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Generac 005796-0 (XG6500) Welding System User Manual

1. The slightest air flow and vacuum in the venturi throat should move the regulator valve off its seat and permit gas to flow 2 4 6 FUEL SUPPLY LINES Propane gas lines must be accessible but protect ed 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 sup ply lines The flexible line must be non metallic non organic and non conductive It must be approved for use with LP gas 2 4 7 EXCESS FLOW VALVE Propane gas tanks should have an excess flow valve according to 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 informa tion 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 2 4 8 LEAKAGE TESTS Do not place the generator into service until the gas system has been properly tested for leaks To test the system a separate source of 12 volts DC to open the gaseous fuel solenoid valve is needed
2. 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 replaced 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
3. GUARDIAN by Generac Power Systems Inc Manual and Installation Instructions Air cooled Recreational Vehicle Generator e Model No 00941 4 IMPACT 36 plus II with Inverter GUARDIAN Ke HOUR METER IMPACT plus Wi Service Locator 1 880 un gt O AS 4 HOURS A DAY STEMS INC I LM This manual should remain with the unit INTRODUCTION Thank you for purchasing this generator by Generac Power Systems Inc This model is designed and manufactured to supply electrical power for recre ational vehicles READ THIS MANUAL THOROUGHLY If any portion of this manualis not understood con tact the 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 CAUTION and NOTE blocks are used to alert per sonnel to special instructions about a particular operation that may be hazardous if performed incor rectly or carelessly Observe them carefully Their def initions are as follows A After this heading read instructions that if not strictly complied with will result in serious person al injury death or severe property damage WARNING amp After this heading read instructions that if not strictly complied with may result in personal injury or property damage caution amp After this heading
4. 221 2 L1 857 2T 2 2 C 6 2ET 13aIn83s 719101 v5 SS JN3LISV 4 ONILNNON 8n 119130 ONIINAON V02 v 0 06 L ZL STI 00v c 01 8S2 LLS v SvI LET 66 201 El 90 2 51 88 pe S761 pip 8 011 S42 8 61 208 4 1 108172 SSS 0 21 SOE J39NSO 12N3 SCISNI 39 71 1 WAWINIW 47 Generac Power Systems Inc Section 8 Warranty WARRANTY IMPACT 36 plus II Recreational Vehicle Generator 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 stan dards 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 improper main tenance 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
5. Maintenance ecce nenne 10 3 1 VETE nadal qd ox PM EDU 10 3 2 Checking the Engine Oil Level 2 2 treten 10 3 3 Change EnO ME naaa 10 o Change Ol Filter ROB EE 10 3 5 Encme Ar Cleaner narnia 11 3 6 Clean Alt Intake iio dias 11 or Pig essa 11 3 8 PP O 11 3 9 Cleaning the GeneratoL ainia lid 11 qe RTT NN 12 3 11 Service and Adjustments 12 9 12 Adj s ng the Carburetor msi cnn 12 Sdo Adjpusunp Valve misses 12 3 14 Major Service Manual 13 3 15 Exercising the Generator eee 13 3 16 Out ol Service Protection siria iria 13 3 17 Return Unit to Service After 13 Section 4 NOt8S occocccccnonaccnnnnnnnenananennnnanrnnnno rana nennen mnnn n 14 Table of Contents a CONTENTS Part 11 Installation Instructions cuv lmMeet ces su 16 Section 1 General Information 18 1 1 Purpose and Scope of the Manual 18 PEE A 18 1 3 Standards BOOK CS uni 18 1 4 Equipment Description o ococccnccccnccncnncncnnnncnnnnnnnnn 18 1 5 Engine Generator Operating 5 18 Section 2 Installation 19 2 1
6. To locate the nearest GENERAC AUTHORIZED SERVICE DEALER please call this number 1 800 333 1322 ONLY DEALER LOCATION INFORMATION CAN BE OBTAINED AT THIS NUMBER IMPACT 36 plus II Recreational Vehicle Generator Part Owner s Manual Introduccion Inside Front Cover Read This Manual Thoroughly IFC COMICAS sra IFC Operation and Maintenance eee IFC HOW to od pu IFC Authorized Service Dealer Locator Number IFC Safety RULES 2 Section 1 General Information 4 1 1 4 1 2 Generator Applicability rindi 6 L3 Mc cr 6 1 4 Generator Control Panel serrat 6 1 5 Enceme Protecuve Devices nia 7 Section 2 Operation iii 7 2 1 betore Startino the Engine aora iaa 7 2 2 Starts th Generator sisi 8 2 3 DOPPIE the Generator anida 8 2 4 Applying Loads to Generator 9 2 5 Attention Required After Submersion 9 2 6 Operation in High Grass or Brush 9 2 7 Operating PrecauliOHS sinti 9 2 8 Fuel Requirements LP Units unicos atlas 9 2 9 Engine Oil Requirements merindad 9 2 10 LP Generator Specifications 9 2 11 Engine SOCCIICAM ONG mera al 9 Section 3
7. 3 17 RETURN UNIT TO SERVICE AFTER STORAGE To return the unit to service after storage proceed as follows Check tag on engine for oil viscosity and classifica tion 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 up to at least 50 of the units rated wattage capacity When engine is thoroughly warmed up shut it down THE GENERATOR IS NOW READY FOR SERVICE Generac Power Systems Inc 13 NOTES Section 4 Notes IMPACT 36 plus II Recreational Vehicle Generator 14 Generac Power Systems Inc PART 1 INSTALLATION INSTRUCTIONS AFETY RULE vere Safety Rules IMPACT 36 plus II Recreational Vehicle Generator DANGER For fire safety installation of a generator into a recreational vehicle must comply strictly with NFPA 70 latest edition National Electrical Code Article 551 and NFPA 1192 latest edition Standard for Recreational Vehicles In addition installation must comply with the manufacturer s instructions and recommendations NOTICE TO INSTALLER These Installation Instructions have been published by Generac to aid in the
8. DRAWING NUMBER A6203 FLOOR FOR EXHAUSTAAND 469mnt 18 46 OYTLET THIS 1 OPTIONAL AIR INLET OPENING IN THE CUMPARTMENT FLOOR THE PREFERRED AIR INLET IS TO BE IN THE COMPARTMENT DOOR AIR INLET ALLOWS OUTSIDE AIR INTO S THE AIR FILTER AND PROVIDES GENERATOR C DLING A MINIMUM OF 26280mm 40 SQ IN I 1 1 1 1 1 438mmL17 24 i 1 1 I 93 0mmL3 68 ee Generac Power Systems Inc OF OPEN AREA MUST BE PROVIDED INTO THE COMPARTMENT 15 5mm 0 61 16mmL0 63 e58mn 10 16 MOUNTING HOLES 4 REQUIRED IMPACT 36 plus II Recreational Vehicle Generator 2 2 5 ACOUSTICS If excessive noise levels should become a problem the installer may wish to consider the following Using special sound insulating materials Construction of a special noise abatement com partment 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 levels Such a compartment might be constructed as follows Figure 2 8 Use 5 8 inch thick or 3 4 inch thick plywood in the compartment Construct the compartmen
9. 20 X 1 1 4 NUT HEX M8 1 25 WASHER LOCK M8 5 16 WASHER FLAT 5 16 M8 VIBRATION MOUNT CUSTOMER MOUNTING BRACKET SCREW HHC 8 1 25 X 35mm EARTHING STRAP PART NO QTY 092000 079246 086731A 094670 089680 086715 056892 089471 086724 086729 090518 022471 022264 089045 086711 049226 051716 0 9196 089049 049721 089047 0 9172 091526 084867 0A9031 050830 047290 007649 023484D 0E8245 PARTS ib ues O DESCRIPTION BRACKET MUFFLER HANGER SCREW HHC M6 1 0 X 16mm W LOCK WASHER ASSEMBLY MUFFLER CLAMP EXHAUST SCREEN SPARK ARREST HOUSING LOWER FAN SCREW CRIMPTITE 10 24 X 3 8 DEFLECTOR AIR OUT PLATE BASE COVER CONTACTOR STARTER BOOT CONTACTOR NUT HEX 8 32 WASHER LOCK 8 4 SEAL WASHER EXHAUST PIPE MODULE IGNITION WASHER LOCK M5 NUT HEX M5 0 8 COVER IGNITION BRACKET ASSEMBLY IGNITION COIL SCREW HHC M6 1 0 X 35mm SPACER IGNITION COIL BRACKET IGNITION SYSTEM SCREW PPHM M5 0 8 X 12mm RUBBER U CHANNEL WIRE ASSEMBLY BLOCKING DIODE SCREW HHC M5 0 8 X 40mm REGULATOR ASSEMBLY SEE E V OF1092 HOSE 3 8 I D x 11 LONG CLAMP HOSE 0 38 0 87 SNAP BUSHING BRACKET REGULATOR MOUNT Generac Power Systems Inc 41 i us Section 6 Exploded Views and Parts Lists 0 gt IMPACT 36 plus Il Recreational Vehicle Generator KO GN 220 RV Long Block Drawing No 0A6202 H 42 Generac Power Systems Inc Section 6 Exploded Views and Parts Lists
10. standards laws and regulations Adhere strictly to local state and federal electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has established Also ensure that the generator is installed in accor dance with the manufacturer s instructions and recommendations After proper installation do nothing that might alter the installation and render the unit in noncompliance with the aforemen tioned codes standards laws and regulations Keep fire extinguisher in the vehicle at all times Extinguishers rated by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical sys tem Keep the extinguisher properly charged and be familiar with its use If there are any questions pertaining to fire extinguishers consult the local fire department EXPLOSION HAZARDS Do not smoke around the generator Wipe off any fuel or oil spills immediately Ensure that no com bustible material is left in the generator compart ment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free of debris e All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and handling of fuels Inspect the unit s fuel system fre quently and correct any leaks immediately Before placing this equipment i
11. 4 1 FUEL PRIMER Before starting a cold engine if it has not been start ed in more than two weeks press this switch to bring fuel from the tank to the fuel carburetor This rocker type switch springs back into its original posi tion when released 1 4 2 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 1 4 3 FUSE Protects the engine DC control circuit against electri cal overload If the fuse element has melted open due to overloading the engine cannot be cranked If the fuse must be replaced use only an identical replace ment fuse 1 4 4 CIRCUIT BREAKERS Protects generator s AC output circuit against overload i e prevents unit from exceeding wattage amperage capacity OPERATION Section 2 Operation IMPACT 36 plus II Recreational Vehicle Generator 15 1 45 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 the generator set 1 5 ENGINE PROTECTIVE DEVICES This generator has a computer that monitors low oil pressure oil temperature engine speed and low voltage output This section discusses those protec tive devices 1 5 1 AUTOMATIC LOW OIL PRE
12. CG us IMPACT 36 plus II Recreational Vehicle Generator GN 220 RV Long Block Drawing No 0A6202 H O PART NO QTY DESCRIPTION 078621 1 ASSY CONNECTING ROD 076389 1 PISTON PIN 088411 1 PISTON RING SET 072657A 2 PLUG 1 4 NPTF PIPE 077176 1 COVER BREATHER 088057 1 PISTON DIA 75 076390 2 RING PIN RETAINER 083379A 1 ASSY C SHFT CCG TPR 089923 1 SPRTR OIL BREATHER 089213G 1 CRNKCASE SUBASY W PLUG GN220RV 0E3811 2 SEAL D 28 X 41 47 VITON OIL 090604 1 ASSY BREATHER CUP 078699B 3 SLEEVE SEAMED DOWEL 12 DIA 0A9878 1 CAMSHAFT ASSY 089096 1 GASKET C CASE 0A8822 1 GASKET CYL HEAD 078691 1 COVER OIL PRES RELIEF 0A5772 1 SPRING OIL RELIF 220 0A5776 1 BALL DIA 11 32 PRELF 074908 1 SCREW HHTT M5 0 8 X 10 BP 078606 4 SCREW amp LW 1 12 0D2414 6 SCREW HHFC 8 1 25 35 003733 2 RETAINER VALVE 004390 2 SPRING VALVE 088590 1 DOWEL DIA 12 X 18L 083152 1 GEROTER INNER 6 5 076381 2 BOLT CON ROD 021705B 1 ASSY CYL HD GDS amp STS 0C3590 1 VALVE EXHAUST 0C3591 1 VALVE INTAKE 0D9853A 2 PUSHROD 145 76 083235 2 TAPPET DIA 7 5 0C8754 1 GASKET VALVE COVER 077161 2 STUD PIVOT BALL 077160 2 ARM ROCKER GN191 076307 2 NUT JAM ROCKR ARM 088403 1 PLATE PUSHROD GUIDE 077168 5 HEADBOLT 8 56 088413 1 COVER ROCKER W OUT BREATHER 078629 2 GASKET BREATHER 090388 2 SCREW HHTT M6 1 0 X 12 YC 083153 1 GEROTER OUTER 6 5 092977 1 ASSY OIL SUMP 220RV 084186 2 WEAR WSHER VLV SPRNG 088156 1 SEAL VALVE STEM 6 0 072347 1 SPAR
