Generac Portable Generator 00941 4 User Manual

Owner’s Manual and

Installation Instructions

Air-cooled Recreational Vehicle Generator

• Model No: 00941-4

IMPACT-36 plus II with Inverter

This manual should remain with the unit.

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Table of Contents

IMPACT-36 plus II Recreational Vehicle Generator

Part I – Owner’s Manual

Part II – Installation Instructions

Safety Rules..................................................................................16

Introduction....................................................Inside Front Cover

Read This Manual Thoroughly ............................................IFC

Contents ..............................................................................IFC

Operation and Maintenance ................................................IFC

How to Obtain Service ........................................................IFC

Authorized Service Dealer Locator Number ............................IFC

Section 1 – General Information ............................................18

1.1

1.2

1.3

1.4

1.5

Purpose and Scope of the Manual............................18

Safety ......................................................................18

Standards Booklets..................................................18

Equipment Description ............................................18

Engine Generator Operating Speed ..........................18

Safety Rules....................................................................................2

Section 1 – General Information ..............................................4

1.1

1.2

1.3

1.4

1.5

Generator Identification ..................................................4

Generator Applicability....................................................6

Safety ..............................................................................6

Generator Control Panel..................................................6

Engine Protective Devices ................................................7

Section 2 – Installation ............................................................19

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

Location and Support....................................................19

Generator Compartments..............................................20

Cooling and Ventilating Air ............................................23

Propane Gas Fuel System ..............................................25

Exhaust System ............................................................27

Electrical Connections ..................................................28

Battery Installation ........................................................31

Optional Accessories......................................................32

Section 2 – Operation..................................................................7

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

Before Starting the Engine ..............................................7

Starting the Generator ....................................................8

Stopping the Generator ..................................................8

Applying Loads to Generator ..........................................9

Attention Required After Submersion..............................9

Operation in High Grass or Brush ..................................9

Operating Precautions ....................................................9

Fuel Requirements (LP Units)..........................................9

Engine Oil Requirements ................................................9

Section 3 – Post-installation Startup Checks ......................33

3.1

3.2

3.3

3.4

3.5

Post Installation Tests....................................................33

Before Initial Startup ....................................................33

Initial Start ....................................................................33

Testing Under Load ......................................................33

Installation Checklist ....................................................34

2.10 LP Generator Specifications ............................................9

2.11 Engine Specifications ......................................................9

Section 4 – Troubleshooting ....................................................35

4.1

Troubleshooting Guide ..................................................35

Section 3 – Maintenance ..........................................................10

Section 5 – Electrical Data........................................................36

Section 6 – Exploded Views and Parts Lists........................38

Section 7 – Installation Diagram ............................................47

Section 8 – Warranty..................................................................48

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

Maintenance ..................................................................10

Checking the Engine Oil Level ......................................10

Change Engine Oil ........................................................10

Change Oil Filter............................................................10

Engine Air Cleaner ........................................................11

Clean Air Intake Screen ................................................11

Engine Spark Plug ........................................................11

Inverter..........................................................................11

Cleaning the Generator..................................................11

3.10 Battery ..........................................................................12

3.11 Service and Adjustments ..............................................12

3.12 Adjusting the Carburetor ..............................................12

3.13 Adjusting Valve Clearance..............................................12

3.14 Major Service Manual....................................................13

3.15 Exercising the Generator ..............................................13

3.16 Out of Service Protection ..............................................13

3.17 Return Unit to Service After Storage..............................13

Section 4 – Notes........................................................................14

Generac Power Systems, Inc.

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Safety Rules

IMPACT-36 plus II Recreational Vehicle Generator

SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe

operation be copied and posted in potential hazard areas of the recreational vehicle.

Safety should be stressed to all operators and potential operators of this equipment.

• 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 accordance 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.

WARNING:

The engine exhaust from this product

contains chemicals known to the state

of California to cause cancer, birth

defects, or other reproductive harm.

WARNING:

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.

DANGER

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.

• 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.

Parts of the generator are rotating and/or hot

during operation. Exercise care near running

generators.

• 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.

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.

GENERAL HAZARDS

• For safety reasons, Generac recommends that the

installation, initial startup, and maintenance of

this equipment be performed by a Generac

Authorized Service Dealer.

Generac Power Systems, Inc.

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Safety Rules

IMPACT-36 plus II Recreational Vehicle Generator

• When working on this equipment, remain alert at

all times. Never work on the equipment when

• 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.

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.

FIRE HAZARDS

• For fire safety, the generator must be installed and

maintained properly. Installation must always

comply with NFPA 70 (latest edition), “National

Electrical Code”, Article 551, and NFPA 1192 (lat-

est edition), “Standard for Recreational Vehicles”,

along with all applicable codes, standards, laws,

and regulations. Adhere strictly to local, state, and

federal electrical and building codes. Comply with

regulations the 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 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 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.

• 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 feet are wet. DANGEROUS ELECTRICAL

SHOCK MAY RESULT.

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.

• 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 into service, the fuel supply

lines must be properly installed, purged, and leak-

tested according to applicable fuel-gas codes.

• 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.

Generac Power Systems, Inc.

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Section 1 – General Information

IMPACT-36 plus II Recreational Vehicle Generator

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 ____________________

3. kW Rating__________________________

5. Phase ______________________________

2. Serial Number __________________

4. Rated Voltage __________________

6. Hertz __________________________

1.1.1 IMPACT-36LPG PLUS II FEATURES

◆

REFERENCE NUMBER IDENTIFICATION

1. Generator Air Intake Screen

2. Air Cleaner

9. Data Decal

10. 12 Volt Battery Connection

3. Air Intake Tube

11. Engine Start/Stop Switch

12. Generator DC Output Leads

13. Circuit Breaker

4. LP Fuel Regulator

5. Oil Dipstick and Filler Tube

6. LP Carburetor

14. Fuse

7. LP Fuel Solenoid

8. Fuel Primer Switch

15. Hour Meter

16. Inverter Harness Connector

Generac Power Systems, Inc.

