 1 4 Equipment Description 20 1 5 Engine Generator Operating Speed 20 Section 2 Installatio...

Page 4: ...tor compartment must be completely vapor sealed from the vehicle interior There must be no possi bility of exhaust fumes entering the vehicle interi or Never operate this equipment with a leaking or defective exhaust system Keep hands feet clothing etc away from drive belts fans and other moving or hot parts Never remove any drive belt or fan guard while the unit is operating Adequate unobstructed...

Page 5: ... For fire safety the generator must be installed and maintained properly Installation must always comply with NFPA 70 latest edition National Electrical Code Article 551 and NFPA 1192 lat est edition Standard for Recreational Vehicles along with all applicable codes standards laws and regulations Adhere strictly to local state and federal electrical and building codes Comply with regulations the O...

Page 6: ...__________ 4 Rated Voltage __________________ 5 Phase ______________________________ 6 Hertz __________________________ 1 1 GENERATOR IDENTIFICATION 1 1 1 IMPACT 36G PLUS II FEATURES 1 Generator Air Intake Screen 2 Air Cleaner 3 Air Intake Tube 4 Oil Dipstick and Filler Tube 5 Fuel Pump 6 Gasoline Carburetor 7 Fuel Primer Switch 8 Data Decal 9 12 Volt Battery Connection 10 Engine Start Stop Switch...

Page 7: ...___________ 4 Rated Voltage __________________ 5 Phase ______________________________ 6 Hertz __________________________ 1 1 2 IMPACT 36LPG PLUS II FEATURES 1 Generator Air Intake Screen 2 Air Cleaner 3 Air Intake Tube 4 LP Fuel Regulator 5 Oil Dipstick and Filler Tube 6 LP Carburetor 7 LP Fuel Solenoid 8 Fuel Primer Switch 9 Data Decal 10 12 Volt Battery Connection 11 Engine Start Stop Switch 12 ...

Page 8: ...tion 1 General Information IMPACT 36 plus II Recreational Vehicle Generator 1 1 3 INVERTER FEATURES PART NO 0D4885 1 Inverter 2 12 Pin Connection 3 Customer AC Output 4 DC Input 5 Cooling Fan REFERENCE NUMBER IDENTIFICATION 3 5 2 4 1 ...

Page 9: ...xcessively high electrical loads may damage the generator and may shorten its life Add up the rated watts of all electrical lighting appliance tool and motor loads the generator will power at one time This total should not be greater than the wattage capacity of the generator If an electrical device nameplate gives only volts and amps multiply volts times amps to obtain watts volts x amps watts So...

Page 10: ...engine shuts down by itself and the fuel tank has enough fuel check the engine oil level 1 6 1 1 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 1 6 1 2 Sensing low pressure If the system senses low oil pressure during opera tion the engine sh...

Page 11: ... and other openings in the vehi cle that if open might permit exhaust gases to enter the vehicle The generator engine gives off deadly carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentrations 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 poi soni...

Page 12: ...d 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 2 5 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...

Page 13: ... when temperatures drop below freezing 2 10 ENGINE OIL REQUIREMENTS The recommended oils include the following During summer months SAE 30 An acceptable substitute 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 2 11 GAS GENERAT...

Page 14: ...ngine oil after the first 8 hours of operation Thereafter change oil every 100 operating hours Change oil more frequently if operating consistently under heavy load or at high ambient temperatures Warm up engine for at least five minutes then shut down With engine still warm from running clean area around oil drain plug and remove oil drain plug Figure 3 2 Drain oil completely into a suitable cont...

Page 15: ...m the air intake screen Figure 3 4 at lease once every 100 hours of opera tion Clean more often if necessary Inspect the area around the generator exhaust muf fler periodically and remove all grass leaves dirt etc from this area Figure 3 4 Clean Air Intake Screen 3 7 ENGINE SPARK PLUG Clean engine spark plug and set gap to 0 030 inch 0 76mm every 100 hours of operation Figure 3 5 Clean by scraping...

Page 16: ...xture around the battery for several hours after charging The slightest spark can ignite the gas and cause an explosion Such an explo sion can shatter the battery and cause blind ness or other injury Any area that houses a storage battery must be properly ventilated Do not allow smoking open flame sparks or any spark producing tools or equipment near the battery Battery electrolyte fluid is an ext...

Page 17: ... exercise the engine 3 17 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 pre pare 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 recom mended oil See Specifications Attach a tag to the engine indicat...