13. LP REG ASSY GASKET SOLENOID INLET TWIN REGULATOR NO HOLE PLUG EXPANSION 16MM TWINREG BARBED ELBOW 90 1 2 NPT X 3 8 HOSE PLUG 1 8 NPTF PIPE WASHER FLAT 3 2MM ID X 10MM OD SCREW PFILHM M3 0 5 X 5 46 Generac Power Systems Inc Section 6 Exploded Views and Parts Lists IMPACT 36 plus II Recreational Vehicle Generator LP Regulator Drawing No 0F1092 A 0C5764A 0C4643A 0C6066 0C5968 0C5759 0C5761 0C6069 0C6731 0C6067 0C4706 0C6068 0C5762 045764 025425 0E4170 0C5760 1 1 1 1 1 1 1 1 1 1 1 1 8 1 1 1 DESCRIPTION PART NO QTY SPRING REGULATOR 45N M 29MM INLET TWIN REG 11 11 DIA SEAL INLET REGULATOR SUPPORT INLET SEAL PIN PIVOT ARM LEVER REGULATOR GASKET DIAPHRAGM RIVET 118 X 125 ALUMINUM SUPPORT DIAPHRAGM DIAPHRAGM TWIN REGULATOR CAP DIAPHRAGM SUPPORT COVER TWIN REGULATOR SCREW M4 0 7 X 8 BP ELBOW 45D STREET 3 4 NPT CONNECTION 3 4 NPT 3 8 45D JET LP GN220 ENGINE INSTALLATION Section 7 Installation Diagram IMPACT 36 plus Il Recreational Vehicle Generator Major Features and D No 0F1119 ing Draw mensions 13 11NO0 LSAVHXS 901 Le LZ 1 8 auivin93s d 1 9 91 Ter S3HINI JWW NI SNUISNGNWIG 119 18 LST 85 x 1 019 Sc 4 1 2 LSTI 66 L60 2 13 1NI 1313 d ASLASANI 30 SONS NO MO 1391 903 8 AVSLVWIXOddd MOTIV L 8v1
14. Location and SUP POLL b dated 19 2 2 Generator Compartments 20 2 9 Cooling and Ventilating Air eese 23 2 4 Propane Gas Fuel System espadas 25 2 9 Exhaust SyS LOI sunrise 27 2 6 Electrical Connections 28 2 7 Battery 31 2 8 Optional ACCESSOTIES NNUS 32 Section 3 Post installation Startup Checks 33 3 1 Post Installation TESES aiii 33 3 2 Belore Initial Startup 33 3 3 Indtial UAEU o redacta 33 3 4 Testing Under Load eee 33 3 5 Installation Checklist 34 Section 4 Troubleshooting 35 4 1 Troubleshootine Guide 35 Section 5 Electrical 36 Section 6 Exploded Views and Parts Lists 38 Section 7 Installation Diagram 47 Section 8 Wa 48 Generac Power Systems Inc 1 AFETY RULE vere Safety Rules IMPACT 36 plus II Recreational Vehicle Generator SAVE THESE INSTRUCTIONS The manufacturer suggests that these rules for safe A WARNING A The engine exhaust from this product contains chemicals known to the state of California to cause cancer b
15. NUT WIRE HARNESS HEATSINK TO PCBI WIRE HARNESS HARNESS PCBI TO PANEL NOT SHOWN FOR CLARITY HARNESS HEATSINK TO TERM BLOCK NOT SHOWN FOR CLARITY HARNESS CONTROL PANEL NOT SHOWN FOR CLARITY Generac Power Systems Inc LISTS OG 39 Section 6 Exploded Views and Parts Lists IMPACT 36 plus Il Recreational Vehicle Generator Sheet Metal Drawing No 0F1091 40 Generac Power Systems Inc CONDOR WD PART NO QTY 086705 049813 022097 0A1658 086718 0 3666 056893 0 3638 074908 090141 0 8475 003296 086727 086671 086726 023897 038353 022127 0912970071 0742600103 090537 089048 086719 0A3667 0 7213 079119 045771 022129 022145 066443 0 3764 039414 020668 gt Vor Section 6 Exploded Views and Parts Lists IMPACT 36 plus II Recreational Vehicle Generator Sheet Metal Drawing No 0 1091 DESCRIPTION PLATE DIVIDER NUT HEX M6 X 1 0 WASHER LOCK M6 1 4 WASHER LOCK SPECIAL 1 4 SEAL RUBBER EXTRUSION WRAPPER BOX SCREW CRIMPTITE 10 24 X 1 2 PANEL WRAPPER BOX SCREW M5 0 8 X 10mm STRAP EATON GROUND SPECIAL LOCK WASHER 10 FRAME ASSEMBLY SKIRT SPARK PLUG SIDE COVER ROCKER COVER SKIRT CARB BAFFLE WASHER FLAT 10 VIBRATION MOUNT NUT HEX 1 4 20 STARTER CONTACTOR GROUND WIRE GROUND STRAP UNIT RETAINER SEAL OIL SEAL OIL FILTER HOLE PAN BELLY MOUNTING BRACKET TAG BOLT REMOVAL SCREW HHTT 1 4
16. OR CONSEQUENTIAL DAMAGES EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC S NEGLIGENCE Some states do not allow the exclusion or limitation of incidental or conse quential damages so the above limitation may not apply to you This warranty gives you specific legal rights You also have other rights from state to state GENERAC POWER SYSTEMS INC BOX 297 WHITEWATER WI 53190 Revision 2 04 Part No OF1117 Revision B 11 15 04 Printed in U S A
17. 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 engine is found to be defective in materials or work manship 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 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 or 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
18. are positioned OPTIONAL ACCESSORIES Check that remote start stop panels if used are installed properly Check that all other options and accessories if used are installed properly POST INSTALLATION TESTS Q Check that all tests are completed properly Section 4 Troubleshooting IMPACT 36 plus II Recreational Vehicle Generator 4 1 TROUBLESHOOTING GUIDE PROBLEM Engine won crank Engine cranks but won t start low full load power Engine starts hard runs rough Engine starts shuts down when Start Stop switch is released Start Stop switch at Stop engine continues to run No output from generator CAUSE 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 opark plug defective Loose spark plug boot m PPT 1 Air cleaner plugged or damaged 2 Defective spark plug Engine oil is low Engine is overheated Defective Low Oil Pressure System Defective Control Board Defective Computer Control Board py EU Po e 1 Defective Start Stop switch 2 Open disconnected wire 18 between Start Stop switch and Control Open disconnected wire 0 between Start Stop swit
19. 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 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 whil
20. double thickness of plywood for added strength e All seams splices and joints of the compartment walls unless 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 SIL ICONE RUBBER SEALANT IS RECOMMENDED Holes and openings through the compartment walls for passage of electrical conduit conductors etc into vehicle living area must be sealed vapor tight with silicone rubber base sealant e If using 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 e 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 2 4 Figure 2 4 Types of Lock Seams A ACME LOCK FOLD LOCKED STANDING OFF SET DOUBLE LOCK DOUBLE SEAM GORDON SEAM LOCK SEAM STANDARD LAP JOINT eo Generac Power Systems Inc IMPACT 36 plus II Recreational Vehicle Generator 2 2 1 COMPARTMENT SIZE Plan the compartment size carefully Provide a mini mum of at least 1 inch 2 recommended of clear ance between the generat
21. feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle have the gen erator properly grounded bonded either by solid mounting to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT disconnect the bonding conductor if so equipped DO NOT reconnect the bonding conduc tor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum In case of an accident caused by electric shock immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a nonconduct ing implement such as a dry rope or board to free the victim from the live conductor If the victim 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 amp FIRE HAZARDS A 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
22. filter into cover and assemble to the base of the air cleaner 3 6 CLEAN AIR INTAKE SCREEN Clean all foreign material from 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 Air Intake Screen GUARDIAN KG IMPACT plus 1 000 333 1322 cora cam d eaten co Ki Service Locat wee cua Sanger 2 START FUEL STOP PRIME MAINTENANCE 2D Section 3 Maintenance 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 or wire brushing and washing with commercial solvent DO NOT BLAST CLEAN SPARK PLUG Figure 3 5 Setting Gap on Spark Plug SET PLUG GAP AT 0 030 inch 0 76 mm cauroN amp Sparking can occur if wire terminal does not fit firmly over spark plug terminal end If nec essary reform wire terminal to obtain a tight fit 3 8 INVERTER All repairs of the inverter must be handled by an authorized service dealer see Figure 3 7 Figure 3 7 Inverter Warning Label AN WARNING h HIGH VOLTAGE UNIT TO BE SERVICED ONLY BY AN AUTHORIZED GENERAC SERVICE DEALER ALLOW 2 MINUTES FOR UNIT TO POWER DOWN BEFORE OPEN
23. min utes with loads applied 6 Turn off all electrical loads by setting the genera tor main circuit breaker to OFF or OPEN 7 Let the unit run at no load for a few minutes to stabilize internal engine generator temperatures Then shut down the engine IMPORTANT THE GENERATOR SET WAS THOR OUGHLY TESTED AND ADJUSTED AT THE FAC TORY BEFORE SHIPPING NO ADDITIONAL ADJUSTMENT SHOULD BE NECESSARY ONLY QUALIFIED SERVICE TECHNICIANS WHO HAVE BEEN TRAINED SHOULD PERFORM ADJUST MENTS OUTLINED IN THIS MANUAL 3 4 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 Do not allow the unit to overheat during prolonged operation NOTE The generator engine is equipped with a high tem perature switch The switch has normally open N O contacts When the temperature is too high switch contacts close and engine shuts down automatically IMPORTANT GENERAC RECOMMENDS THAT THE GENERATOR IS TESTED FOR ADEQUATE COOLING Generac Power Systems Inc 33 POST CED INSTALLATI N START UP ADJUSTMENTS 3 5 INSTALLATION CHECKLIST LOCATION AND SUPPORT Generator is properly located Generator is properly supported Generator is properly restrained G
24. read instructions that if not strictly complied with could result in damage to equipment and or property NOTE After this heading read explanatory statements that require special emphasis These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compli ance with the special instructions while performing the service are essential for preventing accidents Four commonly used safety symbols accompany the DANGER WARNING and CAUTION blocks Here are the types of information indicated by each symbol A This symbol points out important safety infor mation that if not followed could endanger personal safety and or property to self and oth ers This symbol points out potential explosion haz ard This symbol points out potential fire hazard A This symbol points out potential electrical shock hazard Generac Power Systems Inc The operator i e the driver is responsible for the proper and safe use 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 This manual contains pertinent owner s information including warranty e
25. 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 not 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 co
26. sufficient room to allow minimum 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 2 1 2 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 framework 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 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 method is to suspend the generator below the horizontal support tubing by means of suit able structurally sound metal framework The fol lowing general rules apply Vehicle construction MUST be capable of support ing the weight of the generator Whether the generator is mounted above the hori zontal support tubing or suspended below the tub ing the supporting frame used must be structural ly soun
27. 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 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 e 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 e Exhaust piping must be large enough to prevent excessive back pressure on the generator engine 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 Plan exhaust system installation carefully Comply with all applicable codes standards and regula tions 2 6 ELECTRICAL CONNECTIONS The following general rules apply to electrical con nections in a recreational vehicle e Qualified electricians who are familiar with applic able codes standards and regulations should install electrical wiring e The wiring should comply with co