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Section 1 – General Information

IMPACT-36 plus II Recreational Vehicle Generator

1.1.2 INVERTER FEATURES (PART NO. 0D4885)

◆

REFERENCE NUMBER IDENTIFICATION

1. Inverter

4. DC Input

2. 12 Pin Connection

5. Cooling Fan

3. Customer AC Output

Generac Power Systems, Inc.

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Section 1 – General Information

IMPACT-36 plus II Recreational Vehicle Generator

1.2 GENERATOR APPLICABILITY

1.3 SAFETY

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.

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.

DANGER

1.4 GENERATOR CONTROL PANEL

Mounted on the generator control panel (Figure 1.1)

are the following features:

For fire safety, the generator must have been

properly installed in compliance with (1) ANSI

119.2-1975/NFPA 501C-1974 “Standard for

Recreational Vehicles”, Part III, “Installation of

Electrical Systems.” The generator also must

have been installed in strict compliance with

the manufacturer’s detailed installation

Figure 1.1 — Typical Control Panel

Fuse

Circuit Breaker

instructions. After installation, do nothing

that might render the unit in non-compliance

with such codes, standards and instructions.

Hour Meter

This generator has been designed to work with an

inverter (P/N 0D4885). 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”).

Fuel Primer

Start/Stop Switch

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 plus

II.

1.4.1 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.

Do not overload the generator. Some installa-

tions may require that electrical loads be

alternated to avoid overloading. Applying

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.

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.

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.

Generac Power Systems, Inc.

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Section 2 – Operation

IMPACT-36 plus II Recreational Vehicle Generator

1.4.5 HOUR METER

1.5.4 LOW VOLTAGE

◆

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.

The computer monitors the voltage output of the gen-

erator. If voltage 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.

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.

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.

1.5.1 AUTOMATIC LOW OIL PRESSURE

SHUTDOWN

◆

The engine is equipped with an oil pressure sensor

that shuts down the engine automatically when oil

pressure is too low. If the engine shuts down by itself

and the fuel tank has enough fuel, check the engine

oil level.

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.

1.5.1.1 Initial Startup

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.

During initial startup, a time delay built into the shut-

down control system allows oil pressure to build. The

delay allows the engine to run for about 10 seconds

before sensing oil pressure.

1.5.1.2 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.

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.

1.5.2 HIGH TEMPERATURE SHUTDOWN

◆

2.1.2 ENGINE LUBRICATION

◆

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.

Have engine crankcase properly serviced with recom-

mended oil before starting. Refer to "Maintenance"

and "Specifications" sections for oil servicing proce-

dures and recommendations.

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.

Any attempt to crank or start the engine

before it has been properly serviced with the

recommended oil may result in engine failure.

2.1.3 FUEL SUPPLY

◆

The engine must have adequate supply of proper fuel

to operate. Before starting, check that sufficient fuel

is available.

Do not attempt to physically adjust or control

the engine speed. Equipment damage or per-

sonal injury may result.

Generac Power Systems, Inc.

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Section 2 – Operation

IMPACT-36 plus II Recreational Vehicle Generator

To crank and start the generator engine, proceed as

2.1.4 COOLING AND VENTILATING AIR

◆

follows:

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.

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 load circuits may be

turned ON after the generator has started, stabi-

lized and warmed up.

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.

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.

DANGER

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) weakness, 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.

2. To crank and start the engine, hold the start/stop

switch at START. Release the switch when the

engine starts.

If the engine does not start after it has been

cranking for 15 seconds, release the start/stop

switch and try again. Holding the switch for

longer than 15 seconds may damage the

starter motor.

3. Let the engine run at no-load for a few minutes to

stabilize and warm up the engine.

4. Turn ON electrical loads, using whatever means

provided (such as a main circuit breaker or

transfer switch).

DANGER

NOTE:

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.

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.

2.2 STARTING THE GENERATOR

IMPORTANT: READ THE VEHICLE MANUFACTUR-

ER’S INSTRUCTIONS. THE OWNER/OPERATOR

SHOULD BECOME FAMILIAR WITH THE VEHICLE

IN WHICH THIS GENERATOR IS INSTALLED.

DIFFERENCES EXIST BETWEEN VEHICLES. FOR

EXAMPLE, SOME VEHICLES MAY USE A 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

2.3 STOPPING THE GENERATOR

1. 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-generator tem-

peratures.

3. Hold Start/Stop switch in its STOP position.

DC LOADS.

Generac Power Systems, Inc.

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Section 2 – Operation

IMPACT-36 plus II Recreational Vehicle Generator

LP gas may consist of propane, butane or a mixture

2.4 APPLYING LOADS TO GENERATOR

When applying electrical loads to the generator,

observe these guidelines:

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.

• Before applying electrical loads, let the generator

stabilize and warm up for a minute or two.

• DO NOT overload the generator.

FUEL CONSUMPTION (IN GALLONS PER HOUR):

2.4.1 LETTING ENGINE STABILIZE

◆

LOAD

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.

0.20

0.41

0.77

HALF

FULL

2.9 ENGINE OIL REQUIREMENTS

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.

The recommended oils include the following:

• During summer months: SAE 30. An acceptable

substitute is SAE 10W-30.

• During winter months: SAE 5W30. DO NOT USE

SAE 10W-40.

2.5 ATTENTION REQUIRED AFTER

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.

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.

