Yamaha NPS 4500 User manual

OWNER'S GUIDE

Introduction
Welcome to N.P.S. Company, LLC's (NPS) Owner's Guide (Guide) for the NPS Generator
Models Y4500 and Y5500U (Generator). These Generators are designed with your comfort and
ease in mind. NPS is proud to provide these Generators to enhance your experience in the
outdoors and the wild places of this planet.
NPS is dedicated to ensuring you will be able to focus on the adventures at hand and will have
peace of mind knowing your recreational vehicle (RV) will have Generator power when and
where you need it.
This Guide will provide you with an overview of the safety issues and precautions you will need
to be aware of while operating, maintaining and storing the Generator with your RV. Safety is of
utmost importance and failure to follow this Guide may result in performance degradation of the
Generator and extreme bodily injury to the owner. The Safety section below is followed by
information, photos and details specific to your Generator to help you make the most of your
adventures and prolong the life of your unit.
This Guide should be used for NPS Generator Models Y4500 and Y5500U only.
Page 2 of 30
Rev 1.7

A. Safety
A.1 Throughout this Guide, you will see several warnings repeated to
alert the Generator owner or operator to existing and potential hazards. These
warnings are in place to ensure the safety of the Generator owner or operator.
A.2 Safety is of utmost importance and failure to follow the procedures as
set forth in this Guide could result in performance failure of the Generator
and severe bodily injury or death to the owner or operator.
A.3 These warnings will include:
DANGER: Indicates an immediate hazard, which if not avoided, will
result in death or extreme bodily injury to installer or operator.
WARNING: Indicates a hazard level between caution and danger and
indicates a hazardous situation, which if not avoided, could result in
death or serious bodily injury to installer or operator.
CAUTION: Indicates a potential hazard, which if not avoided may
result in minor or moderate bodily injury to installer or operator.
A.4 Other words requiring attention and/or action, as stated include:
HAZARD
ALERT
SAFETY INSTRUCTIONS
PROHIBITION
INFORMATION
MANDATORY ACTION
SAFETY PROCEDURES
SAFETY SHUTDOWN
PROCEDURES
ATTENTION
Page 3 of 30
Rev 1.7

PROHIBITION
A.5 Do not attempt to service or repair Generator:
•Unless you are mechanically knowledgeable and experienced or are being supervised
by a qualified technician
•When physically tired or mentally weary
•If alcohol has been consumed within previous twenty-four (24) hour period
•If drugs have been consumed or administered, including prescription drugs which in
any way alter normal physical functioning or mental capacity with-in previous twenty-
four (24) hour period
•While smoking
•If children or pets are in close proximity to service or maintenance area
•While wearing jewelry on hands, wrists or around neck
•While wearing loose clothing which could fall into or be caught by moving parts in, or
around Generator
•While Generator is running
MANDATORY ACTION
A.6 Required prior to commencement service or maintenance:
•Locate and keep multi-class ABC fire extinguishers within reach of RV and readily
available at all times
•Determine, locate and wear personal protective equipment (PPE) necessary for
Generator service and maintenance, including but not limited to safety glasses, as
required by NPS
•Verify negative (-) battery cable is disconnected at the battery (or batteries), prior to
preforming maintenance. Always disconnect the negative (-) battery cable first and
only reconnect it after maintenance or repairs have been fully completed to prevent
unplanned starting or arcing while working on the Generator
•Locate and identify all moving parts including fans, belts, pulleys, hinged covers,
etc., to raise awareness of potential hazard areas in and around the Generator
•When working in an enclosed space, locate and verify operational carbon monoxide
and smoke detector(s) in the service area
A. Safety
Page 4 of 30
Rev 1.7