28. torque After tight ening the jam nut recheck valve clearance to make sure it did not change Figure 3 9 re 3 9 Nut SN Tighten Jam Nut to 65 85 inch pounds 7 10 N m 3 14 MAJOR SERVICE MANUAL To obtain a service manual for the generator order it from the dealer distributor Be sure to identify the units MODEL NUMBER and SERIAL NUMBER 3 15 EXERCISING THE GENERATOR Generac recommends that the generator is started and operated at least once every seven days Let the unit run for at least 30 minutes to exercise the engine MAINTENANCE LD Section 3 Maintenance 3 16 OUT OF SERVICE PROTECTION If the generator cannot be exercised every seven days and it is to be out of service longer than 30 days pre pare the generator for storage as follows e 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 e 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 e Clean and wipe the entire generator
29. 3B 0912970025 0A6470 091269A 023484D 082121A 051713 025105 084867 051718 001457 036933 0A6423C 029333A 023762 0D4885 051714 0A6464 0D4884 0D4882 0A6700 0A9183 QTY oot ss c a E E EA al A o fo KS Section 6 Exploded Views and Parts Lists ca IMPACT 36 plus II Recreational Vehicle Generator Control Panel Drawing No 0E7560 DESCRIPTION M5 0 8 X 12MM PHILLIPS PAN HD MACH SCR BOX CONTROL TOP BOX CONTROL PANEL SCREW PPHM M5 0 8 X 20 M5 0 8 HEX NUT TAPTITE M5 8 X 10MM SNAP BUSHING CIRCUIT BREAKER 15 LOCK WASHER M5 M4 0 7 X 16MM M4 0 7 HEX NUT M4 FLAT WASHER M5 FLAT WASHER CONTROL PANEL FRONT RUBBER GROMMET SWITCH SPDT ROCKER SWITCH SPDTMOM 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 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 WASHER FLAT M5 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 M3 0 5
30. 6 plus II Recreational Vehicle Generator ELECTRICAL Wiring Diagram and Schematic Drawing No 0D4947 B DATA A CUSTOMER P REMOTE PANEL 13 J3 0 0 BLK 85 vid th 85 I BLK A ST Swi GENERATOR CONTRO 15 bu ouo o L 56 DK 2200 0 15 RED Le J2 TC 1 BLK M vm s T T RED p O j GRN _ 1l RED BLK ib O BLU ORG se TL 7 BLK YEL RED e DC 0 BUS ew 8 INVERTER CONTROL CCCCCCC y ee quA Ig do lI CHASSIS INVERTER NEUTRAL CONNECTION OMER BY CUSTOME 11 0 CUSTOMER GREEN BLACK AC CONNECTION ENGINE GENERATOR Generac Power Systems Inc 37 Ce dee Section 6 Exploded Views and Parts Lists UP IMPACT 36 plus II Recreational Vehicle Generator 0 Control Panel Drawing No 0E7560 M 38 Generac Power Systems Inc CONDOR WD PART NO 091526 020093 0E7556 075477 051716 074908 023484M 0 8592 049226 075476 051715 022985 023897 0 7557 030809 087798 092113 0 9611 032300 0 6422 065795 022264 0 7555 096874 0A6060 043181 043182 089744 0A6423A 045756 086722 0752104 0A642
31. CKOFF SOLENOID VAPOR WIDTHDRAWAL TANK Use only approved components the gas supply system All components must be prop erly installed in accordance with applicable codes Improper installation or use of unau thorized 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 Generac Power Systems Inc 25 INSTALLATION 1113 Section 2 Installation 2 4 2 SOME IMPORTANT CONSIDERATIONS When installing an LP gas system consider seriously the following items e 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 leakage 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 connector to attach to the fuel supply line e Use a length of approved flexible fuel hose between gaseous fuel solenoid valve and rigid gas piping The flexible line should be at least six 6 inches longer than necessary 2 4 3 VAPOR WITHDRAWAL Liquid propane LP gas is st
32. CT 36 plus II Recreational Vehicle Generator 2 6 6 SENSING HARNESS A sensing harness has been provided with the gener ator to connect to the inverter Figure 2 22 It is 12 feet long however it is also available in a 24 foot length Model 04612 0 The four 4 DC power wires Red Blue Black and Green may be cut to the desired length to meet the installation see Figure 2 22 caution amp DO NOT in any way cut or shorten the sensing harness If the harness is too long simply tie the excess up neatly with standard cable ties 2 7 BATTERY INSTALLATION 2 7 1 RECOMMENDED BATTERY Install a battery that meets the following require ments Battery must be a 12 volt automotive type storage battery INSTALLATION TED Section 2 Installation e For prevailing ambient temperatures above 32 F 0 use a battery rated 70 amp hours and capa ble of delivering 400 cold cranking amperes e For prevailing ambient temperatures below 32 F 0 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 A BATTERY WITH A LARGER CAPACITY MAY BE NEEDED 4 2 7 2 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 batter
33. E BRIDGE RECTIFIER IS IGNITION SENSOR Bom ud CUSTUMER SUPPLIED m LUP SWITCH LOW OIL BATTERY CIRCUIT BREAKER 10 2 POLE CLOSES ON LOW PRESSURE CHOKE COIL M STEPPER MOTOR THROTTLE CONTROL CH CHOKE HEATER PCB1 CONTROL CIRCUIT BOARD F1 FUSE RI 1 OHM 50 WATTS FP FUEL PUMP UN GASOLINE SC STARTER CONTACTOR SHUT OFF VALVE ON L P STARTER MOTOR sc INV INVERTER wi SWITCH START STOP HM HOUR METER SW2 SWITCH FUEL PUMP PRIME 1116 SWITCH HIGH TEMPERATURE DIL SPI SPARK PLUG CCLUSES UN HIGH TEMPERATURE LUG BARREL IC IGNITION COIL TERMINAL CONNECTOR 4 TAB TB TERMINAL BLOCK Fi swe 14A REMOTE 15 PANEL CONNECTOR 15 2 tY o 0 90 7 4 66 BATTERY CHARGE WINDING 77 55 nid SL 1 POWER WINDING Ace TIMING POWER SUPPLY TIMI PS AN AC TIM2 REMOTE PANEL C gt i BLK 1 ji A o y Je fo E LLLI 2 lt lt SHIELD 31 8 7 SENSE OS O IS 6 LLLILL L L 2 FANS ES 4 UMS ELL LHLHLLEI L L L e ER 1 _ A 2 8 5 85 2 17 WHITE B T2 E SE 14 120V CUSTOMER AC CONNECTION 36 Generac Power Systems Inc Section 5 Electrical Data IMPACT 3
34. ENERATOR COMPARTMENT Compartment construction is proper Holes Openings are vapor sealed Compartment size is correct Compartment is vapor sealed Sound insulation is correct Floor cutouts are properly completed COOLING AND VENTILATING AIR U Airflow is adequate Air inlet opening is correct Compensate for restrictions Check that installation has been tested DIESEL FUEL SYSTEM Fuel tank complies with all applicable codes Fuel system is properly installed and checked for leaks DATE OF INSTALLATION NAME OF INSTALLER SIGNATURE OF INSTALLER 34 Generac Power Systems Inc Section 3 Post installation Start up Checks IMPACT 36 plus II Recreational Vehicle Generator EXHAUST SYSTEM Exhaust system complies with all applicable codes Exhaust system 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 installed Cables are clean and tight Cables are connected properly Proper ventilation is provided Terminals are coated with anti corrosion grease and terminal covers
35. ENERATOR RESTRAINT Use four 5 16 18 hardened steel bolts Grade 5 to fasten the generator to the supporting frame or the support tubing These bolts must pass through a the generator mounting base b the compartment floor if a compartment is used and c the support ing framework Figure 2 3 All bolts must be long enough so that when tight at least 3 threads are vis ible past the retaining lock nuts Refer to COM PARTMENT section for location of generator mount ing holes Figure 2 3 Typical Generator Restraint METAL LINED 1 2 INCH THICK BASE PLYWOOD TUBULAR METAL SUPPORT FRAME VEHICLE METAL LINED CHASSIS BOTTOM 2 2 GENERATOR COMPARTMENTS The generator set may or may not be installed inside a compartment that is constructed specifically for housing a generator This section applies to generator compartments when they are installed The following general rules apply to compartments IMPACT 36 plus II Recreational Vehicle Generator The generator compartment should be either con structed 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 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
36. ING TO REDUCE RISK OF INJURY OR ELECTROCUTION 3 9 CLEANING THE GENERATOR Keep the 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 windings will be retained in voids and cracks of the windings 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 elec trical conductor Generac Power Systems Inc 11 MAINTENANCE LD Section 3 Maintenance amp Do use a forceful spray of water to clean the generator Water will enter the generator interior and cause problems and may also contaminate the generator fuel system 3 10 BATTERY All lead acid storage batteries will discharge when not in use Inspect the generator battery as follows 3 10 1 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 3 10 2 EVERY SIX MONTHS Have the battery state of charge and condition checked by an automotive service facility This should be done with an automot
37. ITCH GROUND WIRE PRESSURE SWITCH TEMP SWITCH WIRE OIL PRESSURE SWITCH WIRE SCREW SHC M6 1 0 X 25mm WASHER LOCK M6 1 4 GASKET OIL DRAIN PLUG SCREW HHC 12 1 75 X 20mm SWITCH THERMAL OIL TEMP WASHER LOCK M3 SCREW PPHM M3 0 5 X 8mm GASKET CARBURETOR SPACER HEAD CARBURETOR SPACER SKIRT BAFFLE GASKET CARBURETOR SKIRT CARBURETOR ASSEMBLY GASKET CARBURETOR INLET ADAPTOR ADAPTOR CARBURETOR INLET PPHMS M6 1 X 90mm LONG HOSE CLAMP BAND 20 HOSE CARBURETOR INLET O RING 562 I D OIL FILL TUBE O RING 1 062 I D ASSEMBLY OIL FILL CAP amp DIPSTICK WASHER LOCK M5 SCREW CRIMPTITE 10 24 X 1 2 RUBBER MOUNTS SCREW HHTT 3 8 16 X 3 4 BRACKET ENGINE MOUNT FRONT BRACKET ENGINE MOUNT REAR SPACER ENGINE MOUNT WASHER LOCK 3 8 SCREW HHC 3 8 16 X 1 1 4 PART NO QTY 086705 090192 089477 086706 089478 078609 086674 078601 059635 090613 089062A 086673 090021 049815 023897 087993 090536 094665 045756 042907 022129 093859 074908 055822 022264 086697 086692 0A5892 080934 066449C 0D4883 074906 0912970004 0A8475 096627 039253 082774 092800 088905 083512 059636 0D4408 022145 0912970002 092059 049821 5 g00 6 po Ph Aa PO PO OO Po a po PARTS Rags O DESCRIPTION PLATE DIVIDER WASHER CARBURETOR CLIP ADJUSTMENT ROD THRO
38. K PLUG 00940 ONLY 0E7585 1 SPARK PLUG 00941 ONLY 099922 1 WASHER SPRING Generac Power Systems Inc 43 an Section 6 Exploded Views and Parts Lists LISTS IMPACT 36 plus II Recreational Vehicle Generator 0 Generator Drawing No 0F1134 60 4 68 gt a 1 69 70 71 72 TAZA ap 1 6 11111 64 12 79 o S Yes a _ Y 44 Generac Power Systems Inc gt PART NO QTY 0 2467 094583 083312 081810 070185B 086730 089476 040976 0D2446 087478 086714 0 8584 0912970071 0912970003 0912970005 097962 022097 002908 052617 094090 043182 001085 090051 086708 086726 078631 0 2774 096459 086709 089050 035586 0F1225 090072 094637 090071 089263 049226 056893 038353 059637 086701 086702 086704 022237 022511 lo cl cl po a O BR SS SS SS S po pono O Bw A PO PO Section 6 Exploded Views and Parts Lists IMPACT 36 plus II Recreational Vehicle Generator Generator Drawing No 0F1134 DESCRIPTION ENGINE LONG BLOCK FLYWHEEL FAN WASHER CONICAL NUT HEX M16 1 5 FILTER OIL TUBE EXHAUST OUTLET GASKET EXHAUST SCREW SHC M8 1 25 X 20mm ADAPTOR OIL FILTER GASKET OIL FILTER ADAPTOR SCREEN OIL PICK UP 10 PSI OIL PRESSURE SW
39. LL mark 2 Check the fuel supply Gas fuel lines must have been properly purged and leak tested in accor dance with applicable fuel codes All fuel shutoff valves in the fuel supply lines must be open A If an LP propane gas fuel system has been installed it must have been properly tested for leaks before operating the system in com pliance with ANSI A119 2 NFPA 501C No leak age is permitted Be sure no gaseous fuel vapors enter the vehicle interior 3 3 INITIAL START When absolutely certain that the unit has been prop erly 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 CHECKS 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 Section 3 4 Run the unit at least 30