2.10 LP GENERATOR SPECIFICATIONS

Model ..............................................Impact-36LPG plus II

Rated Maximum Continuous

2.6 OPERATION IN HIGH GRASS OR

AC Power Output ..............................3400 watts (3.4 kW)

Rated Voltage ................................................120 volts AC

Rated Maximum Continuous

Current at 120 volts................................28.3 AC amperes

Phase ............................................................Single Phase

Rated AC Frequency ................................................60 Hz.

Recommended Battery

Cranking Current ..............................................400 amps

Gross Weight............................................................99 lbs

Maximum Cranking Current..............................250 Amps

Maximum Charging Current ..................................2 Amps

BRUSH

Never operate the generator while the vehicle is

parked in high grass, weeds, brush or leaves. Such

materials can ignite and burn from the heat of the

exhaust system. The generator exhaust system

becomes extremely hot during operation and remains

hot for a long time after it has shut down.

2.7 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.

2.11 ENGINE SPECIFICATIONS

Type of Engine ......................................................GN-220

Cooling Method..................................................Air-cooled

Displacement............................................................220cc

Type of Governor ..............................................Electronic

Air Cleaner ..................................................Paper element

Starter ..................................................12 volt DC electric

Ignition System ................................................Solid state

Recommended Spark Plugs ................Champion RC14YC

Spark Plug Gap..................................0.030 inch (0.8mm)

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.

Generac Power Systems, Inc.

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Section 3 – Maintenance

IMPACT-36 plus II Recreational Vehicle Generator

3.1 MAINTENANCE

3.3 CHANGE ENGINE OIL

This section includes information about simple

maintenance which includes the following tasks:

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.

• Checking engine oil level.

• Changing engine oil.

• Changing oil filter.

• Air cleaner maintenance.

• Cleaning the air intake screen.

Cleaning spark arrestor.

• Cleaning spark plug.

Replacing fuel filter.

• 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.

Servicing inverter.

• When oil has drained, install and tighten drain

plug.

3.2 CHECKING ENGINE OIL LEVEL

Check engine crankcase oil level at least every eight

hours of operation, or before each use (Figure 3.1).

• 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 “FULL” MARK.

• Be sure the generator is as level as possible.

• Remove oil dipstick and wipe dry with clean, lint-

free cloth.

• Install and tighten dipstick cap before operating

engine.

• Install and tighten oil dipstick, then remove again.

• Oil should be at dipstick FULL mark. If necessary,

add the recommended oil to the FULL mark only.

DO NOT FILL ABOVE “FULL” MARK.

• Install and tighten oil dipstick cap before operating

the engine.

3.4 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

Figure 3.1 — Oil Dipstick and Fill Tube

Oil Dipstick and Fill Tube

NOTE:

• 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.

See “Engine Oil Requirements”, Section 2.9 for

recommended oils.

• Run engine and check for leaks.

NOTE:

Check oil level and fill to full mark after checking

for leaks. Filter will retain some oil.

10 Generac Power Systems, Inc.

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Section 3 – Maintenance

IMPACT-36 plus II Recreational Vehicle Generator

3.5 ENGINE AIR CLEANER

3.7 ENGINE SPARK PLUG

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.

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 3.3 — Engine Air Cleaner Assembly

Figure 3.5 — Setting Gap on Spark Plug

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

• Remove air cleaner cover, then remove paper filter.

• 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.

• Clean air cleaner cover then insert new paper filter

into cover and assemble to the base of the air

cleaner.

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

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

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

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Section 3 – Maintenance

IMPACT-36 plus II Recreational Vehicle Generator

3.11 SERVICE AND ADJUSTMENTS

3.11.1 ENGINE SPEED

Do NOT 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.

◆

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

the power required, resulting in fuel economy as well

as lowering the overall noise emitted.

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.

◆

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.

Also check battery fluid level, and, if necessary, fill

with DISTILLED WATER ONLY. DO NOT USE TAP

WATER IN BATTERY.

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.

3.10.2 EVERY SIX MONTHS

Have the battery state of charge and condition

checked by an automotive service facility. This should

be done with an automotive type battery hydrometer.

◆

DANGER

Storage batteries give off explosive hydrogen

gas. This can form an explosive mixture

around the battery for several hours after

charging. The slightest spark can ignite the

gas and cause an explosion. Such an 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.

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).

Battery electrolyte fluid is an extremely caus-

tic sulfuric acid solution that can cause severe

burns. Do not permit fluid to contact eyes,

Figure 3.8 — Adjusting Valve Clearance

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-

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.

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Section 3 – Maintenance

IMPACT-36 plus II Recreational Vehicle Generator

2. When valve clearance is correct, hold the pivot

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:

ball stud with the allen wrench and tighten the

rocker arm jam nut with a crows foot. Tighten the

jam nut to 65-85 inch-pounds torque. After tight-

ening the jam nut, recheck valve clearance to

make sure it did not change (Figure 3.9).

• 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.”

Figure 3.9 — Tightening Jam Nut

• Attach a tag to the engine indicating the viscosity

and classification of the oil in the crankcase.

• Remove spark plug and add about 1/2 ounce

(15ml) of clean, fresh engine oil into spark plug

threaded opening. Crank engine several times to

distribute oil, then install and tighten spark plug.

• Remove the battery and store in a cool, dry room

on a wooden board. Never store the battery on any

concrete or earthen floor.

• Clean and wipe the entire generator.

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.

3.14 MAJOR SERVICE MANUAL

To obtain a service manual for the generator, order it

from the dealer/distributor. Be sure to identify the

unit’s 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.

• Apply electrical loads up to at least 50% of the

unit’s rated wattage capacity.

• When engine is thoroughly warmed up, shut it

down.