HAZARD ALERT
A.7 Gasoline is flammable and explosive:
•Keep multi-class ABC fire extinguisher(s) within reach and readily available
throughout the service or maintenance process
•Do not smoke or permit others to smoke at or near repair or maintenance location
•Any rags soiled with gasoline or oil must be discarded in fire proof container
•Routinely check for leaks and collections of gasoline pooling in the service area
•Secure and shield fuel lines separately and away from electrical wiring and/or ignition
wiring to prevent accidental fire and/or explosion
•Keep all ignition sources away from fuel lines including:
oopen flames
oarc producing equipment
osparks
opilot lights
oelectrical switches
DANGER
A.8 Engine Exhaust:
Gasoline-powered engines and tools present a serious health hazard. They produce high
concentrations of carbon monoxide (CO). CO is a poisonous gas that can cause illness,
permanent neurological damage and death. CO is colorless, odorless, and non-irritating
and therefore can overcome exposed persons without warning. CO can rapidly accumulate
(even in areas appearing to be well ventilated).
A.9 Review cdc.gov/niosh/topics/co/default.html for additional precautions and
recommendations regarding "Carbon Monoxide Hazards from Small Gasoline Powered
Engines"
A.10 Read and understand the OSHA Fact Sheet and Quick Reference Sheet for Carbon
Monoxide Poisoning
https://www.osha.gov/OshDoc/data_General_Facts/carbonmonoxide-factsheet.pdf
https://www.osha.gov/Publications/3282-10N-05-English-07-18-2007.html
A. Safety
Page 5 of 30
Rev 1.7

A.11 Failure to follow the service and maintenance procedures as set forth in this Owner's
Guide may void NPS' Limited Warranty and result in death or extreme bodily harm to
owner or operator
A.12 Do not operate Generator in an enclosed space such as a garage or storage stall
A.13 Ensure RV is equipped with working CO detector
A.14 Verify CO and smoke detector(s) are functioning properly while the Generator is
operating
A.15 Inspect entire Exhaust Assembly and Exhaust Support Strap and verify fittings are
tight and secure and pipe opening is free of debris or other obstructions at initial start-up
and after every ten (10) hours of operation
A.16 Inspect and ensure CO and/or smoke detectors are operating properly at
every start-up and replace batteries at intervals recommended by CO detector
manufacturer for RVs
DANGER
A.17 Generator Voltage Arc-Flash and Electrical Shock Hazard
MANDATORY ACTION: Prior to performing any work on the Generator, all electrical
connections must be identified and designated as either energized or non-energized to all
service team members. Verification of energized or non-energized connection(s) or
surfaces must be constantly monitored by a qualified technician
A.18 Test equipment shall be used to ensure that electrical parts and circuit elements have
been de-energized prior to performance of any and all Generator service or maintenance
A.19 Testing instruments and equipment shall be visually inspected for external defects or
damage before being used to determine de-energization (29 CFR 1910.334(c)(2))
A. Safety
Page 6 of 30
Rev 1.7

DANGER
A.20 Generator Voltage Arc Flash and Electrical Shock Hazard:
Prior to working on live electrical equipment:
•Disconnect shore power to RV
•Disconnect negative (-) terminal battery or batteries
•Remove any metal or conductive apparel. Articles of jewelry and clothing such as
metal: watch bands, bracelets, rings, keychains, necklaces, ear or other metal
piercings, metalized aprons, cloth with conductive thread, or metal headgear shall not
be worn. (29 CFR 1910.333(c)(8))
•NPS recommends working on a dry non-conductive material
•Ensure clothes, hands and hair are dry
A.21 Condition specific PPE, including safety glasses, must be worn to protect
eyes and face from electric arcs, flashes or from flying objects resulting from an
electrical explosion
A.22 Use only tools with non-conductive and/or non-combustible covered handles
A.23 Electrical connections shall be made by a qualified person experienced and familiar
with construction and operation of electrical equipment and the hazards involved. Qualified
persons are intended to be only those well acquainted with and thoroughly conversant in
electric equipment and electrical hazards involved with work being performed
A.24 Review placard and warnings on Generator for amperage and voltage information to
protect installers and operators from hazards which could cause injury due to electric shock,
burns or failure of electrical components.
A.25 Visually inspect all Generator mounting components (Exhaust Assembly, Service
Access Door, Fuel Connections, Electrical Connections, Remote Control Panel) every ten
(10) hours of operation.
A.26 NPS' Generator is not designed to be a primary source of power for life support
systems or devices but can support temporary operating or charging of recreational or
battery powered components.
A. Safety
Page 7 of 30
Rev 1.7