40. N 1 2 GENERATOR APPLICABILITY These generators have been designed and manufac tured for supplying electrical power for recreational vehicles Do 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 advised by a competent authority EX For fire safety the generator must have been properly installed in compliance with 1 ANSI 119 2 1975 501C 1974 Standard for Recreational Vehicles Part Ill Installation of Electrical Systems The generator also must have been installed in strict compliance with the manufacturer 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 004885 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 of the inverter must be handled by an authorized service dealer see Page 12 in Maintenance Use this generator to supply electrical power for operating 120 volts single phase 60 Hertz electrical loads These loads can require up to 3400 watts 3 4 kW for the Impact 36 plus II The maximum current at 120 volts is 28 3 amperes for the Impact 36 plu
41. 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 isolation recepta cle Connecting to a transfer switch or isolation receptacle must prevent vehicle electrical circuits from being connected to two different power sup plies at the same time such as generator and dockside power e Conductors must be rated 221 F 105 C or must be of a larger conductor size 2 6 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 19 The unit is provided with a ground which is connected to the generator and should be connected to the chassis of the recreational vehicle INSTALLATION Section 2 Installation Figure 2 19 Inverter J Box for AC Output WIRES PROVIDED BY OWNER 120 CHASSIS GROUND Circuit breaker protection is provided on the genera tor and protects the unit against overload Do not apply loads which exceed the rated wattage or amperage 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 sh
42. O NOT TEE THE GENERATOR LINE INTO A GAS CIRCUIT FEEDING OTHER APPLIANCES 2 4 5 GASEOUS CARBURETION LP gas vapors should be supplied to the generator regulator inlet at about 11 inches water column pos itive pressure The engine piston draws air in during the intake stroke Figure 2 16 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 ven turi the lower the pressure at the venturi throat the greater the diaphragm movement and the greater the movement of the regulator valve The more the regu lator valve opens the greater the gas flow that is pro portional to air flow through the carburetor The following facts about the secondary regulator must be emphasized Figure 2 16 Propane Gas Carburetion Diagram P ji gt n n li 4 26 Generac Power Systems Inc ay E IMPACT 36 plus II Recreational Vehicle Generator 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
43. SSURE 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 down by itself and the fuel tank has enough fuel check the engine oil level gt 1 5 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 gt 1 5 1 2 Sensing low pressure If the system senses low oil pressure during opera tion the engine shuts down If the engine has not been restarted after a low oil pressure shutdown and the low oil level has not been corrected the engine runs for about 10 seconds as described above then stops 1 5 2 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 1 5 3 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 4 Do not attempt to physically adjust or control the engine speed Equipment damage or per sonal injury may result 1 5 4 LOW VOLTAGE The computer monitors the voltage output of the gen erator If voltag
44. TTLE CONTROL SNAP RETAINING BOLT AIR CLEANER COVER COVER AIR BOX ELEMENT AIR FILTER PLASTITE SC 8 X 0 37 COVER BREATHER CANAL HOSE BREATHER BASE AIR BOX BRACKET AIR CLEANER SUPPORT SCREW HHC M5 0 8 X 16mm WASHER FLAT 10 ELBOW AIR CLEANER OUTLET GASKET AIR CLEANER OUTLET HOUSING FAN UPPER SCREW M6 1 0 X 10mm SCREW HHC 8 1 25 X 16mm WASHER LOCK 8 5 16 FAN GENERATOR SCREW 5 0 8 X 10mm SCREW PHM M4 0 7 X 8mm WASHER LOCK 8 M4 ASSEMBLY IGNITION SENSOR ADAPTOR STATOR ASSEMBLY MAGNET HOUSING RETAINING RING STATOR BOLT M6 1 0 X 80mm LONG ASSEMBLY STATOR SCREW HHTT M6 1 0 X 20mm TEMP SWITCH GROUND WIRE LOCK WASH SPECIAL 10 BRACKET STARTER SIDE ENGINE MNT SCREW HHC 8 1 25 X 20mm WOODRUFF KEY 4 x 19MM WRAPPER ENGINE TOP EXTENSION SPRING SCREW HHTT M8 1 2 X 16mm SCREW PPPH 4 X 0 37 STARTER MOTOR WASHER FLAT 5 16 8 STARTER WIRE STEPPER MOTOR SPEED CONTROL SCREW SHC M8 1 25 X 30mm Generac Power Systems Inc 45 age ITEM OND 4 CO n2 h 12 13 14 LISTS PART NO QTY 0D5694 075475 022264 043180 0F3154 006070 004680 004647 004643 0D3973 0D7023 072683A 0D3308 070728 1 cl cl cl cl qe Ps a 2 3 5 4 Ss id Coens DESCRIPTION CASTING TWIN REGULATOR HOUSING SCREW PPHM M4 0 7 X 10 WASHER LOCK 8 M4 WASHER FLAT M4 SOLENOID COIL 12VDC SPRING SOLENOID PLUNGER PLUNGER
45. The leak test must comply fully with NFPA Paragraph 318 All connections hoses valves regu lators 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 equiva lent solution to check for leaks Other approved methods of testing for leaks may be used if appro priate DO NOT USE ANY FLAME TO TEST FOR LEAKS INSTALLATION Section 2 Installation PIG A 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 however is a negative pressure about 1 inch water column and can draw flame inside a line or fitting and cause an explosion 2 5 EXHAUST SYSTEM The generator exhaust system must be safely and properly installed Only approved mufflers and other exhaust system parts must be used A properly installed exhaust system must be vapor tight quiet and completely safe caution amp Never tee the generator engine exhaust pipe into the vehicle engine exhaust piping This causes excessive back pressure on the genera tor engine Also water from one engine can damage the other engine NE The generator engine gives off deadly carbon A monoxide gas through its exhaust system This dangerous gas if breathed sufficient concentrations can cause unconsciousn
46. W 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 10 LP GENERATOR SPECIFICATIONS Model saca e Impact 36LPG plus Rated Maximum Continuous AC Power Output stands 3400 watts 3 4 kW Rated Voltage escisiones 120 volts AC Rated Maximum Continuous Current at 120 Vol Susi a 28 3 AC amperes D Single Phase ia 60 2 Recommended Battery Cranking Current miis 400 amps Gross WEI a 99 lbs Maximum Cranking 250 Amps Maximum Charging 2 Amps 2 11 ENGINE SPECIFICATIONS Typeof ENGINE a n eer rr errr tr errr GN 220 Cooling Method Air cooled DiS praia tidad 220cc AY DE Ol GOVERNOR a Electronic Lone moms Paper element e Be t ud T ADM 12 volt DC electric ici bc Solid state Recommended Spark Plugs Champion RC14YC Spark PIT Gap id 0 030 inch 0 8mm Generac Power Systems Inc 9 MAINTENANCE LD Section 3 Maintenance 3 1 MAINTENANCE This section includes information about simple maintenance which includes the following tasks Checking engine oil
47. ailure to isolate the vehicle s circuits from the dockside power supply when the generator is run ning may result in damage to the generator or in serious injury or death to dockside utility power workers due to backfeed of electrical energy In case of an accident caused by electric shock immediately shut down the source of electrical power If this is not possible attempt to free the victim from the live conductor AVOID DIRECT CONTACT WITH THE VICTIM Use a noncon ducting implement such as a rope or board to free the victim from the live conductor If the vic tim is unconscious apply first aid and get immediate medical help e 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 e For fire safety the generator must be installed and maintained properly Installation always must comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations the Occupational Safety and Health Administration OSHA has estab lished Also ensure that the generator is installed in accordance with the manufacturer s instructions and recommendations Following proper installation do nothing that might alter a safe installation and render the unit in noncom pliance with the aforementioned codes stan d
48. ards laws and regulations e Keep a fire extinguisher in the vehicle at all times Extinguishers rated ABC by the National Fire Protection Association are appropriate for use on the recreational vehicle generator electrical system Keep the extinguisher properly charged and be familiar with its use If there are any questions per taining to fire extinguishers consult the local fire department EXPLOSION HAZARDS 4 Do not smoke around the generator Wipe up any fuel or oil spills immediately Ensure that no com bustible materials are left in the generator com partment or on or near the generator as FIRE or EXPLOSION may result Keep the area surround ing the generator clean and free from debris All fuel types are potentially FLAMMABLE and or EXPLOSIVE and should be handled with care Comply with all laws regulating the storage and han dling of fuels Fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes before placing this equipment into service There must be no possibility of fuel vapors enter ing the vehicle interior It is required to install an approved flexible non conductive fuel line between the generator fuel con nection point and the rigid fuel lines Generac Power Systems Inc 17 1 1 PURPOSE AND SCOPE OF THE MANUAL These Installation Instructions have been prepared especially for the purpose of familiarizing installers and owners o
49. ational Vehicle Generator ZA ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages that can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Ensure all appropriate covers guards and barri ers are in place before operating the generator If work must be done around an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or feet are wet DANGEROUS ELECTRICAL SHOCK MAY RESULT During installation onto the vehicle properly ground bond the generator either by solid mount ing to the vehicle frame or chassis or by means of an approved bonding conductor DO NOT connect the bonding conductor to any generator part that might be removed or disassembled during routine maintenance If the grounding conductor must be replaced use only a flexible conductor that is of No 8 American Wire Gauge AWG copper wire minimum e 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 s circuits at the same time The dockside utility power source must be positively isolated from the vehicle s circuits whenever the generator is operat ing F
50. ator tem peratures 3 Hold Start Stop switch in its STOP position OPERATION Section 2 Operation IMPACT 36 plus II Recreational Vehicle Generator 15 2 4 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 e DO NOT overload the generator 2 4 1 LETTING ENGINE STABILIZE The generator supplies correctly rated frequency and voltage only at the proper governed speed Some elec trical appliances may be extremely sensitive to volt age and frequency Incorrect frequencies and or volt ages 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 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 authorized Generac Service Facility thoroughly clean and dry the generator 2 6 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 extreme
51. ce should be allowed at each end of the inverter for adequate ven tilation IT SHOULD NOT BE LOCATED IN THE SAME COMPARTMENT AS THE GENERATOR 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 SUPPLIED sensing harnesses The DC power wires may be cut to the required length Allow enough length to make connection Coil excess inside J Box 2 3 5 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 the unit shows signs of overheating enlarge the air openings Never place a unit into service until absolutely certain that cooling and ventilation is adequate IMPORTANT TEST THE INSTALLATION ESPE CIALLY IF BRINGING IN AIR FROM BELOW THE GENERATOR SET INSTALLATION Section 2 Installation 2 4 PROPANE GAS FUEL SYSTEM 2 4 1 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 and e primary regulator used to store the gaseous fuel and deliver it to the gaseous fuel sole noid Figure 2 15 Figure 2 15 Diagram of LP Gas System CARBURETOR d D PRIMARY 0 ni LO