THE GENERATOR IS NOW READY FOR SERVICE.

Generac Power Systems, Inc. 13

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Section 4 – Notes

IMPACT-36 plus II Recreational Vehicle Generator

14 Generac Power Systems, Inc.

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PART II –

INSTALLATION

INSTRUCTIONS

DANGER

ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS

SHOULD ATTEMPT INSTALLATION!!

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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

GENERAL HAZARDS

These Installation Instructions have been published

by Generac to aid in the 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.

• 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

exhaust system.

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-

uct's safety are not endangered by the method, pro-

cedure, or technique selected.

• 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, NEG, 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.

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 improve this product at any time, with-

out prior notice.

DANGER

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.

Parts of the generator are rotating and/or hot

during operation. Exercise care near running

generators.

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.

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Safety Rules

IMPACT-36 plus II Recreational Vehicle Generator

ELECTRICAL HAZARDS

FIRE 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.

• 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-

dards, laws, and regulations.

• 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.

• 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. Failure 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.

EXPLOSION HAZARDS

• 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.

• 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.

Generac Power Systems, Inc. 17

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Section 1 – General Information

IMPACT-36 plus II Recreational Vehicle Generator

2. NFPA 70, “NFPA Handbook of the National

1.1 PURPOSE AND SCOPE

Electric Code,” available same as Item 1.

3. 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.

OF THE MANUAL

These Installation Instructions have been prepared

especially for the purpose of familiarizing installers

and owners of the applicable equipment with the

product's installation requirements. Give serious

consideration to all information and instructions in

the manual, both for safety and for continued reliable

operation of the equipment.

4. California Administrative Code, Title 25, avail-

able from the State of California, Documents

Section, P.O. 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.

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.

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.

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.

1.5 ENGINE GENERATOR OPERATING

SPEED

1.2 SAFETY

The generators are driven by gasoline-powered, sin-

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.

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 manufacturer's recommendations. The

following standards booklets (latest revision) are

available from the sources indicated:

1. NFPA 1192, “Standard for Recreational Vehicles”

(replaces ANSI A119.2/NFPA 501C), available

from the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

18 Generac Power Systems, Inc.

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

• If the generator cannot be bolted directly to the

2.1 LOCATION AND SUPPORT

supporting frame or support tubing, consider

using additional tubing, angle brackets or other

supports to give the supporting frame sufficient

strength.

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.

Figure 2.1 —Typical Horizontal Support Frame

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.”

• 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.

2.1.3 SUSPENDED MOUNTING

◆

• 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 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.

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:

• 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.

• 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.

Figure 2.2 — Typical Suspended Mounting

System

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 sound.

• 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

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

• The generator compartment should be either con-

2.1.4 GENERATOR RESTRAINT

◆

structed of, or lined with, 26 gauge galvanized

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.

steel.

IMPORTANT: ALUMINUM IS NOT AN ACCEPTABLE

ALTERNATIVE TO GALVANIZED STEEL, DUE TO

ALUMINUM'S LOW MELTING POINT.

• If the compartment is lined with galvanized steel, it

may be constructed of any material. Generac rec-

ommends that the compartment be constructed of

1/2-inch thick plywood, with the floor made of a

double thickness of plywood for added strength.

• All seams, splices and joints of the compartment

walls (unless vapor tight by design) should be

caulked.

Figure 2.3 — Typical Generator Restraint

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.

• 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.

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:

• 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

20 Generac Power Systems, Inc.

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

• Line the entire compartment interior with 26 gauge

2.2.1 COMPARTMENT SIZE

◆

galvanized steel as described above.

• Line the exterior (underside) of the compartment

floor with 26 gauge galvanized steel.

Plan the compartment size carefully. Provide a mini-

mum of at least 1 inch (2” recommended) of clear-

ance between the generator 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).

• Vapor seal all compartment seams and joints, to

prevent poisonous, flammable or explosive vapors

from entering the vehicle interior. Refer to the

sealant information as noted previously.

NOTE:

Silicone rubber base sealant is an acceptable

caulking material. Pressing putty tape onto com-

partment joints and seams is NOT acceptable.

Refer to the “Major Features and Dimensions”

drawing in the back of this manual.

• 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.”

Figure 2.5 — Provide Clearance Around

Generator

DANGER

Do not install sound insulation or any

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.

• Openings in compartment walls for passage of elec-

trical conduit, conductors, hoses, cables, etc.,

must be made vapor tight with suitable caulking

material.

• Flexible conduit must be sealed internally at the

end where it terminates inside a compartment's

electrical junction box.

2.2.2 COMPARTMENT CONSTRUCTION

◆

NOTE:

• 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).

The preceding is required because flexible con-

duit, due to its unique construction, is not vapor-

tight along its entire length.

DANGER

Figure 2.6 — Typical Compartment Construction

Do not install any flammable material directly

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

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

2.2.3 SOUND INSULATING MATERIALS

2.2.4 COMPARTMENT FLOOR CUTOUTS

◆

Once installers have determined that compartments

are properly constructed and metal lined, they can

add acoustical material. This may include additional

sealant or insulating material, to reflect noise away

from the vehicle interior.

Provide openings in the generator compartment for

the following items (Figure 2.7):

• Engine exhaust and cooling air outlets

• Generator cooling air inlet

• Four holes for passage of generator mounting

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.

bolts. See “Generator Restraint” on Page 19.

DANGER

Fuel lines and exhaust piping must not pene-

trate into vehicle living area.

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.

Figure 2.7 – Compartment Floor Cutout (0A6203-A)

22 Generac Power Systems, Inc.

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

• Line the compartment door interior (except for air

2.2.5 ACOUSTICS

If excessive noise levels should become a problem,

the installer may wish to consider the following:

◆

openings) with suitable, fire proof sound insula-

tion (such as 1-inch thick fiberglass with a 2-

pound density).