B. Getting to know your Generator
B.3 This Guide will walk you through the following features and attributes of the
NPS Generator Models Y4500 and Y5500U, where they can be found, how they
work, how to operate and when to service
•NPS Generator See Exhibit 1
•Generator Components Located within Service Access Door See Exhibit 2
•Generator Exhaust Assembly See Exhibit 3
•Generator Base See Exhibit 4
oLocation of Air Intake and Air Outflow
oRubber Isolation Strips for anti-vibrations
•Generator Fuel Line and Vapor Purge Line See Exhibit 5 (applicable to non-
powered RV installations)
•Never store anything underneath or around the bottom or front of the
Generator. Lack of a proper ventilation parameter may cause the Generator
to overheat and/or ignite tall grass, vegetation or other objects in proximity to
the running Generator. This presents a fire hazard which could ignite from
hot exhaust pipe assembly, fumes and vapors and result in death or extreme
bodily harm to the Owner or Operator.
•Maintain a proper ventilation parameter extending 914.4 mm or (3') in all
directions from all manufacturer installed Generator components.
B.1 NPS Generator Models Y4500 and Y5500U are designed with the following
features and benefits:
•Partnered with and Powered by Yamaha
•NPS' Yamaha-backed Limited Warranty
•Pure sine wave inverter technology providing clean, safe and stable power
•Enhanced fuel efficiency
•Advanced cooling system
•Integrated pull-start
•Hand-held remote-start keyfob
•Largest Network of Service Locations
B.2 NPS Generator(s) provides AC Power to applicable components
Page 8 of 30
Rev 1.7

B. Getting to know your Generator
B.3 (continued)
•Pre-Start Check and Inspection
•Starting and Operating the Generator
•Maintenance Requirements
•Trouble Shooting
•NPS' Limited Warranty
•Specifications
•Maintenance Record
Page 9 of 30
Rev 1.7

Exhibit 1 - NPS Generator
Generator
Casing
Generator Service Access Door
(closed position)
Generator Service Access Door Latches
Generator
Model Number
Warning Tags
Generator
Base
Warning
Labels
Generator
Nameplate
NPS' TEI United States
and Canada Certification
Mark
Warning Label
Page 10 of 30
Rev 1.7

C. Generator Components Located within
Service Access Door
C.1 Generator Components Located within Service Access Door See Exhibit 2
•Fault Indicator Lights
•Carburetor Fuel Drain
•Carburetor
•Hand-held Remote-Start Keyfob (NPS original transport location)
•Automatic Engine Choke
•Engine Air Filter Housing
•Emergency Pull-Start Handle
•Generator Service Access Door Opening
•Warning Labels
•Engine Oil Dipstick
•Engine Oil Drain Plug
•Control Panel
•Nameplate
•NPS' TEI United States and Canada Certification Mark
•Master 12Volt Power Switch
•12Volt Battery Connection (Positive) (+)
•12Volt Circuit Breaker
C.2 Nameplate provides the following information See Exhibit 2
•Manufacturer Name and Contact Information
•Emissions Control and Compliance
•Generator Model Number
•Serial Number
•Rating
•Voltage
•Required Fuel: Unleaded Gasoline
Section "A. Safety" of this guide for the details and descriptions of each warning or hazard.
Page 11 of 30
Rev 1.7

C.3 Control Panel See Exhibit 2
•Start/Stop Prime Switch
•Oil Alert fault indicator light
•Overload Alarm fault indicator light
•Locater arrows for the 30amp AC Circuit Breaker
C.4 Warning Labels are located on and around the Generator to alert the Owner
to location specific hazards associated with operating, servicing and maintaining the
Generator. See Exhibit 1, Exhibit 2 and Exhibit 3
C. Generator Components Located within
Service Access Door
Page 12 of 30
Rev 1.7