52. ch amp Control Bd 4 Defective Control Board Check circuit breaker Check vehicle circuit breaker amp fuses Transfer sw set to NORMAL position Generator internal failure Bua ES A 5 Inverter defective TROUBLESHOOTING CORRECTION aO sw een eps ooo Dye p c Bopp 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 Clean 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 Generac Power Systems Inc 35 Section 5 Electrical Data IMPACT 36 plus Il Recreational Vehicle Generator ELECTRICAL a gt Wiring Diagram and Schematic Drawing No 004947 A LEGEND BCR BATTERY CHARGE RECTIFIER IND INDUCTOR ASSEMBLY BRIDGE RECTIFIER IM IGNITION MODUL
53. creational Vehicle Generator When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Inspect the generator regularly and contact the nearest Generac Authorized Service Dealer imme diately for parts needing repair or replacement Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental startup First disconnect the cable from the battery post indicated by a NEGATIVE NEG or Reconnect this cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts resulting in dangerous operating conditions due to leaking exhaust gases fuel leakage oil leak age etc Never insert any tool or other object through open ings in the generator interior even if the unit is not running Seriouse injury or damage to the equip ment may occur ELECTRICAL HAZARDS The generator covered by this manual produces dangerous electrical voltages and can cause fatal electrical shock Avoid contact with bare wires ter minals connections etc while the unit is running Before operating the generator ensure all appro priate covers guards and barriers are in place If work must be donearound an operating unit stand on an insulated dry surface to reduce shock hazard Do not handle any kind of electrical device while standing in water while barefoot or while hands or
54. d INSTALLATION Section 2 Installation e 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 2 1 Typical Horizontal Support Frame SUPPORT TUBING 2 1 3 SUSPENDED MOUNTING If the generator will be suspended below the horizon tal support tubing the suspension method used with the vehicle frame members must have the following a be able to support the weight of the generator and b provide sufficient restraint for the generator One typical suspended mounting system is shown in Figure 2 2 The location of a suspended mounting system must be carefully planned keeping the fol lowing general rules in mind e Protect the generator against road splash and debris Baffles or splash guards may be required to protect certain areas of the generator To make sure the generator is adequately protected road test the installation through mud water and slush Figure 2 2 Typical Suspended Mounting System GENERATOR MOUNTING HOLES FOR 3 8 16 BOLTS BOTH SIDES SUPPORT TUBING VEHICLE FRAME GENERATOR SUPPORT FRAME The installer must make certain that selected loca tion will permit adequate cooling and ventilating air flow to be supplied Generac Power Systems Inc 19 INSTALLATION 11131 Section 2 Installation 2 1 4 G
55. d circuits may be turned ON after the generator has started stabi lized and warmed up NOTE On gas units use of the fuel primer is needed only 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 carbu retor 2 Tocrank and start the engine hold the start stop switch at START Release the switch when the engine starts caution amp If the engine does not start after it has been A 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 Letthe engine run at no load for a few minutes to stabilize and warm up the engine 4 Turn ON electrical loads using whatever means provided such as a main circuit breaker or transfer switch NOTE If starting a warm generator engine press the start switch only slightly to engage the ignition system However press and hold the starter switch for a minimum of two 2 seconds to energize the field boost system If starting the engine without ener gizing the field boost system the generator pro duces no output 3 STOPPING THE GENERATOR Turn OFF all electrical loads using whatever means provided such as a main circuit breaker or transfer switch 2 Let the generator run at no load for a few min utes to stabilize internal engine gener
56. d 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 flam mable type One excellent insulating material is a 1 inch thick fiberglass having a 2 pound density When fiberglass 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 IMPACT 36 plus II Recreational Vehicle Generator 2 2 4 COMPARTMENT FLOOR CUTOUTS Provide openings in the generator compartment for the following items Figure 2 7 Engine exhaust and cooling air outlets Generator cooling air inlet e Four holes for passage of generator mounting bolts See Generator Restraint on Page 19 A A Fuel lines and exhaust piping must not pene trate into vehicle living area Figure 2 7 Compartment Floor Cutout 0A6203 A 23 9mm3 68 60mmL2 36 460mmL 18 11 400mmL 15 75 J Tr eo8mnm 10 16 EN 15 5mnE0 61 1 9mm L 0 35 16mmL0 63 4 HOLES 391 SIHL 3NVd 71041 05 aSIDIV33N39 TS M FULL SIZE COMPARTMENT TEMPLATE
57. deral laws apply on federal lands 2 5 2 TYPE OF EXHAUST SYSTEM The Impact 36 plus and Impact 34 plus II genera tors have a configuration for a bottom out exhaust system and is equipped with such an exhaust muf fler Figure 2 17 Figure 2 17 Exhaust System Exhaust Muffler e Model 004283 0 Exhaust Adapter mates to the O D of the spark arrestor outlet of the muffler It allows the use of 1 1 4 O D exhaust pipe to be clamped in place Figure 2 18 Figure 2 18 Exhaust Adapter 38 1 1 501 302 01197 y 152 4 6 001 R50 8 Re 00 1 1 1 1 1 1 l 1 1 152 4 6 00 4 317 1 25 ID ee Generac Power Systems Inc IMPACT 36 plus II Recreational Vehicle Generator 2 5 3 EXHAUST SYSTEM SAFETY Maintain a clearance of at least 3 inches 76mm between exhaust system parts and any com bustible material such as wood felt cotton organic fibers or other like material If the 3 inch clearance cannot be maintained locate insulate or shield the exhaust part s so that the temperature of any combustible material is not raised more than 117 F 65 C above the ambient air tempera ture 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
58. des standards and regulations The National Electric Code NFPA 70 aS well as state and local codes apply e 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 IMPACT 36 plus II Recreational Vehicle Generator e Wiring must be of adequate size with approved insulative qualities and properly supported Conduit and wire openings into generator com partment if used must be vapor sealed to pre vent entry of flammable explosive or poisonous gases into the vehicle 2 6 1 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 conductors 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 compart ment 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 e If flexible metal conduit is used between the gener ator and the compartment junction box the con duit end that terminates at the compartment junc tion box must be vapor sealed Flexible metal con duit is
59. e 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 DEPARTMENT GENERAC POWER SYSTEMS INC P O BOX 8 WAUKESHA WI 53187 Part 1 43 Generac Power Systems Inc Section 8 Warranty IMPACT 36 plus II Recreational Vehicle Generator WARRANTY EMISSION CONTROL SYSTEM WARRANTY Emission Control System Warranty ECS Warranty for 1997 and later model year engines a Applicability This warranty shall apply to 1997 and later model 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 purchaser owner 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 regulations 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
60. e above the generator for cooling air flow Figure 2 13 Recommended clearance above the top of the generator is at least 2 inches Figure 2 13 Air Inlet in Vehicle Skirt RECOMMENDED eee VEHICLE FLOOR VEHICLE SKIRT AIR INLET MINIMUM CLEARANCE 1 IMPACT 36 plus II Recreational Vehicle Generator 2 3 3 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 pro portionately larger Some materials may offer only a 60 percent free air inlet area Other more efficient materials may pro vide up to a 90 percent free air inlet area The per centage of free air inlet opening is usually available from the material supplier or manufacturer TO DETERMINE THE ACTUAL AIR INLET OPEN ING SIZE REQUIRED DIVIDE 40 SQUARE INCH ES BY THE PERCENTAGE OF FREE AIR INLET AREA FOR THE MATERIAL USED For example If planning 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 measures 4 inches wide by 12 1 2 inch es long provides the required air flow 4 x 12 5 50 Square inches 2 3 4 INVERTER LOCATION The inverter should be located in a dry well ventilat ed area in order for the inverter to work effectively Approximately eight inches of spa
61. e power required resulting in fuel economy as well as lowering the overall noise emitted NOTE The computer will disable the electrical load capabilities of the generator and enter a fault con dition if the throttle is accelerated manually or any other way 3 12 ADJUSTING THE CARBURETOR The carburetor of the generator is preset at the facto ry The carburetor should not be tampered with as this will void the emission control system warranty If the generator is used at altitudes in excess of 5 000 feet consult the Generac Authorized Service Facility regarding high altitude jetting changes 3 13 ADJUSTING VALVE CLEARANCE After the first 50 hours of operation 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 3 8 Figure 3 8 Adjusting Valve Clearance Loosen Jam Nut IMPACT 36 plus II Recreational Vehicle Generator 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
62. e sensors indicate that voltage has dropped below a preset level the engine will auto matically shut down Once the unit has shutdown the computer is automatically reset when the engine is restarted NOTE The computer allows for the low voltage output that occurs during startup A time delay that allows the engine to start and warm up is pro grammed into the monitoring system caution AA 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 2 1 BEFORE STARTING THE ENGINE IMPORTANT INSTRUCTIONS AND INFORMATION IN THIS MANUAL ASSUME THE GENERATOR HAS BEEN PROPERLY INSTALLED CONNECTED SER VICED TESTED AND ADJUSTED BY A QUALIFIED INSTALLATION TECHNICIAN OR INSTALLATION CONTRACTOR 2 1 1 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 2 1 2 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 amp Any attempt to crank or start the engine before it has been properly serviced with the recommended oil may result in engine failure 4 2 1 3 FUEL SUPPLY The engine