• 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.

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-

bustion. The installer must also provide for a path

for exhausting the cooling air to the exterior of a com-

partment, if so equipped.

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):

DANGER

• Use 5/8-inch thick or 3/4-inch thick plywood in the

compartment.

Never use discharged cooling air for heating

or permit such air to enter the vehicle interior.

This air contains deadly carbon monoxide gas

and other poisonous, flammable or explosive

gases.

• Construct the compartment 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.”

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 2.8 — Typical Noise Abatement

Compartment

Figure 2.9 — Air Flow Through Engine-

Generator

DANGER

Do not install any insulation or other

absorbent materials on the interior or under-

side of the compartment floor.

• Seal all compartment door edges to prevent noise

leakage around the door perimeter.

Generac Power Systems, Inc. 23

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

Figure 2.11 — Suspended Mount Inlet Door

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 compart-

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.”

• 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.

For conventional compartment mounted units, the

air inlet is generally provided in the compartment

door.

Figure 2.12 — Air Inlet Using Ductwork

Figure 2.10 — Air Inlet in Compartment Door

10 Square Inches

(Optional Openings)

40 Square Inches

(Minimum Opening)

• By providing an opening in the vehicle skirt and

space 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

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:

• Provide a door in the vehicle skirt having an air

inlet opening (Figure 2.11).

24 Generac Power Systems, Inc.

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

2.3.3 COMPENSATING FOR RESTRICTIONS

◆

2.4 PROPANE GAS FUEL SYSTEM

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.

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).

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.

Figure 2.15 — Diagram of LP Gas System

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 space 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

◆

DANGER

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.

Use only approved components in 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.

IMPORTANT: TEST THE INSTALLATION, ESPE-

CIALLY IF BRINGING IN AIR FROM BELOW THE

GENERATOR SET.

Generac Power Systems, Inc. 25

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

• The installer must be sure the primary regulator is

2.4.2 SOME IMPORTANT CONSIDERATIONS

When installing an LP gas system, consider seriously

the following items:

◆

rated at sufficient gas flow to operate the generator

plus all other gas appliances in the circuit.

NOTE:

• 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.

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. DO NOT TEE

THE GENERATOR LINE INTO A GAS CIRCUIT

FEEDING OTHER APPLIANCES.

• 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.

• 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.

2.4.5 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.

2.4.3 VAPOR WITHDRAWAL

◆

Liquid propane (LP) gas is stored 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

◆

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.

Gas pressure delivered to the solenoid valve must be

properly regulated by means of a primary gas regula-

tor. Mount the primary regulator at the gas tank out-

let or in the supply line from the gas tank, The fol-

lowing rules apply:

• For best results, the primary regulator supplies

gaseous fuel to the secondary regulator at 11 inch-

es water column. Do NOT exceed 14 inches water

column.

The following facts about the secondary regulator

must be emphasized:

Figure 2.16 — Propane Gas Carburetion Diagram

26 Generac Power Systems, Inc.

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

• The regulator must be sensitive to venturi throat

DANGER

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).

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.

• 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.

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.

• 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.

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.

2.4.7 EXCESS FLOW VALVE

◆

Propane gas tanks should have an excess flow valve,

according to NFPA 501C, Paragraph 3-4.4. This valve

and the gas lines must be carefully sized so the valve

will close when a fuel line is severed or broken.

Consult the Natural-LP Gas Association for informa-

tion and limitations of excess flow valves.

DANGER

The generator engine gives off deadly carbon

monoxide gas through its exhaust system.

This dangerous gas, if breathed in sufficient

concentrations, can cause unconsciousness or

even death. 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.

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.

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.

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

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

Failure to provide and maintain a spark arrestor may

2.5.3 EXHAUST SYSTEM SAFETY

◆

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. Federal laws apply on federal lands.

• 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 that exhaust

gases will not be drawn back into the generator

compartment and recirculated.

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

• If there is any possibility of the tailpipe or muffler

being damaged, protect these damage prone areas

by means of a protective device (such as a “skid

bar”).

• Install the generator exhaust system according to

safe automotive practices.

• Use enough exhaust system hangers to prevent any

part of the system from being dislocated.

• Use exhaust system parts recommended by

Generac. Using unapproved exhaust mufflers and

exhaust system parts is the responsibility of the

person(s) installing such unauthorized parts.

• Do not terminate the exhaust system under any

opening, window or vent which can be opened or is

not permanently sealed from the vehicle interior.

• Exhaust piping must be large enough to prevent

excessive back pressure on the generator engine.

• Never tee the generator 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.

Exhaust

Muffler

• 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

• 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:

• Qualified electricians who are familiar with applic-

able codes, standards and regulations should

install electrical wiring.

• The wiring should comply with codes, standards

and regulations. The National Electric Code (NFPA

70), as well as state and local codes, apply.

• Switches and circuit breakers should be of a type

approved for use in recreational vehicles and must

be mounted and installed to prevent damage from

road shock.

28 Generac Power Systems, Inc.

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

• Wiring must be of adequate size, with approved

Figure 2.19 — Inverter J Box for AC Output

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.

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 should be less than the units rated

wattage/amperage capacity.

• 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.

• 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 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).

2.6.3 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.

• Conductors must be rated 221°F (105°C) or must

be of a larger conductor size.

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.

◆

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.