Page 18: ...16 Generac Power Systems Inc Notes IMPACT 36 plus II Recreational Vehicle Generator EJ ...

Page 19: ...PART II INSTALLATION INSTRUCTIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION ...

Page 20: ...pment is carried out by a Generac Authorized Service Dealer The engine exhaust fumes contain carbon monox ide which can be DEADLY This dangerous gas if breathed in sufficient concentrations can cause unconsciousness or even death This exhaust sys tem must be installed properly in strict compli ance with applicable codes and standards Following installation you must do nothing that might render the...

Page 21: ...onductor If the vic tim is unconscious apply first aid and get immediate medical help Never wear jewelry when working on this equip ment Jewelry can conduct electricity resulting in electric shock or may get caught in moving com ponents causing injury FIRE HAZARDS For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards...

Page 22: ...hed standards as well as the manufacturer s recommendations The following standards booklets latest revision are available from the sources indicated 1 NFPA 1192 Standard for Recreational Vehicles replaces ANSI A119 2 NFPA 501C available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 2 NFPA 70 NFPA Handbook of the National Electric Code available same as Item 1 3 A...

Page 23: ... 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 porting frame with horizontal support tubing is shown in Figure 2 1 The generator can be installed so that it sits on top of the horizontal support tubing if the vehicle design permits Another meth...

Page 24: ...STEEL DUE TO ALUMINUM S LOW MELTING POINT If the compartment is lined with galvanized steel it may be constructed of any material Generac rec ommends that the compartment be constructed of 1 2 inch thick plywood with the floor made of a double thickness of plywood for added strength All seams splices and joints of the compartment walls unless vapor tight by design should be caulked IMPORTANT CAULK...

Page 25: ...ring 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 com partment 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 Insu...

Page 26: ...ass 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 material For example a sheet of lead or visco elastic material along with a layer of other acoustical mate rial is more effective than when a single material is used 2 2 4 COMPARTMENT FLOOR CUTOUTS You must provide openings ...

Page 27: ...eter Line the compartment door interior except for air openings with suitable fire proof sound insula tion such as 1 inch thick fiberglass with a 2 pound density 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 o...

Page 28: ...MPORTANT 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 suppl...

Page 29: ...e sure adequate cooling air flow is available to the unit before placing the unit into service If the unit shows signs of overheating you will need to enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is ade quate IMPORTANT YOU MUST TEST THE INSTALLATION ESPECIALLY IF YOU BRING IN AIR FROM BELOW THE GENERATOR SET 2 4 GASOLINE FUEL SYSTEM...

Page 30: ...em parts Use non ferrous metal straps without sharp edges to secure fuel lines 2 4 2 2 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 follow ing rules apply The flexible hose must comply with SAE J30B Standard for Fuel and Oil Ho...

Page 31: ...the kit along with any liquid withdrawal type system 2 5 4 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 out let or in the supply line from the gas tank The fol lowing rules apply For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 i...

Page 32: ...urce of 12 volts DC to open the gaseous fuel solenoid valve The leak test must comply fully with NFPA Paragraph 318 All connections hoses valves regulators fitting and other fuel system parts must be tested under gas or air pressure of not less than 90 psi 620kPa while using soap and water or equivalent solution to check for leaks Other approved methods of testing for leaks may be used if appropri...

Page 33: ...he 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 ...

Page 34: ...nected to two different power sup plies at the same time such as generator and dockside power Conductors must be rated 221 F 105 C or must be of a larger conductor size 2 7 2 GENERATOR AC CONNECTION SYSTEM The Impact plus AC generator output is provided by the remote located inverter module 120V AC is pro vided from the terminal block located inside one of the J boxes on the inverter unit Figure 2...

Page 35: ...ection 2 Installation IMPACT 36 plus II Recreational Vehicle Generator Figure 2 20 Transfer Switch Isolation Method Figure 2 21 Installation with Isolation Receptacle INVERTER INVERTER POWER CORD FOR DOCKSIDE POWER POWER SUPPLY CORD ...

Page 36: ...ring 400 cold cranking amperes For prevailing ambient temperatures below 32 F 0 C use a battery rated 95 amp hours and capa ble 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 2 8 2 BATTERY CABLES Using battery cables that are too long or too small in diame...

Page 37: ...IN RECEPTACLE A plug in receptacle Figure 2 24 is provided on the generator set near the DC power wires Use this receptacle to connect an optional remote mounted start stop panel to the generator Installation of such a panel will permit you to start and stop the genera tor engine from any convenient location inside the vehicle Figure 2 24 Remote Panel Plug In Receptacle 2 9 2 REMOTE START STOP PAN...