63. er s recommendations The following standards booklets latest revision are available from the sources indicated 1 NFPA 1192 Standard for Recreational Vehicles replaces ANSI 119 2 501C available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 18 Generac Power Systems Inc Section 1 General Information IMPACT 36 plus II Recreational Vehicle Generator 2 NFPA 70 NFPA Handbook of the National Electric Code available same as Item 1 ANSI RVIA EGS 1 Engine Generator Sets for Recreational Vehicle Safety Requirements ava ialable from the Recreational Vehicle Industry Association 1896 Preston White Drive Reston VA 22090 4 California Administrative Code Title 25 avail able from the State of California Documents Section PO Box 1015 North Highlands CA 95660 5 CSA Electrical Bulletin 946 available from the Canadian Standards Association Housing and Constructions Materials Section 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 1 4 EQUIPMENT DESCRIPTION Instructions and information in this section pertain to Generac Impact air cooled generators more specifically the installation of Impact 34 plus II and IMPACT 36 plus II Recreational Vehicle Generators These generators are designed specifically for installing in recreational vehicles 1 5 ENGINE GENERATOR OPERATING SPEED The generators are driven by gasoline powered si
64. ess or even death Symptoms of carbon monoxide poisoning are a inability to think coherently b vomiting c twitching muscles d throb bing in temples e dizziness f headache g weakness and sleepiness If any of these symptoms ar experienced move into fresh air immediately If symptoms persist get medical attention Do not operate the generator until its exhaust system has been inspected and repaired 2 5 1 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 per son 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 modification Generac Power Systems Inc 27 INSTALLATION 1113 Section 2 Installation Failure to provide and maintain 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 provide a spark arrestor The vehi cle owner or operator must maintain this device in good condition In the State of California the preced ing is required by law Section 4442 of the California Public Resources Code Other states may have simi lar laws Fe
65. f 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 for every possible installation For that reason instructions and illustrations in this manual are general in nature Illustrations are not intended to serve as detailed installation blueprints The installation should comply strictly with all applicable codes standards and regulations pertain ing 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 standards or regulations must take prece dence over the manual 1 2 SAFETY Before handling installing operating or servicing this equipment carefully read the Notice to Installer and Safety Rules on Pages 18 and 19 Comply with all safety rules to prevent death per sonal injury or damage to equipment and or proper ty Stress safety to all installers operators and ser vice technicians who work on this equipment 1 3 STANDARDS BOOKLETS Installation use and servicing of this equipment should comply strictly with published standards as well as the manufactur
66. hen oil has drained install and tighten drain plug Remove oil dipstick and fill crankcase with the recommended oil See Page 11 The engine crankcase can hold about 1 quart 950ml DO NOT FILL ABOVE FULT MARK e Install and tighten dipstick cap before operating engine 5 4 CHANGE OIL FILTER Replace the engine oil filter after the first 25 hours of operation every 100 operating hours thereafter Turn oil filter counterclockwise to remove Figure 3 2 Figure 3 2 Oil Drain Plug and Engine Oil Filter Y OIL FILTER Coat gasket of new filter with engine oil Turn new filter clockwise until its gasket contacts lightly with the filter adapter Then tighten an addi tional 3 4 to one turn by hand e Run engine and check for leaks NOTE Check oil level and fill to full mark after checking for leaks Filter will retain some oil IMPACT 36 plus II Recreational Vehicle Generator 3 5 ENGINE AIR CLEANER Paper Filter Once every 25 operating hours or once each year whichever comes first clean or replace the paper filter Figure 3 3 Follow the steps on page 12 Figure 3 3 Engine Air Cleaner Assembly PAPER FILTER qe Remove air cleaner cover then remove paper filter e Clean air filter by gently tapping it on a solid sur face If the filter is too dirty replace it with a new one Dispose of the old filter properly e Clean air cleaner cover then insert new paper
67. improve this product at any time with out prior notice DX A A Despite the safe design of this generator operating this equipment imprudently neglecting its maintenance or being careless can cause possible injury or death Permit only responsible and capable persons to operate or maintain this equipment 1 Parts of the generator are rotating and or hot during operation Exercise care near running generators A Potentially lethal voltages are generated by these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator 16 Generac Power Systems Inc GENERAL HAZARDS e For safety reasons Generac recommends that the installation initial startup and maintenance of this equipment 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 do nothing that might ren der the system unsafe or in noncompliance with such codes and standards The generator com partment must be completely vapor sealed from the vehicle interior There must be no possibility of exhaust fumes entering the vehicle interior Never operate this equipment with a leaking or defective e
68. installation of the products described in this manual Generac assumes that installation personnel are familiar with the procedures for installing such products or similar products that Generac manufactures Generac also assumes that personnel 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 Generac cannot possibly know of nor advise the recreational vehicle trade of all conceivable methods procedures or techniques by which to perform an installation Nor can Generac anticipate every possi ble hazard that might result from each installation method procedure or technique Generac has not undertaken any such wide evaluation Therefore people who use a method procedure 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 prod ucts safety are not endangered by the method pro cedure or technique selected Information illustrations specifications etc con tained in these Installation Instructions are based on the latest information available at the time of publi cation Every effort has been expended to be sure that such data are both accurate and current However the manufacturer reserves the right to change alter or Otherwise
69. irth defects or other reproductive harm A WARNING A This product contains or emits chemicals known to the state of California to cause cancer birth defects or other reproductive harm Study these SAFETY RULES carefully before installing operating or servicing this equipment Become familiar with this manual and with the unit The generator can operate safely efficiently and reli ably only if it is properly installed operated and maintained Many accidents are caused by failing to follow simple and fundamental rules or precautions Generac cannot possibly anticipate every possible cir cumstance that might involve a hazard The warn ings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating tech nique that Generac does not specifically recommend satisfy yourself that it is safe for others Also make sure the procedure work method or operating tech nique chosen does not render the generator unsafe A Despite the safe design of this generator operating this equipment imprudently neglect ing its maintenance or being careless can cause possible injury or death Permit only responsi ble and capable persons to operate and main tain this equipment 1 Parts of the generator are rotating and or hot during operation Exercise care near running generators A Potentially lethal voltages are generated by
70. ive type battery hydrometer A Ea A 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 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 extremely caus A tic sulfuric acid solution that can cause severe burns Do not permit fluid to contact eyes skin clothing painted surfaces etc Wear pro tective goggles protective clothing and gloves when handling a battery If fluid is spilled flush the affected area immediately with clear water Do not use any jumper cables or booster bat A tery to crank and start the generator engine If any battery has discharged remove it from the vehicle for recharging 12 Generac Power Systems Inc IMPACT 36 plus II Recreational Vehicle Generator 3 11 SERVICE AND ADJUSTMENTS 3 11 1 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 engine to produce only th
71. lectrical diagrams exploded views and lists of repair parts for generator models 00094 1 4 In addition the latter portion of this man ual contains information necessary for the proper installation of these generators OPERATION AND MAINTENANCE It is the operator s responsibility to perform all safe ty checks to make sure that all maintenance for safe operation is performed promptly and to have the equipment checked periodically by a Generac Authorized Service Dealer Normal maintenance ser vice and replacement of parts are the responsibilities of the owner operator and as such are not consid ered 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 the generator mini mize problems and operating expenses See the Generac Authorized Service Dealer for service aids and accessories HOW TO OBTAIN SERVICE When the generator requires servicing or repairs simply contact a Generac Authorized Service Dealer for assistance Service technicians are factory trained and are capable of handling all service needs When contacting a Generac Authorized Service Dealer or the factory about parts and service always supply the complete model number and serial num ber of the unit as given on its data decal which is located on the generator Model No Serial No AUTHORIZED SERVICE DEALER LOCATION
72. 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 5 2 CHECKING ENGINE OIL LEVEL Check engine crankcase oil level at least every eight hours of operation or before each use Figure 3 1 Be sure the generator is as level as possible Remove oil dipstick and wipe dry with clean lint free cloth e Install and tighten oil dipstick then remove again e should be at dipstick FULL mark If necessary add the recommended oil to the FULL mark only DO NOT FILL ABOVE MARK e Install and tighten oil dipstick cap before operating the engine Figure 3 1 Oil Dipstick and Fill Tube Oil Dipstick and Fill Tube O ER JJ NOTE See Engine Oil Requirements Section 2 9 for recommended oils 10 Generac Power Systems Inc IMPACT 36 plus II Recreational Vehicle Generator 3 3 CHANGE ENGINE OIL Change engine oil after the first 25 hours of opera tion Thereafter change oil every 100 operating hours Change oil more frequently if operating con sistently under heavy load or at high ambient tem peratures e 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 container e W
73. ly hot during operation and remains hot for a long time after it has shut down 2 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 2 8 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 use of an independent heat source may be needed 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 C but butane returns to its liq uid state when the temperature drops below about 32 F 0 C For that reason a higher ratio of propane is desired in the gas mixture when temperatures drop below freezing FUEL CONSUMPTION IN GALLONS PER HOUR 2 9 ENGINE OIL REQUIREMENTS The recommended oils include the following During summer months SAE 30 An acceptable substitute is SAE 10