Generac Power Systems, Inc. 29

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

Figure 2.20 — Transfer Switch Isolation Method

INVERTER

POWER SUPPLY

CORD

POWER

CORD FOR

DOCKSIDE

POWER

Figure 2.21 — Installation with Isolation Receptacle

INVERTER

30 Generac Power Systems, Inc.

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

• For prevailing ambient temperatures above 32°F

2.6.6 SENSING HARNESS

◆

(0°C), use a battery rated 70 amp-hours and capa-

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).

ble of delivering 400 cold cranking amperes.

• For prevailing ambient temperatures below 32°F

(0°C), use a battery rated 95 amp-hours and capa-

ble of delivering 450 cold cranking amperes.

IMPORTANT: IF THE BATTERY IS TO BE USED TO

POWER OTHER VEHICLE ACCESSORIES, AS WELL

AS START THE GENERATOR, A BATTERY WITH A

LARGER CAPACITY MAY BE NEEDED.

2.7.2 BATTERY CABLES

◆

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.

Using battery cables that are too long or too small in

diameter may cause a drop in voltage which causes

starting problems. For best cold weather starting, the

voltage drop between battery terminals and the gen-

erator connection point should not exceed 0.12 volts

per 100 amperes of cranking current.

2.7 BATTERY INSTALLATION

2.7.1 RECOMMENDED BATTERY

Install a battery that meets the following require-

ments:

◆

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.

• Battery must be a 12 volt, automotive type storage

battery.

Figure 2.22 — Generator to Inverter Connection

RED

BLACK

BLUE

GREEN

J-BOX - GENERATOR

TO INVERTER INPUT

Generac Power Systems, Inc. 31

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Section 2 – Installation

IMPACT-36 plus II Recreational Vehicle Generator

CABLE LENGTH

in Feet (Meters)

0 to 10 (0 to 3)

11 to 15 (3.4 to 4.5)

16 to 20 (4.9 to 6)

2.8 OPTIONAL ACCESSORIES

CABLE SIZE

000

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.

* 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.

Figure 2.24 — Remote Panel Plug-In Receptacle

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

Positive Customer

Starter

Contacter

Connection

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 lamp and a wire harness.

Frame Ground

Ground Wire

NOTE:

Figure 2.25 — Optional Remote Panel

(Models 004057 and 004184)

If the generator compartment is grounded to the

vehicle chassis, it’s not necessary to connect a

NEGATIVE battery cable 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.

The remote panels mount a rocker type start/stop

switch, a “Generator Run” advisory lamp and an

hourmeter. The hourmeter should be used in con-

junction with the maintenance operations found in

Part I of this manual.

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.

• Model 004057 includes the remote panel and a 10

foot long, 4 wire harness.

• Model 004184 includes the remote panel and a 30

foot long, 4 wire harness.

32 Generac Power Systems, Inc.

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Section 3 – Post-installation Start-up Checks

IMPACT-36 plus II Recreational Vehicle Generator

CHECKS

3. Let the engine warm up for about five minutes to

allow internal temperatures to stabilize.

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 II 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.

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 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.

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

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.

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 FULL 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.

3.4 TESTING UNDER LOAD

Apply electrical loads equal to about 75-100% of the

unit's rated wattage/amperage capacity.

DANGER

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.

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.

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.

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).

IMPORTANT: GENERAC RECOMMENDS THAT

THE GENERATOR IS TESTED FOR ADEQUATE

COOLING.

Generac Power Systems, Inc. 33

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Section 3 – Post-installation Start-up Checks

IMPACT-36 plus II Recreational Vehicle Generator

EXHAUST SYSTEM

◆

3.5 INSTALLATION CHECKLIST

❑ Exhaust system complies with all applicable

LOCATION AND SUPPORT

◆

codes.

❑ Generator is properly located.

❑ Generator is properly supported.

❑ Generator is properly restrained.

❑ Exhaust system is properly and safely installed.

ELECTRICAL CONNECTIONS

◆

❑ Connections comply with local code requirements

and all National Electrical Codes.

GENERATOR COMPARTMENT

◆

❑ Junction box is properly installed.

❑ Wiring meets all standards.

❑ Compartment construction is proper.

❑ Holes/Openings are vapor-sealed.

❑ Compartment size is correct.

❑ All connections are correct.

❑ Conduit is properly installed and sealed.

❑ Generator is properly bonded to the vehicle.

❑ Compartment is vapor-sealed.

❑ Sound insulation is correct.

❑ Floor cutouts are properly completed.

BATTERY INSTALLATION

◆

❑ Recommended battery is installed.

❑ Recommended cables are installed.

❑ Cables are clean and tight.

COOLING AND VENTILATING AIR

❑ Airflow is adequate.

◆

❑ Air inlet opening is correct.

❑ Compensate for restrictions.

❑ Check that installation has been tested.

❑ Cables are connected properly.

❑ Proper ventilation is provided.

❑ Terminals are coated with anti-corrosion grease,

DIESEL FUEL SYSTEM

◆

and terminal covers are positioned.

❑ Fuel tank complies with all applicable codes.

OPTIONAL ACCESSORIES

◆

❑ Fuel system is properly installed and checked

❑ Check that remote start/stop panels (if used) are

for leaks.

installed properly.

❑ Check that all other options and accessories (if

used) are installed properly.

POST INSTALLATION TESTS

◆

❑ Check that all tests are completed properly.

DATE OF INSTALLATION ____________________________________________________

NAME OF INSTALLER ______________________________________________________

SIGNATURE OF INSTALLER ________________________________________________

34 Generac Power Systems, Inc.

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Section 4 – Troubleshooting

IMPACT-36 plus II Recreational Vehicle Generator

4.1 TROUBLESHOOTING GUIDE

PROBLEM

Engine won't crank.

CAUSE

CORRECTION

1. Fuse is blown.

Replace 15 amp fuse.

Tighten, clean or replace

as necessary.

2. Loose corroded or defective

battery cables.