Page 38: ... since the fuel lines have to be primed Use of the Primer Switch on gasoline units will shorten this time 3 Let the engine warm up for about five minutes to allow internal temperatures to stabilize 4 Carefully inspect the engine generator for fuel oil and exhaust system leaks Before proceeding to the next step correct any leakage immediately 5 When all tests and adjustments at no load are complete...

Page 39: ...tem is properly and safely installed ELECTRICAL CONNECTIONS Connections comply with local code requirements and all National Electrical Codes Junction box is properly installed Wiring meets all standards All connections are correct Conduit is properly installed and sealed Generator is properly bonded to the vehicle BATTERY INSTALLATION Recommended battery is installed Recommended cables are instal...

Page 40: ...ough 1 Air cleaner plugged or damaged 1 Clean or replace as needed 2 Defective spark plug 2 Clean regap or replace plug Engine starts shuts down 1 Engine oil is low 1 Check oil add as needed when Start Stop switch is 2 Engine is overheated 2 Check adequate ventilation released 3 Defective Low Oil Pressure System 3 Have serviced replaced 4 Defective Control Board 4 Have board serviced replaced 5 De...

Page 41: ...NCLCSURE 502 9 8 I 403 5 9 4 l r 1_ 1 511 120 1 I 259 10 2 25 0 1 j I 38 5 1 291 l l 421 16 6 1 1 j __ t 439 17 2 t 400 5 7 t LJo l r 11 I I 1 L P R GULATOR 118 4 7 27 1 06 C D XHAUST CUTUT r 2 7 5 10 9 1 F 305 2 0 1 I I II 27 3 5 0 1 1 0 6 TYP 145 4 1 5 7 I t l jl TYP MOUNT1NG HOLE DETAIL t 399 15 7 1 t 1205 8 1 1 321 7 12 7 I G G ALLOW APPROXIMATELY 8 FOR AIRFLOW ON BOTH ENDS OF INVERTER tiQIE 1...

Page 42: ...L tklf PLJF DN ASDLINE h t Itf1111 INV T r r V DN L P I t STOP 1M HIJJi METER SV2 SWITCH FUEL PLIF PRIME HTD SWITCH HI TEII EIIATUR OIL SPI S PLUG CLOSES DN HI H TE TUREI __LUG IIIIRREL IC I ITIDN CDIL TC TERMINAL CONNECTOR 4 TAl TB TERMINAL BLIJCI STMT I 14 18 11 1Cl1E CI N CT R 4 IB STDP IB il z 0 HTD 85 D I I 18 i I I 17 D tf 66 77 lO 1 66 BATTERY C VINIIIIG 77 55 __L_ SL2 SLI PINER VINDING AC2...

Page 43: ...cle Generator Wiring Diagram and Schematic Drawing No 0D4947 B RED DC I FM r F F LW r I r IIC IUS I I I I RT ii H H 1 l JIL JI I K J L a 1 Jll 71 h Jll F ri n JII 1 Jll 6 J TDO JII S r 1 J J9 mt JIO _j _I I V CHASSIS AC INVERTER ENGINE GENERATOR 11 rP I 0 I I ELECTRICAL DATA D oc l M STATIII ...

Page 44: ...us II Recreational Vehicle Generator Control Panel Drawing No 0D4946 A 14 35 13 i 9 19 3 yl 3 2 4_ __ x v 6 45 46 10 f 27 5 38 JA oo I 2 7 1 sa 3 6 rtf I 44 26 I I co_ f 47 1 I 10 25 l 61 it x 25 24 22 23 21 25 63 59 13 I 30 ITEMS 49 65 8 66 HARNESSES NOT SHOWN FOR CLARITY 64 62 e t ...

Page 45: ...5 X 10MM 34 043182 4 LOCK WASHER M3 35 089744 1 RESISTOR POWER 1 OHM 36 0A6423A 2 BUS BAR OUTER 37 045756 4 TAPTITE M6 1 0 X 10MM 38 086722 1 BRACKET HEAT SINK PCB 41 075210A 1 TERMINAL BLOCK 43 0A6423B 4 BUS BAR INNER 44 0912970025 1 GROUND WIRE 45 0A6470 1 DC POWER HARNESS 46 091269A 1 REMOTE PANEL HARNESS 47 023484D 1 SNAP BUSHING 48 082121A 1 CLAMP CONTROL PANEL HARNESS 49 0A9183 1 HARNESS CON...