74. must have adequate supply of proper fuel to operate Before starting check that sufficient fuel is available Generac Power Systems Inc 7 OPERATION Section 2 Operation 15 IMPACT 36 plus II Recreational Vehicle Generator 2 1 4 COOLING AND VENTILATING AIR Air inlet and outlet openings in the generator com partment must be open and unobstructed for contin ued proper operation Without sufficient cooling and ventilating air flow the engine generator quickly over heats which causes it to automatically shutdown Overheating could also damage the unit or the vehicle 2 1 5 ENGINE EXHAUST GAS Before starting the generator engine be sure there is no way for exhaust gases to enter the vehicle interior and endangering people or animals Close windows doors and other openings in the vehicle that if open might permit exhaust gases to enter the vehicle A The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concen trations can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOX IDE POISONING ARE a inability to think coher ently b nausea c vomiting d twitching muscles e throbbing temples f dizziness g headaches h weak
75. n gle cylinder engines The engines drive revolving fields rotors high frequency permanent magnet alternators 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 IMPACT 36 plus II Recreational Vehicle Generator 2 1 LOCATION AND SUPPORT 2 1 1 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 generator 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 paragraph entitled Generator Support e The location must provide an access opening that is large enough to permit generator removal unless the generator is to be removed from under neath the supporting framework The location must provide easy access to frequently serviced components such as filters oil drains spark plugs and other common maintenance parts The location must provide
76. n The installer must also provide for a path for exhausting the cooling air to the exterior of a com partment if so equipped DX A Never use discharged cooling air for heating LN or permit such air to enter the vehicle interior This air contains deadly carbon monoxide gas and other poisonous flammable or explosive gases 2 3 COOLING AND VENTILATING AIR 2 3 1 GENERATOR AIR FLOW Engine 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 con trol panel Figure 2 9 This air flow cools the engine generator and electronic components The second part of the 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 cool er than exhaust muffler is directed across the muf fler to cool it The heated air flow is then deflected out the bottom toward the ground Figure 2 9 Air Flow Through Engine Generator Generac Power Systems Inc 23 INSTALLATION 1113 Section 2 Installation 2 3 2 COOLING AIR INLET OPENINGS Provide three air inlet openings whether the genera tor is housed in a conventional compartment or not Two of the openings should be 10 square inches and located as shown in Figure 2 10 The third opening should provide for a minimum of 40 square inches unrestricted and be located lower on the c
77. ness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMP TOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired A A A Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset installa tion manual Make sure there is ample fresh air when operating the genset in a confined area 2 2 STARTING THE GENERATOR IMPORTANT READ THE VEHICLE MANUFACTUR 5 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 TRANS FER SWITCH TO ISOLATE DOCKSIDE POWER FROM THE GENERATOR WHILE OTHER VEHI CLES 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 8 Generac Power Systems Inc To crank and start the generator engine proceed as follows 1 Turn OFF electrical loads using whatever means provided in the vehicle such as a main line cir cuit breaker or transfer switch NOTE If the engine is started 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 loa
78. nto service the fuel supply lines must be properly installed purged and leak tested according to applicable fuel gas codes Generac Power Systems Inc 3 Section 1 General Information INFORMATION IMPACT 36 plus II Recreational Vehicle Generator GENERAL 1 1 GENERATOR IDENTIFICATION Please record the following information from the generator DATA DECAL or information decal located below the user control panel 1 Model Number 2 Serial Number 3 kW Rating 4 Rated Voltage 5 Phase 6 Hertz 4 1 1 1 IMPACT 36LPG PLUS II FEATURES Fi Service Lacato woe coal at 11 SOF GUARDIAN EY 3 75AMP IMPACT plus Ms TDS p NING _ z 16 10 9 6 REFERENCE NUMBER IDENTIFICATION 1 Generator Air Intake Screen 9 Data Decal 2 Air Cleaner 10 12 Volt Battery Connection 3 Air Intake Tube 11 Engine Start Stop Switch 4 LP Fuel Regulator 12 Generator DC Output Leads 5 Oil Dipstick and Filler Tube 13 Circuit Breaker 6 LP Carburetor 14 Fuse 7 LP Fuel Solenoid 15 Hour Meter 8 Fuel Primer Switch 16 Inverter Harness Connector ze Generac Power Systems Inc Section 1 General Information GENERAL IMPACT 36 plus II Recreational Vehicle Generator INFORMATION 1 1 2 INVERTER FEATURES PART NO 004885 5 3 4 REFERENCE NUMBER IDENTIFICATION 1 Inverter 4 DC Input 2 12 Pin Connection 5 Cooling Fan 3 Customer AC Output Generac Power Systems Inc 5 GENERAL INFORMATIO
79. o com partment joints and seams is NOT acceptable e 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 A Do not install sound insulation or any AN absorbent material on the compartment floor interior Such materials will become soaked with combustible or explosive vapors and liq uids and will become a fire hazard e Openings in compartment walls for passage of elec trical conduit conductors hoses cables etc must be made vapor tight with suitable caulking material e 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 con duit due to its unique construction is not vapor tight along its entire length A Do not install any flammable material directly AN above or around the compartment Heat transferred through the compartment struc ture may be sufficient to ignite char or dis color seat cushions fiberboard and other flammable materials Use approved non flam mable insulating materials in high tempera ture areas Generac Power Systems Inc 21 INSTALLATIO Section 2 Installation 2 2 3 SOUND INSULATING MATERIALS Once installers have determined that compartments are properly constructed an
80. ompart ment door NOTE Screening louvers or expanded metal that cover air openings restrict air flow that must be com pensated for by making the actual air opening pro portionately larger See Compensating for Restrictions For conventional compartment mounted units the air inlet is generally provided in the compartment door Figure 2 10 Air Inlet in Compartment Door 10 Square Inches Optional Openings 40 Square Inches Minimum Opening IMPORTANT IF PLANNING TO INSTALL THE GEN ERATOR IN A COMPARTMENT BE SURE TO LEAVE AT LEAST ONE INCH 2 recommended OF CLEAR ANCE BETWEEN THE GENERATOR AND COM PARTMENT WALLS AND CEILING INCLUDE 26 GAUGE GALVANIZED STEEL LINING AND SOUND INSULATION WHEN MEASURING 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 e Provide a door in the vehicle skirt having an air inlet opening Figure 2 11 24 Generac Power Systems Inc IMPACT 36 plus II Recreational Vehicle Generator Figure 2 11 Suspended Mount Inlet Door Using ductwork Figure 2 12 The installer must be sure air is available to the top of the generator since air inlets are located at the top Figure 2 12 Air Inlet Using Ductwork ANTI SPLASH BAFFLE GENERATOR e By providing an opening in the vehicle skirt and spac
81. or and compartment walls and 1 inch 2 recommended of clearance between the generator and the ceiling AFTER the compart ment has been lined with metal and AFTER sound insulation has been installed Figure 2 5 NOTE Refer to the Major Features and Dimensions drawing in the back of this manual Figure 2 5 Provide Clearance Around Generator PLYWOOD 1 INCH MINIMUM CLEARANCE ON ALL SIDES 2 RECOMMENDED TOP VIEW OF HN INSULATION 2 2 2 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 2 6 Figure 2 6 Typical Compartment Construction CROSS SECTION VIEW METAL LINING e h K i FLAME PROOF SOUND ISNULATION METAL LINING INF SJ VAPOR SEALED AT ALL TIMES METAL LINING INSTALLATION Section 2 Installation Line the entire compartment interior with 26 gauge galvanized steel as described above Line the exterior underside of the compartment floor with 26 gauge galvanized steel e 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 ont
82. ored in pressure tanks as a liquid The gas systems used with these genera tors were designed only for vapor withdrawal type systems 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 2 4 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 e For best results the primary regulator supplies gaseous fuel to the secondary regulator at 11 inch es water column Do NOT exceed 14 inches water column IMPACT 36 plus II Recreational Vehicle Generator 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 NOTE Recommended MINIMUM gas flow rate for all air cooled Impact 34 plus II 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 DIRECTLY TO GAS TANK PRESSURE D
83. ould be less than the units rated wattage amperage capacity 2 6 5 ISOLATING DIFFERENT POWER SOURCES Conductors from the junction box must terminate in a double pole double throw transfer switch Figure 2 20 An alternate method for isolating different power sources is by using an isolating receptacle Figure 2 21 Whichever method is used be certain that both power sources are NOT connected at the same time 2 6 4 POWER SUPPLY CORD The power supply cord must comply with all applic able codes standards and regulations It must be large enough to handle the full amperage to which it will be subjected 2 6 5 GROUND FAULT CIRCUIT INTERRUPTERS The National Electric Code NFPA 70 551 7 requires installation of ground fault circuit inter rupters GFCIs on all external and some internal electrical receptacles Contact the dealer for recom mendations Generac Power Systems Inc 29 INSTALLATION Section 2 Installation IMPACT 36 plus II Recreational Vehicle Generator A Figure 2 20 Transfer Switch Isolation Method INVERTER VEHICLE WIRING FLEXIBLE CONDUIT DOUBLE POLE POWER SUPPLY DOUBLE THROW CORD SWITCHING DEVICE POWER CORD FOR 30 AMP MAIN BREAKER POWER HACR BREAKERS FOR AIR CONDITIONERS VEHICLE A C FCI DISTRIBUTION BREAKERS PANEL DOCKSIDE POWER RECEPTICAL POWER SUPPLY CORD VEHICLE A C DISTRIBUTION PANEL Generac Power Systems Inc IMPA
84. p and a wire harness Figure 2 25 Optional Remote Panel Models 004057 and 004184 The remote panels mount a rocker type start stop switch a Generator advisory lamp and hourmeter The hourmeter should be used in con junction with the maintenance operations found in Part I of this manual e Model 004057 includes the remote panel and a 10 foot long 4 wire harness e Model 004184 includes the remote panel and a 30 foot long 4 wire harness Section 3 Post installation Start up Checks POST 2 INSTALLATI N IMPACT 36 plus II Recreational Vehicle Generator START UP 3 1 POST INSTALLATION TESTS The air cooled Impact 36 plus II generator set was factory 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 It is not required to adjust the unit any further except under special circumstances WARNING amp Do not make any unnecessary adjustments Factory settings are correct for most applica tions When making adjustments however be careful to avoid overspeeding the engine 3 2 BEFORE INITIAL START UP Before starting complete the following 1 Check engine crankcase oil level and if neces sary fill to dipstick FULL mark with the recom mended oil Do not fill above FU