3. Defective engine Start/Stop switch.

4. Defective starter contactor.

5. Defective starter motor.

6. Low or defective Battery

Replace Start/Stop switch.

Replace contactor.

Replace starter motor.

Charge or replace battery.

Engine cranks but won't start,

low full load power.

1. Out of fuel.

Replenish fuel.

Replace defective fuel pump

or fuel solenoid.

2. Fuel pump is defective (Gasoline), OR,

fuel solenoid is defective (LP).

3. Open Wire #14 from Eng. Control Bd.

4. Engine is flooded.

5. Spark plug defective.

6. Loose spark plug boot.

Reconnect wire.

Wait 5-10 min. before trying.

Clean, regap or replace plug.

Press boot on securely.

Engine starts hard, runs rough.

1. Air cleaner plugged or damaged.

2. Defective spark plug.

Clean or replace as needed.

Clean, regap or replace plug.

Engine starts, shuts down

when Start/Stop switch is

released.

1. Engine oil is low.

2. Engine is overheated.

3. Defective Low Oil Pressure System

4. Defective Control Board

5. Defective Computer Control Board.

Check oil; add as needed.

Check adequate ventilation.

Have serviced/replaced.

Have board serviced/replaced.

Start/Stop switch at Stop,

engine continues to run.

1. Defective Start/Stop switch

2. Open/disconnected wire #18 between

Start/Stop switch and Control

Replace switch.

Reconnect or close wire.

3. Open/disconnected wire #0 between

Start/Stop switch & Control Bd.

4. Defective Control Board

Reconnect or close wire.

Replace board.

No output from generator.

1. Check circuit breaker.

Reset to ON or CLOSED.

Reset and replace if necessary.

Set to GENERATOR position.

2. Check vehicle circuit breaker & fuses.

3. Transfer sw. set to NORMAL position.

4. Generator internal failure.

Take generator to an

Authorized Generac facility.

5. Inverter defective.

Take generator to an

Authorized Generac facility.

Generac Power Systems, Inc. 35

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Section 5 — Electrical Data

IMPACT-36 plus II Recreational Vehicle Generator

Wiring Diagram and Schematic – Drawing No. 0D4947-B

36 Generac Power Systems, Inc.

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Section 5 — Electrical Data

IMPACT-36 plus II Recreational Vehicle Generator

Wiring Diagram and Schematic – Drawing No. 0D4947-B

Generac Power Systems, Inc. 37

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Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator

Control Panel – Drawing No. 0E7560

38 Generac Power Systems, Inc.

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Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator

Control Panel – Drawing No. 0E7560

ITEM

PART NO.

QTY.

DESCRIPTION

091526

020093

0E7556

075477

051716

074908

023484M

0A8592

049226

075476

051715

022985

023897

0E7557

030809

087798

092113

0A9611

032300

0A6422

065795

022264

0E7555

096874

0A6060

043181

043182

089744

0A6423A

045756

086722

075210A

0A6423B

0912970025

0A6470

091269A

023484D

082121A

051713

025105

084867

051718

0C1457

036933

0A6423C

029333A

023762

0D4885

051714

0A6464

0D4884

0D4882

0A6700

0A9183

3.5

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,15A.

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 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. 39

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Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator

Sheet Metal – Drawing No. 0F1091

40 Generac Power Systems, Inc.

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Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator

Sheet Metal – Drawing No. 0F1091

ITEM PART NO. QTY. DESCRIPTION

086705

049813

022097

0A1658

086718

0A3666

056893

0A3638

074908

090141A

0A8475

0C3296

086727

086671

086726

023897

038353

022127

0912970071

0742600103

090537

089048

086719

0A3667

0A7213

079119

045771

022129

022145

066443B

0A3764

039414

020668

3.5'

PLATE, DIVIDER

NUT HEX M6 X 1.0

092000

079246

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-M4

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)

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 HHTT 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"-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 M8-1.25 X 35mm

EARTHING STRAP

086731A

094670

089680

086715

056892

089471

086724

086729

090518

022471

022264

089045

086711

049226

051716

0A9196

089049B

049721

089047

0A9172

091526

084867

0A9031

050830

047290

0C7649

023484D

0E8245

HOSE-3/8" I.D. x 11" LONG

CLAMP HOSE 0.38"-0.87"

SNAP BUSHING

BRACKET, REGULATOR MOUNT

Generac Power Systems, Inc. 41

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Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator

GN 220 RV Long Block – Drawing No. 0A6202-H

42 Generac Power Systems, Inc.

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Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator

GN 220 RV Long Block – Drawing No. 0A6202-H

ITEM

PART NO.

QTY.

DESCRIPTION

078621

076389

088411

072657A

077176

088057

076390

083379A

089923

089213G

0E3811

090604

078699B

0A9878

089096

0A8822

078691

0A5772

0A5776

074908

078606

0D2414

0C3733

0C4390

088590

083152

076381

021705B

0C3590

0C3591

0D9853A

083235

0C8754

077161

077160

076307

088403

077168

088413B

078629

090388

083153

092977

084186

088156

072347

0E7585

099922

ASSY, CONNECTING ROD

PISTON PIN

PISTON RING SET

PLUG, 1/4 NPTF PIPE

COVER, BREATHER

PISTON, DIA 75

RING, PIN RETAINER

ASSY, C'SHFT CCG TPR

SPRTR, OIL BREATHER

CRNKCASE,SUBASY W/PLUG GN220RV

SEAL, D 28 X 41.47 VITON OIL

ASSY, BREATHER CUP

SLEEVE SEAMED DOWEL 12 DIA.