Page 46: ...Section 6 Exploded Views and Parts Lists IMPACT 36 plus II Recreational Vehicle Generator Impact 34 plus II Sheet Metal Drawing No 0A9193 J 44 Generac Power Systems Inc 75 4 78 ...

Page 47: ... 7 FLAT WASHER 10 M5 44 0A1658 3 SPECIAL LOCK WASHER M6 45 0742600103 1 GROUND STRAP UNIT 47 047290 1 HOSE 3 8 I D x 11 1 2 LONG 48 092000 1 BRACKET MUFFLER HANGER 49 025425 2 STREET ELBOW 45 DEG 3 4 NPT 50 026490 1 PIPE NIPPLE 3 4 x 2 51 094670 2 U BOLT W SADDLE 2 NUTS 53 0912970071 1 STARTER CONTACTOR GROUND WIRE 54 089045 1 SEAL WASHER EXHAUST PIPE 55 0A2666 1 FUEL SOLENOID 12V DC 57 022145 2 5...

Page 48: ...46 Generac Power Systems Inc Section 6 Exploded Views and Parts Lists IMPACT 36 plus II Recreational Vehicle Generator Impact 36 plus Sheet Metal Drawing No 0A9194 H 67 66 42 59 39 ...

Page 49: ...SHER ITEM PART NO QTY DESCRIPTION 42 079246 2 HEX HD CAPSCR M6 1 0 x 16MM W LOCKWASHER 44 0A1658 3 SPECIAL LOCK WASHER M6 45 0742600103 1 GROUND STRAP UNIT 47 039450 1 1 8 x 3 16 NPT 90 DEG BARBED FITTING 48 092000 1 BRACKET MUFFLER HANGER 49 030340 1 1 4 FUEL LINE 8 LONG 50 082580D 1 3 16 CARBURETOR LINE 4 LONG 51 086311 1 FUEL FILTER 53 0912970071 1 STARTER CONTACTOR GROUND WIRE 54 089045 1 SEAL...

Page 50: ...48 Generac Power Systems Inc Section 6 Exploded Views and Parts Lists IMPACT 36 plus II Recreational Vehicle Generator GN 220 RV Long Block Drawing No 0A6202 F ...

Page 51: ...ER M6 1 00 X 12MM 28 0D2414 6 SCREW HHFC M8 1 25 X 35 30 0C3733 2 RETAINER VALVE SPRING 31 088401 2 SPRING VALVE 32 088590 1 DOWEL PIN DIA 12 X 18 LONG 33 083152 1 GEROTOR INNER 34 076381 2 BOLT CONNECTING ROD 36 021705B 1 ASSEMBLY CYLINDER HEAD WITH GUIDES SEATS 37 0C3590 1 VALVE EXHAUST 38 0C3591 1 VALVE INTAKE 39 088396A 2 PUSH ROD 40 083235 2 TAPPET 42 0C8754 1 GASKET VALVE COVER 43 077161 2 S...

Page 52: ...loded Views and Parts Lists IMPACT 36 plus II Recreational Vehicle Generator Generator Drawing No 0D4945 A 50 Generac Power Systems Inc 96 4 64 34 65 84 69 59 91 1 r 61 58 96 51 52 17 15 70 48 44 50 49 0 74 94 55 10 ...

Page 53: ...TAL HEATER 940 52 086736 1 LINKAGE CHOKE CONTROL 940 53 045756 3 M6 1 x 10MM TAPTITE ITEM PART NO QTY DESCRIPTION 54 083512 1 TAPTITE M8 1 25 x 16MM 55 097962 4 SHCS M6 1 0 x 25 LG 56 0912970005 1 OIL PRESSURE SWITCH WIRE 57 042907 3 HEX HD CAPSCR M8 1 25 x 16MM 58 022129 10 LOCK WASHER M8 59 074906 4 M6 1 x 20MM TAPTITE 60 0D5259 1 A C DECAL 940 0D5259A 1 A C DECAL 941 61 039253 3 HEX HD CAPSCR M...

Page 54: ...f 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 am...

Page 55: ...w 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 Facil...

Page 56: ...ty Generac RV generators manu factured after January 1 1998 have a transferable warranty to the second owner ONLY for the remainder of the three year limited war ranty Proof of purchase is required and must be presented to a Generac Authorized Warranty Service Dealer prior to the performance of any warranty service All warranty expense allowances are subject to the conditions defined in Generac s ...

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