85. r Control Board part numbers 0A6060 and 0A3369 and inverter if applicable with regard to the gen erator Cylinder Block Cylinder Head Crankshaft Piston s Valve Valve Lifter s Intake and Exhaust Manifolds Generac RV generators manufactured prior to December 31 1997 DO NOT have a transferable warranty Generac RV gen erators manufactured after January 1 1998 have a transferable warranty to the second owner ONLY for the remainder of the three year limited warranty Proof of purchase is required and must be presented to a Generac Authorized Warranty service Facility prior to the performance of any warranty service warranty expense allowances are subject to the conditions defined in Guardian s Warranty Policies and Procedures Guide THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING Generac Guardian generators that utilize non Generac replacement parts Costs of normal maintenance adjustments installation and start up Failures caused by any contaminated fuels oils coolants or lack of proper fluid amounts Failures due but not limited to normal wear and tear accident misuse abuse negligence or improper installation As with all mechanical devices the Generac engines need periodic part s service and replacement to perform well This warranty will not cover repair when normal use has exhausted the life of a part s or engine Failures caused by any external cause or act of God such as collision theft vandalism rio
86. rac Power Systems Inc Generac will at its option repair or replace any part which upon examination inspection and testing by Generac or a Generac Authorized Warranty Service Facility is found to be defective under normal use and service in accordance with the warranty schedule set forth below Any equipment that the purchaser owner claims to be defective must be returned to and examined by the nearest Generac Authorized Warranty Service Facility All transportation costs under the warranty including return to the factory are to be borne and prepaid by the purchaser owner This warranty applies only to Generac generators sold and rated for Recreational Vehicle RV applications as Generac has defined Recreational Vehicle generator applications The factory recommends exercising the unit one half hour every season WARRANTY SCHEDULE COMMERCIAL APPLICATIONS YEAR ONE 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components WARRANTY SCHEDULE CONSUMER PERSONAL APPLICATIONS YEARS ONE AND TWO 100 one hundred percent coverage on part s labor removal and reinstallation listed Engine All components Alternator All components YEAR THREE 100 one hundred percent only on selected part s and labor listed Any labor and part s not listed and removal and reinstallation are the owner s responsibility Rotor Stator Compute
87. rdance with the genset installation manual Make sure there is ample fresh air when operating the genset in a confined area 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 Thus the exhaust system must be installed properly in strict com pliance with applicable codes and standards Following installation do nothing that might ren der the system unsafe or in noncompliance with such codes and standards The generator com partment must be completely vapor sealed from the vehicle interior There must be no possibility of exhaust fumes entering the vehicle interior Never operate this equipment with a leaking or defective exhaust system 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 flow of cooling and venti lating air is critical to correct generator operation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which seriously damages the generator Do not alter the installation or permit even partial blockage of ventilation provisions as this can also seriously affect the safe operation of the generator AFETY RULE Safety Rules 2 aia IMPACT 36 plus II Re
88. s II caution amp Do not overload the generator Some installa tions may require that electrical loads be alternated to avoid overloading Applying excessively 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 Some electric motors require more amps of current for starting than for continu ous operation 6 Generac Power Systems Inc Section 1 General Information IMPACT 36 plus II Recreational Vehicle Generator 1 3 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 recreational vehicle Safety should be stressed to all operators of this equipment 1 4 GENERATOR CONTROL PANEL Mounted on the generator control panel Figure 1 1 are the following features Figure 1 1 Typical Control Panel Fuse Circuit Breaker P N cococa 9 HOUR METER ART FUEL Fuel Primer EXE Start Stop Switch 1
89. t floor of a double thick ness 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 combination of acoustical materials as mentioned in Sound Insulating Materials Figure 2 8 Typical Noise Abatement Compartment PLYWOOD EXTERIOR 5 8 OR 3 4 THICK SOUND INSOLATION MATERIAL ALS PLYWOOD 5 8 OR 3 4 THICK FIBERGLASS INSULATION DX A Do not install any insulation or other A absorbent materials on the interior or under side of the compartment floor e Seal all compartment door edges to prevent noise leakage around the door perimeter INSTALLATION Section 2 Installation Line the compartment door interior except for air openings with suitable fire proof sound insula tion such as l 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 operating difficulties and may also cause fire and personal injury The installer must make sure that sufficient air is avail able to the generator for cooling ventilating and com bustio
90. t or wars nuclear holocaust fire freezing lightning earthquake windstorm hail volcanic eruption water or flood tornado or hurricane Damage related to rodent and or insect infestation Products that 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 the defective part s Failure due to misapplication Telephone cellular phone facsimile internet access or other communication expenses Living or travel expenses of person s performing service except as specifically included within the terms of a specific unit warranty period Expenses related to customer instruction or troubleshooting where no manufacturing defect is found Rental equipment used while warranty repairs are being performed Overnight freight costs for replacement part s Overtime labor e Starting batteries fuses light bulbs and engine fluids THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED SPECIFICALLY GENERAC MAKES NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you GENERAC S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART S AS STATED ABOVE IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL
91. these machines Ensure all steps are taken to render the machine safe before attempting to work on the generator GENERAL HAZARDS e For safety reasons Generac recommends that the installation initial startup and maintenance of this equipment be performed by a Generac Authorized Service Dealer 2 Generac Power Systems Inc operation be copied and posted in potential hazard areas of the recreational vehicle Safety should be stressed to all operators and potential operators of this equipment The generator engine releases DEADLY carbon monoxide gas through its exhaust system This dangerous gas if breathed in sufficient concentra tions can cause unconsciousness or even death Never operate the generator set with the vehicle inside any garage or other enclosed area DO NOT OPERATE THE GENERATOR IF THE EXHAUST SYSTEM IS LEAKING OR HAS BEEN DAMAGED SYMPTOMS OF CARBON MONOXIDE POISON ING ARE a inability to think coherently b nau sea c vomiting d twitching muscles e throb bing temples f dizziness g headaches h weakness and i sleepiness IF EXPERIENCING ANY OF THESE SYMPTOMS MOVE INTO FRESH AIR IMMEDIATELY IF SYMPTOMS PERSIST GET MEDICAL HELP Shut down the generator and do not operate it until it has been inspected and repaired Never sleep in the vehicle while the genset is run ning unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in acco
92. to the frame ground on the generator base Connect the negative cable to the frame ground of the chassis 3 Connect cables so the connections are clean and tight 2 7 4 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 32 Generac Power Systems Inc 2 8 OPTIONAL ACCESSORIES 4 2 8 1 REMOTE PLUG 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 permits starting and stopping the generator engine from any convenient location inside the vehi cle Figure 2 24 Remote Panel Plug In Receptacle 5 ect O OR ION WIRE 18 STOP WIRE 14 ENGINE RUN SIGNAL WIRE 17 CRANK WIRE 10 GROUND 2 8 2 REMOTE START STOP PANEL A remote mounted Start Stop panel Figure 2 25 is available that allows the user to start and stop the generator engine conveniently from inside the vehicle The remote panel includes a Start Stop switch hourmeter generator run lam
93. unterfeit 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 gaskets 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 C 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 Generac Power Systems Inc 49 Section 8 Warranty WARRANTY IMPACT 36 plus II Recreational Vehicle Generator GENERAC POWER SYSTEMS THREE YEAR LIMITED WARRANTY FOR GUARDIAN RECREATIONAL VEHICLE GENERATORS NOTE ALL UNITS MUST BE INSTALLED BY GENERAC POWER SYSTEMS AUTHORIZED SERVICE FACILITIES For a period of 3 three years of operation from the date of original sale Gene
94. xhaust 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 flow of cooling and ven tilating air is critical to correct generator oper ation and is required to expel toxic fumes and fuel vapors from the generator compartment Without sufficient cooling airflow the engine generator quickly overheats which caus es serious damage to the generator Do not alter the installation or permit even partial blockage of ventilation provisions as this can seriously affect safe operation of the generator When working on this equipment remain alert at all times Never work on the equipment when physically or mentally fatigued Before performing any maintenance on the genera tor disconnect its battery cables to prevent acci dental startup First disconnect the cable from the battery post indicated by a NEGATIVE or Reconnect that cable last Never use the generator or any of its parts as a step Stepping on the unit can stress and break parts and may result in dangerous operating con ditions from leaking exhaust gases fuel leakage oil leakage etc Never insert any tool or other object through open ings in the generator interior even if the unit is not running Seriouse injury or damage to the equip ment may occur SAFETY RULES Safety Rules IMPACT 36 plus II Recre
95. y terminals and the gen erator 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 larg er the cable size must be as shown in the following Chart Figure 2 22 Generator to Inverter Connection J BOX GENERATOR TO INVERTER INPUT JE 12PIN SENSING HARNESS REMOTE HARNESS GENERATOR TO DC CONVERTER Generac Power Systems Inc 31 OPERATION Section 2 Installation 15 IMPACT 36 plus II Recreational Vehicle Generator CABLE LENGTH in Feet Meters CABLE SIZE 16 to 20 4 9 to 6 For warm weather use No 2 cable up to 20 feet 2 7 3 BATTERY CABLE CONNECTIONS 1 Connect the battery cable from the battery post or terminal indicated by a POSITIVE POS or to the large lug on the starter contactor as indicated in Figure 2 23 2 Connect the battery cable from the battery post indicated by a NEGATIVE NEG or to the frame ground connection Figure 2 23 Connecting Battery Cables 13 To Panel 16 To Starter Jr A 4 Positive Customer Starter E gt Connection Contacter amp h J e Nh lt S SN us Y QNO Frame Ground Ground Wire NOTE If the generator compartment is grounded to the vehicle chassis it s not necessary to connect a NEGATIVE battery cable

Generac 005796-0 (XG6500) Welding System User Manual

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