CAMSHAFT ASSY

GASKET,C'CASE

GASKET, CYL. HEAD

COVER OIL PRES RELIEF

SPRING,OIL RELIF 220

BALL,DIA 11/32 PRELF

SCREW HHTT M5-0.8 X 10 BP

SCREW & LW M6-1 X 12

SCREW HHFC M8-1.25 X 35

RETAINER, VALVE

SPRING, VALVE

DOWEL DIA 12 X 18L

GEROTER, INNER 6/5

BOLT, CON ROD

ASSY,CYL HD GDS&STS

VALVE, EXHAUST

VALVE, INTAKE

PUSHROD 145.76

TAPPET, DIA 7.5

GASKET, VALVE COVER

STUD, PIVOT BALL

ARM, ROCKER, GN191

NUT, JAM (ROCKR ARM)

PLATE,PUSHROD GUIDE

HEADBOLT M8 X 56 MM

COVER ROCKER W/OUT BREATHER

GASKET, BREATHER

SCREW HHTT M6-1.0 X 12 YC

GEROTER, OUTER 6/5

ASSY,OIL SUMP 220RV

WEAR WSHER,VLV SPRNG

SEAL,VALVE STEM 6.0

SPARK PLUG (00940 ONLY)

SPARK PLUG (00941 ONLY)

WASHER,SPRING

Generac Power Systems, Inc. 43

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Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator

Generator – Drawing No. 0F1134

44 Generac Power Systems, Inc.

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Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator

Generator – Drawing No. 0F1134

ITEM PART NO. QTY. DESCRIPTION

0A2467

094583

083312

081810

070185B

086730

089476

040976

0D2446

087478

086714

0A8584

0912970071

0912970003

0912970005

097962

022097

0C2908

052617

094090

043182

0C1085

090051

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 SWITCH

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 M12-1.75 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 & 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"

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

PLATE, DIVIDER

WASHER, CARBURETOR

CLIP, ADJUSTMENT

ROD, THROTTLE 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 HHTT M6-1.0 X 10mm

SCREW HHC M8-1.25 X 16mm

WASHER LOCK M8-5/16"

FAN, GENERATOR

SCREW HHTT M5-0.8 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 M8-1.25 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

086708

086726

078631

0A2774B

096459

086709

089050

035586

0F1225

090072

094637

090071

089263

049226

056893

038353

059637

086701

086702

086704

022237

022511

039253

082774

092800

088905

083512

059636

0D4408

022145

0912970002

092059

049821

WASHER FLAT 5/16"-M8

STARTER WIRE

STEPPER MOTOR SPEED CONTROL

SCREW SHC M8-1.25 X 30mm

SCREW HHC 3/8"-16 X 1-1/4"

Generac Power Systems, Inc. 45

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Section 6 — Exploded Views and Parts Lists

IMPACT-36 plus II Recreational Vehicle Generator

LP Regulator – Drawing No. 0F1092-A

ITEM PART NO. QTY. DESCRIPTION

0D5694

CASTING, TWIN REGULATOR

HOUSING

SCREW PPHM M4-0.7 X 10

WASHER LOCK #8-M4

0C5764A

0C4643A

0C6066

0C5968

0C5759

0C5761

0C6069

0C6731

0C6067

0C4706

0C6068

0C5762

045764

025425

0E4170

0C5760

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 HHTT M4-0.7 X 8 BP

ELBOW 45D STREET 3/4" NPT

CONNECTION 3/4"NPT - 3/8" 45D

JET LP GN220 ENGINE

075475

022264

043180

0F3154

0C6070

0C4680

0C4647

0C4643

0D3973

0D7023

WASHER FLAT M4

SOLENOID COIL, 12VDC

SPRING-SOLENOID PLUNGER

PLUNGER LP REG. ASSY

GASKET, SOLENOID

INLET, TWIN REGULATOR NO HOLE

PLUG, EXPANSION 16MM TWINREG

BARBED ELBOW 90 1/2"NPT X 3/8"

HOSE

072683A

0D3308

070728

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.

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Section 7 — Installation Diagram

IMPACT-36 plus II Recreational Vehicle Generator

Major Features and Dimensions – Drawing No. 0F1119

Generac Power Systems, Inc. 47

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Section 8 – 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’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’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance on

your engine. However, Generac cannot deny warranty solely because of the lack of receipts or for your failure to ensure the

completion of all scheduled maintenance.

As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage 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 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 while

the engine is being transported/shipped for inspection or warranty repairs.

If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at the

following address:

ATTENTION WARRANTY DEPARTMENT

GENERAC POWER SYSTEMS, INC.

P.O. BOX 8

WAUKESHA, WI 53187

Part 1

48 Generac Power Systems, Inc.

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Section 8 – Warranty

IMPACT-36 plus II Recreational Vehicle Generator

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.

(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 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, counterfeit and/or “grey market” part.

EMISSION RELATED PARTS INCLUDE THE FOLLOWING:

1) Fuel Metering System:

2) Air Induction System including:

a) Intake pipe/manifold

b) Air cleaner

1.1) Gasoline carburetor assembly and its

internal components (if so equipped).

a) Fuel filter (if so equipped)

b) Carburetor gaskets

c) Fuel pump (if so equipped)

3) Ignition System including:

a) Spark plug

b) Ignition module

1.2) LPG carburetion assembly and its

internal components (if so equipped).

a) Fuel controller (if so equipped)

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)

4) Catalytic Muffler Assembly (if so equipped) including:

a) Muffler gasket

b) Exhaust manifold

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

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Section 8 – 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, Generac 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, Computer 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.

All 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, riot 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.

• 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 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.

P.O. BOX 297

•

WHITEWATER, WI 53190

Revision 2.04

Part No. 0F1117

Revision B (11/15/04)

Printed in U.S.A.

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