Exhibit 2 - Generator Components Located within Service Access Door
Control Panel
Nameplate
Warning
Labels
Warning
Labels
Hand-held
Remote-Start
Keyfob
(NPS original
transport location)
Generator
Service Access
Door Opening
Generator Service
Access Door
Opening
Engine Oil
Dipstick
Automatic
Engine Choke
Emergency
Pull Start Handle
Engine
Air Filter
Housing
Carburetor
Carburetor
Fuel Drain
NPS' TEI
United States and Canada
Certification Mark
Engine
Oil Drain
Plug
Master 12Volt
Power Switch
(inside door)
12 Volt Battery
Connection
(Positive) (+)
12 Volt
Circuit
Breaker
(inside
door)
Fault
Indicator
Lights
Page 13 of 30
Rev 1.7

Exhibit 3 - Generator Exhaust Assembly
Bottom of RV
RV Service and
Maintenance
Access Door
Exhaust Support Strap
Exhaust Pipe Clamp and Bolts
Exhaust Pipe
Exhaust Support Strap
Clamp Bolts
Baffle
End of
Exhaust Pipe
Exhaust Pipe Spark Arrester
and Debris Screen
Warning Label
Page 14 of 30
Rev 1.7

Exhibit 4 - Generator Base
Rubber Isolation Strip
Air Outflow
(arrows indicate
outflow direction)
Exhaust Assembly
Muffler and Port
Front of Generator
Generator Service Access Door
Rubber
Isolation
Strip
Air Intake
(arrows indicate
direction of airflow)
Purge Line
Fuel Line
Page 15 of 30
Rev 1.7

Exhibit 5 - Generator Fuel Line and Vapor Purge Line
Vapor Purge Line
(Capped at Factory)
Fuel Line
Electrical Harness
Connecting Generator
to RV
12 Volt Ground
Page 16 of 30
Rev 1.7

D. Pre-Start Check and Inspection
D.1 Battery and Battery Connections
Verify there is sufficient battery voltage. Ensure all battery connections are clean of any
acid build-up and battery cable nuts are securely fastened.
D.2 Locate, Open and Secure the RV Generator Compartment Door
D.3 Locate, Open and Remove Generator Service Access Door and set aside
while performing remainder of Pre-Start Check and Inspection
D.4 Oil Level
•Ensure RV is on a level surface
•Remove the engine oil dipstick from engine
•Wipe off all excess oil from dipstick
•Re-insert engine oil dipstick without threading in dipstick
•Immediately remove and verify oil on dipstick is at FULL mark
D.5 Fuel Level and Connections
•Never store anything underneath or around the bottom or front of the
Generator. Lack of a proper ventilation parameter may cause the
Generator to overheat and/or ignite tall grass, vegetation or other objects
in proximity to the running Generator. This presents a fire hazard which
could ignite from hot exhaust pipe assembly, fumes and vapors and result
in death or extreme bodily harm to the Owner or Operator.
•Maintain a proper ventilation parameter extending 914.4 mm or (3') in all
directions from all manufacturer installed Generator components.
•Verify your RV fuel gauge indicates sufficient fuel
•Verify fuel connection at Generator is secure. See Exhibit 5
•Verify Purge Line fuel vapor vent connection at the Generator is secure. See
Exhibit 5
oIn motorized applications the Purge Line will be unused. Verify
manufacturer installed cap is secured on purge line spout
Page 17 of 30
Rev 1.7

D. Pre-Start Check and Inspection
D.6Exhaust Assembly including Debris Screen See Exhibit 2
•Verify debris screen is intact
•Verify Support Strap is secure
•Verify Pipe Assembly is connected
D.7 Check Engine Air Filter Housing and Element
•Unlatch the Air Filter Housing cover
•Remove the Air Filter Element and inspect for dirt and debris
•Reinstall Air Filter Element
oIf dirt or debris is found, replace with new OEM AE002 Air Filter
Element
•When re-installing the Air Filter Housing, verify the cover seal is intact in
its original location and the cover is latched correctly
D.8 Ensure Overload Alarm and Oil Alert indicator lights on Generator Control
Panel are off See Exhibit 1
D.9 Re-attach Generator Service Access door. See Exhibit 1
•Verify latches at the sides of the access door are both turned to "Closed"
•Close the RV Generator Compartment door and secure in place
Page 18 of 30
Rev 1.7

E. Starting and Operating the Generator
E.1 Before Starting or Operating the Generator, familiarize yourself with the
safety information set forth in the "A. Safety" portion of this Guide.
E.2 DANGER: Engine Exhaust
Gasoline-powered engines and tools present a serious health hazard. They produce
high concentrations of carbon monoxide (CO). CO is a poisonous gas that can cause
illness, permanent neurological damage and death. CO is colorless, odorless, and
non-irritating and therefore can overcome exposed persons without warning. CO
can rapidly accumulate (even in areas appearing to be well ventilated).
E.3 Prior to starting the Generator and upon initial arrival at chosen destination,
perform an inspection of your RV's physical location as set forth in "D. Pre-Start
Check and Inspection"
E.4 After completing the Pre-Start Check and Inspection, close the Generator
Service Access Door. See Exhibit 1
•Turn latches on either side of the Service Access Door and verify both are secure.
E.5 Generator Cold Start would be first start of the day, a start after eight (8)
hours of inactivity or a start in below freezing temperatures
•Depress and hold Stop/Prime switch for ten (10) seconds allowing the Generator
to prime the fuel pump
•Then press and hold the Start switch until the Generator starts
•Remote Control Panel's light will blink and then remain steady once the
Generator is running
•Allow the Generator to run a minimum of two (2) minutes before turning on
devices or appliances connected to the Generator
•The process in E.4 is exactly the same for the Remote Start/Stop Switch inside
the RV and the Start/Stop Switch on the Generator Control Panel inside the
Generator Service Access Door. See Exhibit 6
E.6 At any time after initial Cold Start warm-up has been completed, starting
and stopping the Generator may be performed by
•Start/Stop Switch on Remote Panel inside the RV. See Exhibit 6
•Start/Stop Switch inside the Generator Service Access Door. See Exhibit 6
•Integrated Pull-Start inside the Generator Service Access Door. See Exhibit 6
oTo manually start the Generator with the Integrated Pull Start manual
operation of the choke lever inside the Service Access Door will be
required
ATTENTION
ATTENTION
Page 19 of 30
Rev 1.7

E. Starting and Operating the Generator
E.7 Wireless Hand-held Remote-Start Keyfob was created to conveniently allow
you to start/stop your Generator from a distance of fifty (50) meters (164'). See
Exhibit 6
•To start the Generator, press and hold the "START" button for more than one (1)
second and then release the button
•To stop the Generator, press and hold the "STOP" button for more than one (1)
second and then release the button
E.8 Using the Wireless Hand-held Remote-Start Keyfob for remote starting the
Generator See Exhibit 6
The Keyfob you received with your RV will have its signals already matched to the
Generator during installation. However, if you replace the Keyfob battery, are using a
replacement Keyfob, or you lose your signal you will need to re-match the Generator
and the Keyfob's wireless signals
•To match signals connect the Generator with the RV battery source, turn the
Master 12 Volt Power Switch, inside the Generator Service Access Door, to the
"ON" position. See Exhibit 2
•Press the Signal Match Set Button on the Remote Control Module and hold it for
more than three (3) seconds until the Signal Match Indicator Light on the Remote
Control Module stays on constant
•Release the Signal Match Set Button and press the "STOP" button on the Keyfob
(at this moment the Signal Match Indicator Light on the Remote Control Module
will blink one time and then stay on constant)
•Release the "STOP" button on the Keyfob and press the "START" button on the
Keyfob (at this moment the Signal Match Indicator Light on the Remote Control
Module will blink one time and then stay on constant)
•Release the "START" button on the Keyfob, press and hold the Signal Match Set
Button on the Remote Control Module until the Signal Match Indicator Light on
the Remote Control Module is off
•Start the Generator by pressing"START" on the Keyfob, then stop the Generator
by pressing "STOP" on the Keyfob to verify the signals have matched. If the
match is not made, repeat the above procedure, until the Keyfob and Generator
wireless signals are successfully matched
Page 20 of 30
Rev 1.7